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Wittmann 4.0 The fully integrated production cell
INDUSTRY 4.0 The digitalization of production
ThetermIndustry4.0designatesinteractivenetworkinginproductionbyusingmodernInternettechnologies. The aimistoestablishcommunicationbetweenmanufacturing equipment,products andtheircomponentsto achieve effcient and customized production.
With its modular"Wittmann 4.0^{\prime\prime} library,theWITTMANNGrouphasnumerous4.0technologiestooffer.Thefocus liesonintelligent functionsorefoptimizatiofthediviuauxilarieifomlaffordatatranmissonwenthenjtioldn machineadtheaxliarisfrmWaioumdlefrericeandmaintenacnesyntgrationta
4 categoriesprovidea clearer overviewof the availableWittmann4.0 technologies:
SmartMachine
Thebasicprerequisitesfora stableinjectionmolding process withvaryingenvironmentalconditionsandequipment are precise,absolutelyrepeatable and adaptive injection molding machines and auxiliaries.
SmartWorkCell
Up to now,the“Industrial Internet of Things"(lloT)stopped at the level
of themachines.TheWITTMANNGroupisthefirst and currentlytheonly
companyworldwidewhichcanalsocollectdata correctlyfromconnected auxiliaries and cope withthe complexityof changingworkcellsand automaticcompilationofvaliddatasets.
SmartServices
Theaimistohaveamachineandauxiliarieswithmaximumuptime Thisincludesfast and safemold change,as well as continuous condition monitoring to detect anomalies.However,if supportfromtheWITTMANN Groupshould stillberequired,it canbe securedviaremoteservicing.
SmartProduction
The traditional domain ofIndustry 4.0istheintegrationof themachines and workcellsinto superordinate softwarepackages such asERPandMES.Thisnot only enables production planning and monitoring,but also data collection for the traceability of production parameters.
HiQ Melt Melt quality monitoring
HiQMeltisamethod tomonitorthematerial quality.Theprocessvariableisthe energyconsumptioninplasticizing.Itismeasuredviathetorqueofthescrew
Cross-sectional diagramofthebarrel
The thick,viscousplasticmeltresiststherotation of thescrew.Thedrivetorquerequiredtoovercometheresistanceismeasured.
HiQ Flow Material viscosity quality-related injection control
HiQ Flow uses the melt compressibility and the pressure datafrom theinjection curvetocalculateaparameterproportionaltothecomponent weight,theso-calledSMUVinjectionvolume (SMart Uncompressed Value).The pressure and strokedataarerecordedandtheSMuVvolume is calculatedevery2milliseconds along the injectionstroke.ThecalculatedSMuVvolumeis usedtocontroltheswitchoverpointand/orthe holding pressurephase.Externalmaterial data is notnecessary,since all necessary material parametersaredeterminedduring aproduction cycle.Viscosityfluctuations due to,e.g.the use of regrindorbatchfluctuations can thus be compensated forand enable robust production and component quality.
HiQ Metering Active closing of the check valve
An additional stepisprogrammed between the end of metering and thedecompressionstroke,duringwhich the screwreleasestheshut-off ring andclosesit by controlledmovements.Consequently,theshut-offring isalready closed when injection starts.Even minute deviationsin the screw's end position are compensated by shifting the entire injection profile.
SMARTWORKCELL Communication/MES
Standardizedinterfacesareabasicprerequisiteforthesuccessfulandwide-spreadintroductionof Industry4.0technologies.EventheglobalexpansionoftheInternetitselfcould onlyproceedafter theIEEE802standardshad beenintroduced,observed andfurtherdeveloped.Industrialnetworks arecurrently undergoing asimilar development process.Based ontheOPCUAindustrial M2M communication protocoland undertheumbrela of EUROMAP,the plasticsindustry is developing standardsto unify communication.
Here,theWITTMANN Groupplaysa leadingrolein the development andstandardization and offersthefollowingtypes of standard communicationbetweentheindividualdevicesofaWorkCell andanMES in a variety and consistency which is unique worldwide.
SmartWorkCell
Auxiliarieshaveadirectinfluence ontheresultofaprocess andconsequentlyonproductquality.lna SmartWorkCelltheinjectionmoldingmachineisabletoaccesstheparametersandconditionof the auxiliariesandtorespondintelligentlytoanychanges.TheSmartWorkCellthusallowsforevenhigher quality standards inthemanufactured parts as well as complete data storage and traceability.
SMARTWORKCELL IT Security
Wittmann 4.0 router
This is an in-house development by theWITTMANN Group,which fulfills many different tasks:
》 Network structuring the devices"behind"the router form their own sub-network
》 External communicationgateway aggregationserverfortheindividualparticipantsinthesub-network
》 Proprietary firewall optimizedforusingWittmann4.0auxiliaries and OPCUA communication
》 Automaticrecognition of connected participants
The "onion peel principle"
Severalsecuritylayersprotectthevitalcontrolsystemsoftware againstexternal cyber attacks.The aimisto maintain the productionprocesswithWITTMANNequipmentsevenwhen the corporatenetworkmaybecompromised.
》 Layer 1-ITfirewall:
The outer layer is formed by the customer's network firewall. Thesecuritymechanisms and settingsin place there are unknown tothenetworkparticipants.Therefore thislayer must be regarded as potentially "insecure".
》 Layer2-Wittmann4.0router:
Thenextsecuritylayerisformedbytherestrictivelydesigned Wittmann 4.0firewall.It is specially adapted tocoverthe auxiliaries andfunctionalitieswhichcanbeassumedtoform partof theWorkCell.
》 Layer 3 -machine/auxiliary level:
Theinnermostsecurity layerisformed invarious auxiliaries fromWITTMANNbythedistributed controlsystem componentsworking ondifferentoperating systemstocomplicate evenfurther any possible attempts to infect theinnermost core of the control system.
SMARTWORKCELL "Plug&Produce”
DuringmoldchangeaSmartWorkCellofferstheadvantageofminimaluserinteraction.Theversatile "Plug&Produce”functionof Wittmann4.0enables preciselythisand guidestheoperatorduring amold change to the correct composition and settings of the WorkCell in3 simple steps.
Step 1
Selection of the desired mold data set.
The necessaryfunctions of the machine and auxiliariesfor thismold are displayed in the preview.These can now beprepared and brought tothemachine or,inthe case ofa mold change, plugged in immediatly.
Following the process of connecting and disconnecting various devices,the new configuration of auxiliariesis recognized and displayed within seconds.
Step 3
Now themold dataset can be loaded. The corresponding machine and equipmentsettings,whichhavebeensaved， aretransmittedtotherelevantunits.
THAT'S ALL!
Manual input errors havebecome a thing of the past.
Mderaiatltqltlaretirat dislayrlatttqstathdevitrtethlatt thatialthratirbthenfthchrfthtatretherel requiredtomvebetweentheperatingterminaloftheinjectionmoldingmachineandthoseofthevariousauxiliarie.
WithitsWittmann4.0technology,theWITTMANNGroupnowremediesthissituationwitha"OneScreenSolution": ONEcenralratinfthtidnmachnanlWimaxiiarreinoudthh
The following auxiliaries are supported by"app"technology on the B8control system:
W9 andWXrobots:WITTMANN'smost flexiblerobot line.Offering fixed and movingdemolding axis.Forallrobots additionalrotationaxesinservo orpneumaticexecutioncanbe offered.The R9 TeachBoxwitha screeninportraitformathassetnewbenchmarksintermsofergonomics and datainput withcapacitive touchtechnology and gesture control.Theintegrated digitaltwin providesfacilitiesforimproved andpredictiveanalysis.
Wittmann 4.0 uses othertechnologiesfortheintegration of auxiliaries: VNC and web browser.
VNC technology for mirroring:
W8robot:All modelsof the extensiveW8robotseriesfromWITTMANN areequipped with the innovative,high-performance R8 control system.This systemnot only supports
Remoteengineer-theonlineexpert
WITTMANN BATTENFELD helps users to remedy defects as quickly as possible.
》 SupportviatheInternet:
in additionto telephone support,WITTMANNBATTENFELDoffersa number ofweb-basedserviceswhichenableuserstocontactaWITTMANN BATTENFELD service engineer directly.
Thanks to the WITTMANN BATTENFELD web service,users are only seconds awayfromtheWITTMANNGroup'sentiretechnicalexpertise.
》 Thebasicprincipleoftheremote serviceissimple:
The machine is equipped witha control system softwarewhichmakesit possible tocarryoutnumerousservicefunctions simply via the Internet.If desired, the WITTMANN BATTENFELD service hotline can access the user's system to provide live support, analyze log files, executediagnosticsprogramsorremedy defects directly online.
》 Wide range of services by remote access:
Troubleshooting,usersupport,monitoring and remote inspection
-Round-the-clock access to the expert knowledgeofWITTMANNBATTENFELD worldwide
Increasedmachine availability and more productivitythrough shortresponse times
70% ofallnotifiedtechnicalproblems with injection molding machines are solvedviaremote access.
TEmi+ Do it smarter!
ManufacturingExecutionSystem(MES)isatoolthatprovidesrealtimeinteractivecommunicationandasistswithdata management.MEScantrack and document thewhole processfromtherawmaterialtothefinalproduct.
TEM |+\rrangle isaMES software speciallydeveloped forthe plastics industry. It helps make the best use of time and resources through a highly efficient intuitive human-machine interface.
》 Competitive edge
》Cost reduction 》Return on investment
》 Connectivity and control
Easy operation and intuitive design
》 Automaticdatacollectionfromall auxiliaries connected to theWittmann 4.0production cell
y Can be operated from any location thanks to webbrowser architecture
TEMI ^+ and its modules
TemiPlusisthestandardpackagewhichincludesallproductionlannerproductionmonitrdatamanager andOEEKPIprofunctionsThedatamanagerhandlestheadministrationoftheproductioncellsettingsfor theinjectionmoldingmachineandtheWittmann4.0auxiliary,aswellasthePDFviewerfordocuments, working instructions and product drawings.
TheAdvancedPackageisanextensionwhichincludesallfunctions andmodulessuchasthealarmmanager, theQMSmoduleandthemaintenancemanagerTheseservetoimprovebothproductivityandproductquality by reducing downtimes in conjunction with digital quality inspection.
TheConnectPackageisanextensionwhichaddstheinterfacetoconnect theTemiPluswithERPsystems and cloud services.
IMAGOxtis anoptionalhardware and softwarepackageformeasuring energy consumptionand other externaldata.Thankstothentuitivevisualizationofthemeasureddata,energypeaksduring theproduction process canbe optimized and reduced.
ERPconnectionmodule
Work orders from an existing ERP(Enterprise Resource Planning)system can be transmitted automatically to {\mathsf{T E M I}}+ and completionfeedback senttothe ERPsystemfrom there.
IMAGOxt
IMAGO is a module providing detailed analysis of energy consumption to make one's own company"greener". Byinstallingsensorsatallpointsofconsumptionenergy consumption can be measured and visualized across the entire facility.
QMSmodule
Theinstructions for quality inspection saved in \mathsf{T E M l+} tion,and therecorded process data ormeasurementreadingsforany parts produced canbe traced completely and correctlyallocated to the relevant lot.
Moldand machine maintenance
The maintenance module of {\mathsf{T E M l}}+ keeps track of all maintenance work performed in the plant.The data are also transmitted to theproduction plannerso that delivery times can be planed more accurately.
Production monitor
Here,the condition of all machines and their current order processing canbechecked live"at a glance".More detailed information about the individual production cells can be accessed easily from there.
Production planner
Knowing what needs tobe done,and when, is the key to successful production planning.This module provides an easy way to make the right decisions and optimize the production process.
presents in the form ofa simple,clear graphic chart thekey productionfigures which are essential forthe commercial success of an injection molding plant.
Themarket isconstantlyevolvingwith anincreasing needfor optimization ofenergyresources.More and more companiesare being pushed to install systems to monitor their consumption to get accessto state incentives,and to optimize their processesin theface of new regulations in the energy effciency field.No longer just simple meters,but comprehensive devices,whichcollect, store and process data comingfrom measurements at thepoints of consumption,provide process administrators with toolsfor optimizing energyresources.
Addedvalue
The advantages of this new model include not only potential economic savings,but also a more responsible approachto energy consumption that makes one's own company even greener and more eco-friendly.
》Intuitivity:The simplelayout and intuitive graphical representation helptogetafullpicture of all data and to understandcomplex analyses immediately.
》Awareness:The preciserepresentation and analysis of the company's actual resource consumption enables theimplementation of effective and strategic decisions for action.
》Wastereduction:The analysisenables earlyidentificationand implementation of the most viable methods and processes to minimize resource and energy waste.
》Environment:All measures contribute to improving the state of the environment and making the own company more sustainable!
IMAGOisanintegratedsystemabletocreateadynamicimageofenergyconsumptionbycommunicatingwithawidespreadnetworkofmeasuringinstrumentsadditiontorecordingtheconsumptiontrendsitenablesthecreatin ofcustomizedKPls(Keyperformanceindicators)sothattheenergyperformanceofthecompanycanalwaysbekept in mind.
ThecustomizationoftheIMAGOmonitoringsystemistailoredtothecustomer'needsdesignedfortheintegration ofallindustrialcommunicationinstruments,includingpreviouslyexistingequipment.Thankstothecloudservice IMAGOcanguaranteereliableaccesstothedataacquiredandoffersanextensivechoiceofsolutionsfordata processing andvisualization.Allthesefeaturesensuretheachievementoftheimportantobjective:maximizingthe effectiveness of the entire company.
INTERNETARCHITECTURE
TEMI+wasdevelopedonthebasisofawebbrowserarchitecturesothatallusersareabletoretrieve and process the data saved in {\mathsf{T E M l}}+ usingtheirpersonal accessdatafrom anywhereonthecorporate premises.
PRODUCTION CELLS
{\mathsf{T E M l}}+ is thefirstsoftwareproductwithaconceptbasedonthelogicof theInternetof Things.In thiswayit is nowpossible to network not only the machinesof a production plantwitheachotherandtosavetheirdata,butalsotoincludetheadditionalauxiliaries and their data, thanks to the advantages offered by Wittmann 4.0 manufacturing cells.
TRACEABILITY
With {\mathsf{T E M l}}+. companystaffno longerneedsto bother aboutsaving the production data.The system. takescareofthissimplyandclearlybyitsautomaticaccesstotherelationaldatabasesconnectedwith the production equipment.
TURNKEYSOLUTION
Not only the integration of {\mathsf{T E M l}}+ in a company is easy: its intuitive, user-friendly HMI requiresnolengthyandcostlystaff training courses.Thismeansthat userscanbenefit fromthesystemimmediately,whichalso contributesto shortening thepaybackperiod.
UNBEATABLEPRICE/PERFORMANCERATIO
Inspiteofthe enormousversatilityof the {\mathsf{T E M I}}+ packagesandmodules,therequired investment remainsmoderate,evenforsmallandmedium-sizedcompanieswishingtobenefitfromtheadvantagesofdigitizingtheirproduction.
SMART FACTORY
Withthe technologies presented here,theWITTMANN Groupisthefirstcompany worldwideto lay thefoundationforitscustomers'successinthe eraofdigitization.
Services suchas CMS andwebservicemakeit possibletominimize machine downtimes and maximizeefficiencyinproduction.
Wittmann4.0providesthebasisforbarrier-freedataexchangewithintheproductioncell with simultaneous network security.
TheTEMl+software module is a low-cost manufacturing execution system which supplies information from the production cells without time lag.
These solutions,which arealready availabletoday,openpartofthewaytowards autonomous injection molding production.Thanks to networking,production cells will communicate with each otherinfuture andbe abletoinform each other concerning disturbance variables. Autonomous machines will compensate process disturbance variables automaticallybytargeted corrective actions.
In this way,customers of the WITTMANN Group are optimally prepared for future development towards theSmart Factory.
WITTMANNBATTENFELDGmbH WienerNeustadterStrasse81 2542 Kottingbrunn|Austria Tel.: +43 2252 404-0 info@wittmann-group.com www.wittmann-group.com
