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Digitalization @ Schaeffler
The Machine Tool 4.0
Sebastian Mergler
07.04.2017 Machine Tool 4.0 | Sebastian Mergler2
Agenda
Digitalization@Schaeffler1The Machine Tool 4.02Product ideas & added value3
07.04.2017 Machine Tool 4.0 | Sebastian Mergler3
Agenda
The Machine Tool 4.02Product ideas & added value3
Digitalization@Schaeffler1
07.04.2017 Machine Tool 4.0 | Sebastian Mergler4
SchaefflerPre-Processor
3rd party devices
Smart Sensorization
Vario-Sense
XelerisSmart Check
…
Service
MaintenanceContracts
…
RULAutom.
DiagnosisGrease
RUL
… … …
Smart Actuation
Concept 8 PWG HLE …
Mec
hat
ron
ics
Se
nso
rs &
Act
ua
tors
Vir
tual
Tw
in
Mo
del
s &
Da
ta
Ap
plic
atio
ns
Se
rvic
e
Service Analytics
BearinX TELOS Caba3D
CAx MBS …
Big Data Analytics
Physical Analytics
Sch
aeff
ler
Do
mai
n K
no
wh
ow
Product
LifetimePrediction
…
Production
ProcessMonitoring
…
Improvement of… availability/TCO… reliability… process quality…
Simulation of… operating condition… critical load… remaining life-time…
Interaction by… measuring process data… visualization of
operating conditions… active process control
Machine Tool 4.0
Schaeffler Smart Ecosystem 4.0
07.04.2017 Machine Tool 4.0 | Sebastian Mergler5
Agenda
Digitalization@Schaeffler1
Product ideas & added value3
The Machine Tool 4.02
The Machine Tool 4.0
07.04.20176 Machine Tool 4.0 | Sebastian Mergler
Vibration sensors
Condition monitoringCrash detection
Force sensor
Calculation serviceProcess monitoring
Vibration sensor
Needed based lubrication
Pressure sensors
Load modelDisplacement model
Lubricant sensor/actuators
Needed based lubrication
More then 60 additional sensors are integrated into the Machine Tool 4.0
Machine Tool 4.0 Demonstrator
Machine Tool 4.0 Demonstrator
07.04.2017 Machine Tool 4.0 | Sebastian Mergler7
The Machine Tool 4.0
Field experience in a series production
Machine Tool 4.0
07.04.20178 Machine Tool 4.0 | Sebastian Mergler
Digital connection of all physical cell objects and sensors enables big data and analytics
tool set-up / measuring 3D measuring / inspection
laser markingsystem
electrified clampingsystem
machine tool 4.0
tool set-up / measuring
digitalization of toolstool management
laser marking system
individualization of every partenabler for analytics
3D measuring / inspection
digitalization of dimensionsenabler for analytics
machine tool 4.0
digitalization of machining processenabler for analytics
The Machine Tool 4.0 as a part of a digitalized production cell
07.04.2017 Machine Tool 4.0 | Sebastian Mergler9
Agenda
Digitalization@Schaeffler1The Machine Tool 4.02Product ideas & added value3
Availability losses: unplanned downtimesOverall Equipment Effectiveness
Critical components
07.04.2017 Machine Tool 4.0 | Sebastian Mergler10
Machine Tool 4.0
OEE=
x
x
Availability
Quality
Productivity
Main spindle 33%
Feed axis 30%
Automation 11%
Quelle: IFW Hannover, WZL Aachen, GMN Paul Müller Industrie GmbH & Co.KG
Others 13%
Fluidic 13%
Availability
Analytics forDigital Services
Big Data Analytics
Physical Analytics
Product idea | SmartGuidance
Machine Tool 4.0 | Sebastian Mergler
Machine Tool 4.0
Smart Sensorization
Data Pre-Processing
Maintenance
PredictiveMaintenance
Smart Actuation
Me
chat
ron
ics
Vir
tual
Tw
inA
pp
licat
ion
s
Sch
aeff
ler
Do
mai
n K
no
w-h
ow
MaintenanceHolisitc
Condition Monitoring
Production
Condition based lubricatrion
42%
29%
11%
9%
5% 4% Ball screw
Linear Guide
Electr. device
Cover
Others
30%
Vibration
*2: Source: ZUPRO & Schaeffler claims
*1: Source: IFW Hannover, WZL Aachen, GMN Paul Müller Industrie GmbH & Co.KG
*2
*1
2 3
1 09/17
09/18
07.04.201711
Product idea | SmartSpindle
Machine Tool 4.0 | Sebastian Mergler
Machine Tool 4.0
Smart Sensorization
Displacement
60%
11%
9%
7%
13%
Crash / overload
Wear
Leakage
Lubrication
Others
33%
Data Pre-Processing
Maintenance
Spindle History
Smart Actuation
Me
chat
ron
ics
Vir
tual
Tw
inA
pp
licat
ion
s
Analytics forDigital Services Big Data Analytics
Physical Analytics
Sch
aeff
ler
Do
mai
n K
no
w-h
ow
Product
Bearing History
Production
StaticCrash Detection
*1: Source: IFW Hannover, WZL Aachen, GMN Paul Müller Industrie GmbH & Co.KG
*1
*1
09/17
07.04.201712
Thank you.
07.04.2017 Machine Tool 4.0 | Sebastian Mergler13
Schaeffler Technologies AG & Co. KG
Sebastian MerglerProject manager Machine Tool 4.0
Georg-Schaefer-Straße 3097421 Schweinfurt
Machine Tool 4.0MDA-Forum
Hannover Messe Industrie25.04.2017