The change to digitization is becoming clearer – particularly in the field of machine tool design. In turn, this means that software in the production environment is becoming increasingly important. For this reason, companies in the industry are following developments particularly attentively. They know precisely that the foundations for Industry 4.0 must be laid today and in the immediate future in day-to-day production. DMG MORI is supporting its customers in the digital transformation with the help of integrated solutions, which can be connected seamlessly to one another.
CELOS from DMG MORI
A central component of DMG MORI’s customer-oriented innovation strategy is the app-supported CELOS operating and control system, which the machine tool manufacturer introduced approximately three years ago. Since then, it has been continuously and very specifically developed. Using a common interface for machine and office PC, both manufacturing and production planning staff can manage, document and visualize the sequence of jobs and processes as well as the machine data.
Along with its tasks on the factory floor, CELOS also enables data to be exchanged with high-level structures thanks to its open architecture. CELOS therefore enables the customer to fully integrate his machines into the company organization while, at the same time, creating an interface between the machining process and cyber-physical production systems of the future. The advantages for day-to-day operation are impressive: a time-saving of 30 per cent for set-up, and half the effort and time required for calculating technical values or for searching of important data are just a few examples of savings, which can be achieved with CELOS. Thanks to the continuous development of further future-oriented applications, CELOS ensures a trouble-free introduction of software solutions for Industry 4.0.
An excellent example is the CELOS Condition Analyzer. In conjunction with the I4.0 sensor pack, on the one hand, this provides the user with a perfect software tool for monitoring machine condition and machining process, enabling him to carry out timely performance and condition analyses directly at the machine or externally via CELOS PC.
On the other hand, in the second step, the data gathered by the sensors and local conditions can be forwarded to a cloud platform. Here decisive knowledge for a reliable ‘predictive maintenance’ solution can be derived using an algorithm-based long-term evaluation. Customers therefore save maintenance costs and have an effective tool for substantially avoiding unplanned downtimes.
In addition, along with 50 functional expansions and improvements relating to the 16 current standard APPs, at AMB, DMG MORI will for the first time be presenting optional APPs, such as the CELOS Performance Monitor for measuring Key Performance Indicators (KPI) or for so-called OEE analyses.
What is more, with the CELOS Developer as a creative development environment, the CELOS ecosystem has now also been opened up to third-party providers. The CELOS Clamp Check and the CELOS Surface Analyzer are the first two representatives of this new generation of CELOS partner APPs, which will now be successively followed by further innovations.
CELOS Clamp Check significantly increases machine safety in the turning area based on a wireless in-process monitoring of clamping forces. On the other hand, the CELOS Surface Analyzer, which is certified for medical and aerospace applications, determines the surface quality of the component during the process.
The DMG MORI process chain – a key component of the software strategy
The DMG MORI process chain is a good example of a successful digital transformation and a practical link between the virtual and the real world. This statement is substantiated not only by the many successful customer applications, but also based on the competence partnership between DECKEL MAHO Seebach GmbH and the Porsche LMP1 team. The background of this collaboration is the premium partnership between DMG MORI and the Porsche Motorsport team. Last season, Porsche were victorious in the long-distance world championships as well as in the driver’s and constructor’s championships.
Among other things, the so-called Porsche Motorsport Center in Seebach manufactures complex pump housings in small batches in different materials and technically demanding fixing elements. For this purpose, the racing stable’s developers provide the necessary CAD data, while the manufacturing experts in Seebach are responsible for the whole process right up to the finished workpiece – starting with the processing of the CAD data and the CAM programming using Siemens NX CAM, to 1:1 simulation with the DMG MORI Virtual Machine and highly accurate finishing on the high-tech machine tools.
Based on the virtualized process chain, the machining centers can be optimized in advance and thus enable perfect planning, effective collision protection and a reduction in set-up times to the absolute minimum. In other words, the importance of the DMG MORI Virtual Machine can definitely be compared with that of a racing simulator for the drivers. The system provides 1:1 simulation under real conditions – including the machine kinematics and control. The result is a high degree of safety and fast implementation in the (equally exciting) real world.
Technology cycles from DMG MORI – programming software offensive in the production hall
Shop-floor-oriented programming is still extremely important, particularly in the production of individual workpieces and with small and medium-sized production batches. And it will remain equally important for a long time to come. Working with cycles is today the norm; standard cycles for turning, milling and drilling have long been part of the performance spectrum of modern control systems.
Backed by its decades of application experience, DMG MORI has gone well beyond this standard and currently offers 24 special DMG MORI technology cycles for turning/turning & milling or milling/milling & turning in its portfolio. This enables the operator to carry out complex machining functions directly at the machine up to 80 per cent faster using a dialog system and parameterized context menus.
Outstanding examples include the machining of free-form surfaces using 5-axis interpolation, and different cycles for tooth-cutting and gear wheel production. Other highlights of the cycles include protective control for machine, workpiece and tools, the 3D quickSET Toolkit for checking and correcting the kinematic precision of 4 and 5-axis milling machines, and the cycle for process-oriented optimization of feed speeds at the press of a button taking into account the table loading.
At the same time, it must be said that all strategies for the future at DMG MORI are people-oriented, particularly in the case of the new future trend towards the ‘Smart Factory’. As a machine tool manufacturer, the company sees the optimum integration of employee potential as the most important success factor when implementing new approaches in production. This applies particularly to the operation of machine tools, which encompasses a multitude of complex tasks.