Smart machine tools originally referred to various stand-alone auxiliary software functions developed by machine tool factories to improve operating efficiency. In recent years, under the wave of Industry 4.0, smart machine tools have received new explanations. In addition to further strengthening the stand-alone software auxiliary functions, it also needs to be able to successfully play the role of the core equipment in the future intelligent chemical factory, and complete production in coordination with all the equipment in the factory through the communication interface.
What is a smart machine?
The world's first CNC machine tool is a piece of mechanical equipment that combines computer and control technology. However, since CNC machine tools began to be widely used in the mechanical processing industry, the machine tool factory has focused on the development of the machine tool's own mechanical and control performance, such as structural rigidity, spindle speed, feed speed, differential calculation accuracy, contour accuracy, etc. Less use of a lot of software technology to improve machine performance and productivity.
It was not until 1990 to 2000 that due to the popularization of five-axis machine tools and turning and milling machines, the functions of machine tools became more complex than before, and it was difficult for users to fully utilize the capacity of the machine. At this time, the machine tool industry Began to pay attention to the importance of software in machine tools, so the international major manufacturers began to propose the concept of the so-called smart machine tool and began to develop unique software functions to assist users in the performance of the machine tool. Currently, the smart machine tool is still more focused on stand-alone functions, providing various operational safety protection and processing performance. Lifting, diagnostic monitoring, and other functions.
By 2015, almost all major machine tool manufacturers have invested a lot of resources in the development of software technology and claimed that their products are smart machine tools. However, the most important elements of smart machine tools are as follows:
- Virtual and real integration system:
CPS is to establish various virtual models for different aspects of manufacturing systems and to establish interactive interfaces between virtual and real physical systems. The data of the production process can be obtained from the sensor of the machine, the parameters of the CNC controller and the user's operation history, and a cloud database is constructed to store the heterogeneous data related to the sensor, production management, and quality control system, and then develop the target Innovative analysis methods for heterogeneous data and establishment of cloud-based value-added services.
- Internet of Things
IoT is to create a network of various objects, sharing information between objects. By sharing information between objects and connecting the information to the data center for background analysis, objects can be managed and controlled to achieve the goal of a smart environment. In the Internet of Things, the industry can use software to directly adjust the parameters of the product through related information and provide a more complete after-sales service through the analysis of huge amounts of information.
- Big data
The CPS and IoT backgrounds both require data exploration technology, and different processing methods will be used according to the speed of data generation, source heterogeneity, and quantity. Due to the complexity of the working environment and process requirements of the machine tool, the speed and quantity of the captured data may reach a huge level. Huge data tools provide data management, distributed computing, data exploration, and automatic execution, and other related modules to help users focus on solving data analysis problems and provide customers with better service quality.
The application of signal sensing, data processing, intelligent decision-making, and action control to develop intelligent automation technology is the best application of virtual and real integration systems. Each element has a sensor and a programmable parameter interface, such as an intelligent spindle. Transmit the sensing signals of temperature, acceleration, deformation, and current during operation to the integrated platform. These sensor signals, together with the machine parameters and operation logs, are transmitted to the cloud data warehouse. Through data analysis methods, the current theoretical processing response characteristic distribution model can be analyzed, and the value-added service intelligent APP can be compared with the actual results to know the current situation. Whether the processing is abnormal, whether the abnormality can be corrected by modifying the parameters of the spindle or the controller, when the spindle should be maintained, and even a virtual comprehensive inspection of the processed product can be performed.
The industrial upgrade 4.0 of the global manufacturing industry is mainly towards the development of intelligent technology, combining the Internet of Things and AI artificial intelligence to realize intelligent manufacturing. The five-plus two plans promoted by the government, and the smart machinery industry is one of the five innovative industries, and its main purpose is to upgrade precision machinery to smart machinery. The definition of smart machinery refers to the integration of various smart technology elements to enable it to have smart functions such as failure prediction, accuracy compensation, automatic parameter setting, and automatic scheduling, as well as the functions of providing Total Solution and establishing differentiated competitive advantages. Smart manufacturing refers to the introduction of smart machinery into the industry. The establishment of smart production lines requires high efficiency, high quality, and high flexibility (customization), providing many customized products, and joining the Internet of Things to form a manufacturing service system. Precision machinery combined with smart technology (AI artificial intelligence, Internet of Things, big data, sensors, etc.) smart machinery brings differentiated competitive advantages to smart production lines.
How to upgrade precision machinery to smart machinery?
Smart machinery is paired with human experience to upgrade smart manufacturing. The current manufacturing supply trend is gradually focusing on customized orders. Small and medium-sized enterprises have limited energy for technology upgrades. In addition, the production method and quality rely on the inheritance of experience, so upgrading to a smart production line needs to be gradually Step forward. If the manufacturing machinery and equipment are endowed with intelligence, the human error and loss rate can be greatly reduced. How should manufacturing machinery and equipment be given the ability to self-test or be intelligent? The easiest way to upgrade a machine to a smart machine is to add a monitoring module to the machine and use the human experience to adjust the parameters and operating procedures. Then add some automation equipment such as robotic arms, Internet of Things, etc., and then gradually adjust and build smart production lines according to market order requirements.
The benefits that smart machinery brings to the industry:
"Intelligent" includes intelligent technology and the explanation of wisdom in manufacturing systems. The so-called intelligent technology includes robots, the Internet of Things, big data, CPS, which is a virtual and real integration system, lean management, 3D printing, and sensing technology. Through the digital method, data is converted into information, and then the information is converted into appropriate actions.
In smart manufacturing, this optimization process should include two levels. The first is Experience-based, combined with Model-base, and integrated verification through AI-base to find the optimal manufacturing parameters, and transform the data into the most optimal manufacturing parameters. Optimal manufacturing information. Furthermore, this intelligent and optimized manufacturing information will be replicated in the digital avatar in the virtual environment. Through the continuous addition of on-site manufacturing data, machine, market, and logistics data through sensors and the Internet of Things, this digital clone will continue to use artificial intelligence algorithms for optimized calculations and continue to evolve in a virtual digital environment. Generate new wisdom, and pass this new wisdom back to the mechanical equipment and robots in the real environment for smart manufacturing with real-time optimized parameters.
Smart manufacturing is not just adding wisdom to manufacturing. Smart manufacturing is through the "optimization" process of smart technology, the planning and selection of product lines and manufacturing methods, supply chain and logistics chain, customers, market, and product development and design are all optimized. The core value of smart manufacturing is combining manufacturing, information, and communication technologies, introducing optimized domain know-how and smart technologies, and connecting the entire manufacturing system from the supply chain to the outlets to improve industrial efficiency and competitiveness of technology.