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November 2017

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Linking Industrial Production with Digitization



HELLER Machine Tools' Industry 4.0 approach is to enhance transparency of the current machine status, and evaluate the information gained in combination with existing data to allow purposeful diagnostics, yielding better productivity and value for the user.

The unchanging objective in production manufacturing is to further increase productivity, creating added value for the customer. That is the reason for continual development of machine tools and for complementing them with optional extensions for added capability. "HELLER has been providing availability and productivity for decades with a broad range of products comprising 4- and 5-axis machining centers, mill/turning centers and flexible manufacturing systems," said a company spokesperson.

It has now further developed the linkage of industrial production with digitization and network integration of information and production technologies in terms of its machine tools. While achieving this, efficient and productive manufacturing and the reduction of workpiece costs continue to be the main goal.

HELLER emphasizes ease of operation, customized manufacturing of the workpiece and expanded evaluation of existing sensor data.

  • HELLER4Operation is an easy-to-use, operator-oriented user interface for HELLER machines. The use of touch controls at the tool/workpiece loading station enables fast and robust operation. In addition to the familiar Siemens standard operation, the new main operator panel allows execution of customer-specific programs from web environments. The 24" touch HELLER Operation Interface can be upgraded with expansion programs, called XTENDS, enhancing performance and functionality.
  • The second area, HELLER4Services, comprises digital services. The HELLER Services Interface focuses on transparency of manufacturing and maintenance processes. The module forms the basis for evaluations and statistics, thus providing support in reducing machine downtimes. Additionally, the visualization of specific information, including status displays of axes, spindles or other assemblies, enables users to determine wear and to take preventive measures in order to avoid unscheduled downtimes.
  • The third area, HELLER4Performance, comprises the machine analysis for process and performance optimization, time-synchronous extraction of real-time data into the internet as well as evaluation and graphical display, e.g. using the SAP-HANA internet platform.

This enables precise representation of the toolpaths (including tolerances) in which tool wear is expected. Subsequently, the workpiece program is run on the machine. The data generated is directly transferred to the cloud. This way the paths to be traversed by the machine/tool can be pre-assessed on the basis of the workpiece design prior to machining to see whether the machine will be able to perform the operation.

Cloud Helps to Reduce Idle Times

The example of tool provisioning shows how further savings can be achieved with HELLER4Industry by linking the digital and the real world. Usually, tool magazines are loaded in a way to provide optimal storage capacity. Often, however, the tool access sequence differs from the sequence of the machining operations. It means that the distance from the tool to the spindle has a significant influence on the duration of the tool change.

To reduce these idle times, the stock of workpieces to be optimized can be selected from the pallet management and be transferred to the cloud along with the details. This way, both the tool change times and the tool idle times can be analyzed and evaluated in view of the sorting order, providing the shortest idle times for the given workpiece and the machining operation. Subsequently, HELLER generates the CNC program for re-sorting in the cloud and provides it to the machine to re-sort the tool magazine.

For more information contact:

HELLER Machine Tools

1225 Equity Drive

Troy, MI 48084

248-288-5000

sales.us@heller.biz

www.heller-us.com

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