Trending topics Q&A: digitalization

MyMachine: machine tool digitalization
With Vivek Furtado, director of machine tool digitalization software & Dave Morley, senior manager, machine tool digitalization, Motion Control Systems, Siemens Industry Software Inc.

Aerospace Manufacturing and Design (AM&D): What makes a machine or a virtual machine shop-floor smart?

Furtado & Morley: Using technology, software, and data from the machine, it’s possible to meet increasing productivity, quality, and efficiency demands, thereby enabling the CNC machine, virtual machine (digital twin), and shop floor to become smart.

AM&D: What’s needed to make a machine smart? (What’s on the shopping list?)

Furtado & Morley: Start with basic connectivity options such as OPC UA or using advanced adaptive control algorithms to reduce cycle time or increase tool life. Furthermore, add an edge box capable of capturing high frequency data streams from the CNC without any impact to its performance. High frequency data opens unlimited possibilities to implement smart manufacturing practices. The Industrial Edge for Machine Tools, as we call it, comes with ready to use apps like Analyze MyMachine, but it also provides the capability to develop custom apps.

AM&D: There are several key terms used in the Siemens product. What’s meant by “Smart Machine?”

Furtado & Morley: A good analogy for the use of the term “smart” here is the smart phone. The smart phone we use today, enabled by technologies like data streaming, apps, and sensor integration, transforms it from a classical communication device to a highly functional and versatile device to boost our awareness and productivity.

AM&D: What’s does the feature Optimize MyMachining do?

Furtado & Morley: Optimize MyMachining reduces cycle time and protects cutting tools from breakage, while preserving quality of the machined part through adaptive control and monitoring.

AM&D: What’s in Analyze MyMachine?

Furtado & Morley: Analyze MyMachine is a flexible monitoring system of the machine’s condition, permitting users to implement condition-based maintenance. This is a key component to bring awareness to a maintenance department without random inspections. It’s a precursor to the predictive maintenance topic.

AM&D: What’s in Analyze MyWorkpiece?

Furtado & Morley: Analyze MyWorkpiece captures the data from your CNC Machine for advanced data analytics, improved testing and re-working, accelerated workpiece quality improvement and automated visual inspection for improved tool usage, optimized programming, and root cause analysis procedures.

AM&D: What’s the function of Protect MyMachine?

Furtado & Morley: Protect MyMachine is an automated visual inspection for improved machine protection against damage and operational errors to very expensive CNC machine tools.

AM&D: What sensors, software, data/access, etc. are needed?

Furtado & Morley: Our software is made available to our customers on three platforms: On Machine, On Prem, and Cloud-based. Mostly, no additional sensors or software are required. Sometimes accelerometers for vibration monitoring or cameras for image processing are included for data access. We use a proprietary plug-and-play mechanism for Siemens only products, but use all the standard data protocols like OPC UA, MT connect, MQTT, or REST APIs to support further integration to all other machines and machine controllers.

AM&D: Where roles do cloud/Edge computing/artificial intelligence (AI) have?

Furtado & Morley: We have apps that use the cloud/Edge computing as well as AI. For example, image analytics are used to detect the tool wear status, breakage of a tool, or tool insert used in CNC manufacturing. In this, the camera image is streamed via the industrial edge to the cloud where an AI model is trained. This AI model is then provided back to the edge which then checks for tool wear break in real time. A similar concept is used for workpiece monitoring, wherein a wrong blank or positioning can be detected by the AI model.

AM&D: Process improvement, toolpath optimization – is this automated? Or by analysis? By Siemens personnel or the customer?

Furtado & Morley: Process improvement is basically the outcome of using our software platform like Mcenter which focuses on resource management such as tools and CNC programs. Because of the high level of integration between the engineering, planning, and manufacturing phases, manual processes can be automated with different department inputs for process optimization.

Tool path optimization can also be automated with Analyze MyWorkpiece/Monitor by building a data model to trigger responses if the tool path is beyond a certain tolerance band. PC-based tools such as Analyze MyWorkpiece/Toolpath offer deeper analysis of tool path and velocity profile to further optimize the workpiece for enhanced surface quality and faster cycle time.

Sinumerik One
With Chris Pollack, virtual technical application center manager, Siemens Industry Software.

AM&D: What’s included in digital native and digital manufacturing?

Pollack: Digital native is used in reference to the fact that the Sinumerik One control was fully developed and tested in a digital environment using our NC Kernel technology. The Kernel allows the brain of the CNC to be harnessed at a user’s PC.

Digital manufacturing speaks to the concept of being able to simulate processes typically only seen in the real world at the actual machine tool.

Digital twins rely on accurate representations of real-world behavior to model virtual machine behavior, such as modelling all the variables of a machine tool, such as tool chatter, vibration, and material hardness in developing the simulations. Our digital twin is designed to simulate the choices the CNC is making when it comes to its motion profile. We aren’t simulating cutting conditions such as vibration, wear, etc.

AM&D: What are the differences between Create MyVirtual Machine Operate/3D/Run MyVirtual Machine?

Pollack: Create MyVirtual Machine is designed for the machine tool builder to use as a design and development tool while creating the actual CNC machine – PLC validation, machine design verification, customer requirement testing, to name a few.

Run MyVirtual Machine is designed for the end-user who wants to validate their manufacturing process.

3D can be used with either Create- or Run MyVirtual Machine if there is a desire to see the machine model. Without 3D, you can still simulate the CNC’s HMI.

AM&D: How can the smaller machine shop owner leverage digital twin technology?

Pollack: Using Run MyVirtual Machine allows machine shops of any size to reduce the downtime associated with part setup. By validating their part programs, as well as their setup, they can mitigate conditions that would cause their machine to sit idle. Additionally, it is a great tool to train new machine operators without the risk of damage to their machine.

AM&D: What’s required to get started (hardware, software, training)?

Pollack: Create- and Run MyVirtual Machine is a software solution that can run on any standard workstation capable of running a CAM system. Depending on the knowledge of the user. If they are already familiar with the Sinumerik CNC control, the learning curve is very short. Keep in mind that the human machine interface (HMI) in Create- and Run MyVirtual Machine is identical to the real CNC, so any knowledge they have of the control will apply to the software. The only piece a user would need to learn is the 3D portion that can be picked up in a few hours. 

Additive manufacturing
With Steve Vosmik, Siemens head of additive manufacturing, U.S.

AM&D: It appears Siemens is offering its additive manufacturing knowledge similar to a consulting group or advisory firm. How does its Charlotte Advanced Technology Collaboration Hub (CATCH) differ or compare with other initiatives?

Vosmik: CATCH is focused on physically performing additive projects – much different than the typical consulting model. CATCH houses a diverse offering of both polymer and metal additive machines and engages with our customers to understand their unique additive manufacturing (AM) requirements and provide guidance on how to achieve their goals.

AM&D: What can you do at the CATCH AM hub?

Vosmik: Our collaborations are focused on component/assembly printing feasibility or design for additive manufacturing (DfAM), developing specific process parameters linked to advanced materials and specific AM processes, as well as developing in-process monitoring and machine learning that is big data friendly.

AM&D: Siemens has a vast portfolio of hardware and process control solutions. How are these being organized and applied to work with customers and their choice of machine suppliers? Vosmik: Siemens’ goal of providing the digital thread throughout the manufacturing process is in our DNA.

Our portfolio of products is finding its place very quickly with the machine builders (original equipment manufacturers) who are faced with complex problems, whether it be digital twin, edge computing, and probably most valuable is our knowledge in digitalization and the important aspect of connecting information technology (IT) and operational technology (OT).

AM&D: Having digital twins on the factory floor is a large, comprehensive approach to product management. What are the applications for the smaller (contract) manufacturer?

Vosmik: The beauty of a virtual factory floor is that it doesn’t matter what size the company is. Digital twins are equally valuable for high-mix/low-volume or high-volume/low-mix factory floors. The value of the digital twin can be realized by small, mid-sized, and large companies interested in refining and making their existing manufacturing processes more interactive and efficient. The objective of using a virtual factory is to quickly refine and simulate changes to material or process workflow as well as how humans and machines interact.

AM&D: Much AM optimization has been obtained by trial and error. How have you reduced that through simulation and digital twins?

Vosmik: A lot of process simulation software tools being developed are quite good at in-process monitoring that allow us to predict how specific AM processes influence or create thermal stress. If we can better predict this issue, we can modify the process parameters to maintain a more balanced heat signature and print parts with less stress in them.

AM&D: Can you share any examples of aerospace AM decarbonization or sustainability projects?

Vosmik: We have several projects focused on energy recouperation from exhaust gas heat. These are unique designs that leverage the power of generative design, topology optimization, and the ability to print these very organic shapes to maximize the use of wasted energy. Also, during the DfAM process, we can optimize part design to reduce waste and light-weight parts, all of which contribute to decarbonization and sustainability. These are not directly aerospace but are aero- derivative and transportation related.