LIGNA Hall 12 | Stand
LIGNA Hall 12 | Stand D72 Stage Début for the Grotefeld Project “Power Unit Digitalisation“ Drill Spindle Unit DBE 24 “Industry 4.0 Ready“ Now The system supplier Grotefeld GmbH from Espelkamp, Germany is a highly specialised producer of premium power unit technology. The range of high-performance components can be used in a wide variety of applications - from wood, plastic and metal to gypsum and cement through to composites. The company is carrying out real pioneering work in the comprehensive digitalisation of production processes with the initial development of digitalised drilling and milling units - including the drilling spindle unit DBE 24 with extensive sensor technology and evaluation software. At the leading trade show ”Ligna 2019”, Grotefeld will be presenting its concepts and products for Industry 4.0 with innovative developments at its stand D72 in hall 12, and will be setting trends in digital power unit technology going far beyond the lumber and furniture industry. Digitally determined predictive maintenance for DBE24 The focus of Grotefeld and its development partners lies in predictive maintenance. With its drill spindle unit DBE 24 the power unit pioneer from East Westphalia will be showcasing a first-time product that collects data itself for predictive maintenance and feeds it into the IT systems of a manufacturing company in real time. Drill spindle units of the DBE 24 series are intended for programme- controlled application in CNC machines. Virtually any drill patterns can be realised - various vertical drill spindles can be combined with horizontal drill spindles and vertical drilling gears with drilling distances from 16 mm. The individual spindles are optionally freely accessible and are preadapted at 50 mm. The maximum rotational speed is 8,600 1/min. High-quality sensor technology for a large number of power unit parameters In order to digitalise power units like the DBE 24, various sensors for diverse parameters are required in and on the power unit. For this purpose, various recording channels will also be drilled into the bearing housing as a serial feature in the future and then the sensors will be positioned or fixed. The complete wiring will be carried out on the power unit itself so that only a few wires need to lead away from the unit. By doing so, the assembly group can be exchanged more swiftly as only one plug has to be removed in order to decouple the sensor technology. Thanks to the wiring, it is also possible to place the SPC (stored program control) outside of the power unit, for instance in a separate control cabinet - a step which definitely makes sense. On the one hand, the SPC acts as a collecting point for the sensor data and, on the other, as a gateway. The various measured values of the operating condition of the DBE 24 are initially scaled, then converted into logic values, packed into data packages and uploaded to a Cloud. Cloud-based big data to predict precisely scheduled maintenance work The data is stored and analysed in the Cloud. The Cloud makes it possible to access the power units at any time and from any location, to call up their current status, to have the real-time values displayed in various graphic representations, and even to derive value trends therefrom. Here, several sensors of the same type are compared with each other and it is possible to identify the behaviour of the individual power units of the entire system. It is already possible to get the evaluation software to learn. The algorithms compare various sensor data with each other, create logical connections and attempt to draw conclusions on the condition of the power unit. In this way, it is possible for the first time to make accurate, cost-saving predictions as to when the next maintenance work is really necessary or which individual parts need to be exchanged during such work. The drill spindle unit DBE 24 from Grotefeld is the first available digital power unit to meet the demands of Industry 4.0. www.grotefeld.com In the Grotefeld test lab: Testing of the sensors on the digitalised drill spindle unit DBE 24 for recording temperatures - an integral part of the collection of data on operating status to accurately determine maintenance times. The complete wiring of the sensor technology is done directly on the power unit so that only the plug (black connector at the back) of the control cabinet data cable needs to be removed in case of an exchange of an assembly group. 34 No. 2 • May 2019
Robots Take the Wheel “Best Performance For Your Success” Hall 12 Stands D49 D50 E50 Robotics will be a major issue at the booth of the IMA Schelling Group at LIGNA. In fact, no less than three robots are part of the fully automatic high-volume line for single component manufacture shown by the Group. Other highlights are the BIMA Px80 gantry routing machine with diode laser and 6-axis robot, the Novimat Contour L20 lipping and veneer edge banding machine with multi-profile technology as well as the ls 1 panel cutting line with leaner processes and the fh 4 panel saw. Highlight 1: Cutting of free-form parts At the booth D49 in hall 12, the IMA Schelling Group will show a fully automatic integrated line for single component manufacture in action. The highlight of the production line, which has been sold to Spain already, is a Performance.Cut machining centre that can also cut free-form parts such as nested desktops. Another specific feature of the line is the edge banding process on a Combima Systems running in a production environment that enables formation of pairs for efficient panel arrangement in the circular work cell. The whole cell is equipped with two 4-axis and one 6-axis robot. Highlight 2: Lipping and veneer edge banding machine with multi-profile technology The Novimat Contour L20 lipping and veneer edge banding machine with multi-profile technology is specifically designed for automatic processing of multiple profiles. It is equipped with the IPC.NET plant control system. Panels travel out of the Novimat edge bander on a Feedback 2.1 panel return conveyor which differs from its predecessor in that its design has been optimized. The new circular workcell concept of the ls 1 panel cutting line distinguishes itself by leaner processes and reduced floor space requirements. Highlight 3: Gantry routing machine with 6-axis robot and diode laser At the booth D50, the IMA Schelling Group will show an upgraded BIMA Px80 gantry routing machine for processing furniture elements. Highlights are a movable 6-axis robot, the load pick-up device of the robot with integrated part orientation recognition (“vision technology”) and an LDM diode laser with a power of 3 kW for producing a perfectly seamless joint. Highlight 4: Panel cutting line with new circular workcell concept IMA Schelling has revised the circular workcell concept of the ls 1 panel cutting line. The benefits of the new system are leaner processes and reduced floor space requirements. Moreover an electrically actuated clamping bar reduces cycle times and allows for a constant takt time. At the booth D50, visitors can convince themselves of the advantages of the new ls 1 and at the same time get an impression of the vs 12 area storage system with an upgraded version of the Evolution Storage software which utilizes a new significantly improved search algorithm. Also the HPO cutting plan optimization software and the XBoB software for manual management of residual parts have been extended with new features. These include, amongst other things, multiple optimisation solutions and a layout selection for the printouts. Highlight 5: Holistic IoT and service platform The new IoT and service platform of the IMA Schelling Group will be a key focus of the Group’s trade show presence. It closes the data gap between the machine manufacturer and the customer, bringing essential insight and giving target-oriented recommendations to the machine user for efficient plant operation - a crucial assistance that can decide about success or failure in times of budget trimming and compressed schedules and, at the same time, increasing product diversification. The open flexible software offers maximum customer benefit and forms the basis for sustainable development of companies in a rapidly changing digital environment. In particular, the field of handling and analysing large quantities of data in close proximity to the machine as well as taking appropriate action resulting from the analysis are absolutely unique features in machine and plant manufacturing. www.imaschelling.com No. 2 • May 2019 35
