VIEWPOINTS INDUSTRY LEADER OPINION & ANALYSIS Facilitating the Factory of the Future v F
actories of the Future will transform the manufactur- ing process from a patchwork of isolated sectors and cells to an agile, integrated environment, with seamless
downstream and upstream communications. Data will be key. With more to manage, and related pro- cesses to integrate, a Lean approach is more important than ever. Information is the new business currency. From shop fl oor to board room, it must be easily updated and evaluated. Well segmented, actionable data creates the premise for new customer experiences. However, challenges in security, standardization and skills must be overcome.
Security
The IT world is fi ghting its own security battles as data multiplies. This consideration is even more complex in indus- trial automation. Cyber-physical security is critical: security must evolve with the technology it protects.
Standardization Standardization is the fundamental principle underpinning success, ensuring that machines, operators, and analysts all talk the same language. It forms the basis for communication between production, automation and oversight. It is the basis for the Industrial Internet of Things (IIoT). Factories of the Future will interconnect every step of the manufacturing process, integrating systems across domains, hierarchy, geographic boundaries, value chains and life cycle phases. The effi ciency and viability of this integration will be strongly dependent on technologies, supported by global consensus-based standards.
Skills
A unique skillset is required to operate industrial and ‘vir- tual’ machining processes. This skills gap represents a huge challenge. There are also cultural considerations to overcome in bringing together two ‘legacy’ teams that have traditionally had responsibility for, and expertise in, very different areas. The human operator will interact with smart assistance systems, integrated with production equipment and cyber-
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AdvancedManufacturing.org | January 2016 Sensing
Machine tools have evolved into advanced systems, with faster spindle speeds and traverse feed rates, automatic tool changers, and complex controls. However, advancement in the development of the machine tool hasn’t been matched by a system to monitor it. Although much information can be collected, there are still sub-systems and performance pa- rameters that require additional sensing solutions for proper monitoring. New sensing solutions or adaptations are needed to enable inclusive, accurate and robust monitoring strate- gies to characterize, diagnose and control manufacturing. Smart tools and inserts, with sensing capabilities will allow users to monitor the process and/or condition of the cutting tool, enabling accurate control of condition and prevention of breakage. This technology is in the early research stage, but once available, could revolutionize tool condition monitoring and shape the future of machining.
Software and Analytic Models Most solutions today only address cutting or grinding
process design and parameters, and tooling optimization. Future analytic tools will be continually adaptable to operat- ing conditions. Data must determine decisions and machines must self-correct to optimize effi ciencies. A solution to the infl exibility of CNC programs is adaptive
control: monitoring cutting conditions in real time and providing automatic optimization. Adaptive control is often part of a tool or machine condition monitoring system, and involves different sensing, data processing, and actuation solutions.
physical systems. To keep up with rapid advancements, manufacturers will need to invest in developing technical tal- ent to harvest the benefi ts offered by fast-paced factories.
Monitoring of data should eventually lead to adaptive control, in which machine tools can optimize themselves according to data from sensors.
Dr. Radu Pavel
Chief Technology Offi cer OPTIS
optis-solutions.com
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