The Art of the Possible Manufacturing Engineering Solutions. Armin Gruenewald, Vice President MBG Janakiram Pepakayala - MBG

Transcription

1 The Art of the Possible Manufacturing Engineering Solutions Armin Gruenewald, Vice President MBG Janakiram Pepakayala - MBG Unrestricted Siemens AG 2016 Realize innovation.

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3 Digitalization is transforming the business world and creating major challenges for manufacturers Crowdsourcing design Lifecycle analytics Additive manufacturing Advanced robotics Systems-driven product development Intelligent automation Page 3

4 Economies around the world are investing in manufacturing USA Germany China Japan "Manufacturing Renaissance" Formation of a "National Network for Manufacturing Innovation" Lower cost energy initiatives Smart Manufacturing Leadership Coalition Maintain leading industrial position Sustainable investment in innovative strength High level of exports Adjust to aging workforce Industry 4.0 as new guiding principle Higher product quality by use of high-end technology Rising wages Need for quality driven demand for automation Energy efficiency legislation Intelligent Manufacturing A cohesive innovation program at all levels Science, technology and industry linked together HR development Retain manufacturing of complex products Innovation 25 initiative Page 4

5 The paradigm shift of manufacturing The Digital Twin is the heart of the smart factory Page 5 Digital twin of the product Digital Twin Digital twin of production process Physical production system Digital twin of the equipment The virtual and the real worlds are linked by the Manufacturing Master Data Model and the Common Plant Model created from Automation Decisions can be made based on real-time data from Automation Feeding back all relevant information from production execution creates a nearly real-time image of the digital twin of product, process and resources

6 State of the Art Innovation From 1899 Cars are Getting Smarter and More Connected Page 6

7 Agenda User Interaction 3D Printing & Additive Mfg. Advanced Robotics Next Generation Factory Layout Connection to Shop Floor Page 7

8 NC Programming Page 8

9 User Interaction Immersive Experience, Augmented Reality, Touch and Mobility Virtual Reality Augmented Reality Mobility Immersive Page 9

10 User Interaction Immersive Experience, Augmented Reality, Touch and Mobility Right information. Right time. Right context Easy to use Easy to interact Availability for all Page 10

11 Additive Manufacturing - Example Parts Cooling Channels Page 11

12 Additive Technologies - Depending on Material Type Technology/ Process Material Extrusion Fused deposition modeling (FDM) Thermoplastics, HDPE, eutectic metals Wire Granular / Powder Electron Beam Freeform Fabrication (EBF) Direct metal laser sintering (DMLS) Electron beam melting (EBM) Selective laser melting (SLM) Selective heat sintering (SHS) Selective laser sintering (SLS) Almost any metal alloy Almost any metal alloy Titanium alloys Titanium alloys, Cobalt Chrome alloys, Stainless Steels, Aluminium Thermoplastic powder Thermoplastics, metal powders, ceramic powders Laminated Laminated object manufacturing (LOM) Paper, metal foil, plastic film Light polymerized Stereo lithography (SLA) Digital Light Processing (DLP) photopolymer photopolymer Page 12

13 Siemens PL supporting Additive Manufacturing process Customer value: NX Technology (directions) Design (CAD) Analyze (CAE) Manufacture (CAM) Design of light weight structures (lattice & honeycomb structures) Complex surface pattern Support structures Additive Mfg design rules Multi-material support Topology optimization tools Deformation calculation Laser power regulation Multi-axis Additive solution Hybrid (additive/subtractive) manufacturing NX direct printer interface Page 13

14 Hybrid Manufacturing Combining 3D Printing and Machining Restricted Siemens AG 2015 Page 14

15 Additive manufacturing is disrupting industries Aerospace Marine Machinery Automotive NASA 3D-printed turbopump has 45% fewer parts and delivers 1,200 gallons liquid hydrogen per minute. Hoedtke3dadditive stainless steel propeller 3D-printed/machined in 36 hours versus traditional 6-8 weeks. Mapal manufactures cutting tools that perform better (increased coolant flow by 100%) than traditional designs. Local Motors developing 3D-printed car that exceeds FMVSS standards by Page 15

16 Advanced Robotics The Robotics Market Trend Global market value 32 billion US dollars for Will double to ~400,000 units per year by Spot welding Automotive & Transport. Aerospace & Defense Ship building & Energy Metal & Machinery Arc welding & Edge profiling Virtual commissioning Electronics Surface treatment Drilling & Riveting Robotic machining Assembly robotics Page 16

17 Trends in Industrial Robotics Human Robot teams Easy to use Autonomous robots Vision & Sensors Drilling & Riveting Machining Energy Efficiency Advanced materials Page 17

18 Transforming assembly with advanced robotics Drill & riveting Machining Cooperative robots Human and robot interaction Page 18

19 NX CAM Robotics Example Applications Page 19

20 Advanced Robotics Process commissioning Process commissioning of a part manufacturing workcell using hardware in the loop Page 20

21 Next Generation Factory Layout Teamcenter Based Layout Solution Plant Structure and Object Library Managed in Teamcenter Seamlessly Integrated Process / Layout Design Layout becomes foundation for process validation and simulation Leverages NX Platform Data Exchange from AEC & CAD Advanced Modeling and Drafting capabilities Multi-Cad Support Page 21

22 Next Generation Factory Layout Line structure and Equipment Library managed in TC Line Design Common Library Process Planning Process Simulation One common Bill of Resources Page 22

23 Next Generation Factory Layout Production system simulation and optimization Line structure and equipment library managed in TC Integration with Material Flow Simulation Line Designer Identify bottlenecks Optimize throughput Buffer dimensioning Optimize lot-sizes/ production mix Optimize number of part-carriers Plant Simulation Page 23

24 Next Generation Factory Layout Line structure and Equipment Library managed in TC Integration with Material Flow Simulation Integration with Robotic Simulation/Offline-Programming Line Designer Process Simulate Page 24

25 Next Generation Factory Layout Line structure and Equipment Library managed in TC Integration with Material Flow Simulation Integration with Robotic Simulation/Offline-Programming Multiple representations / powerful simplification Advanced, associative modeling and drafting capabilities Parametric, UI based extension of object library Handling project metadata, Visual Reporting Point Cloud support Page 25

26 Virtually travel through space and time Travel through space Intosite Travel through time Plant Simulation Page 26

27 Part Manufacturing Solutions - The challenge: Disconnected systems CAD Fixture Design CAM - NC programming Part design has been modified? Order Management Multiple data sources! Tool Design Process Planning DNC Quality Measurement Separate niche applications! Resource Management Work Instructions Is this the right tool list? Tool Management Where is the tool? CNC Controller Machine Tool Which machine tool? Wrong NC File! Page 27

28 Adaptive System Part Manufacturing Solution Part model preparation Tooling and fixture design CAM DNC Shop Floor Program Validation CNC Data & process management CMM programming Process planning Tool libraries Shop floor data access Tool management CMM inspection execution Planning Production Page 28

29 Restricted Siemens AG 2015 Page 29

30 The paradigm shift of manufacturing The Digital Twin is the heart of the smart factory Restricted Siemens AG 2015 Page 30 Digital twin of the product Digital Twin Digital twin of production process Physical production system Digital twin of the equipment The virtual and the real worlds are linked by the Manufacturing Master Data Model and the Common Plant Model created from Automation Decisions can be made based on real-time data from Automation Feeding back all relevant information from production execution creates a nearly real-time image of the digital twin of product, process and resources

31 Armin Gruenewald Vice President MBG Manufacturing Engineering Software Frankfurt Germany Cellular: Janakiram Pepakayala Director MBG APAC Manufacturing Engineering Software Bangalore India Cellular: Page 31

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