November 2020 Volume 2

FORGING RESEARCH AND TECHNOLOGY

These points illustrate the economic potential of such measures, since the parts in question no longer must be changed in a certain rotation; a change of part is based on the real condition. It is possible that this procedure can extend the service life of certain wear parts and thus save costs. But even with an unexpectedly short service life

Similarly, in order to determine an ideal state, it was proposed to performa test cycle at a time outside production in order to eliminate any influences on the observed parameters. The duration should be a maximum of five minutes; preferably dead times should be used for this purpose (Figure 3). An investment budget for the realization of this project had to be fixed, followed by data logging and data analysis. Initial results are shown here. What does Industry 4.0 mean in forging companies? What does Industry 4.0 mean in forging companies?

of wear parts, this can counteract machine downtime. 2.2 Results, Analysis, and Conclusions

In the course of the analysis, various state parameters are observed both in the ideal state and over time. If a component fails, the process can be traced to failure. For example, if one or more parameters shows an exponential value history, forecasts for future events can be created. In the first step, as far as possible, all data bases are used to identify certain correlations. This basis can be reduced to the main influencing factors by following findings. This procedure has been applied to the processes in operation at a German forge. For this purpose, a Rail bound ForgingManipulator type SSM1000 (50 tons carrying capacity) supplied ten years ago by DANGO & DIENENTHAL with a corresponding press of a German Supplier was selected for data analysis (Figure 2). The Siemens controllers installed here are to be used as a data source for the time being, whereby the data collection can be carried out on the one hand via a cloud solution from Google or Microsoft and on the other hand locally with our own existing data storage devices. A cloud solution was finally selected. In this context, the parameterization for both the SSM 1000 and the press was determined. The analyzable sensor technology applied originally contained less than 100 elements. With 150 sensors, a storage requirement of about 100 Mbytes per year is required. Another step in the project process is the identification of the most important components for the analysis. Prioritization results from the potential savings in maintenance and increasing machine availability. elements. With 150 sensors, a storage requirement of about 100 Mbytes per year is required. Another step in the project process is the identification of the most important components for the analysis. Prioritization results from the potential savings in maintenance and increasing machine availability.

s

FIA MAGAZINE | NOVEMBER 2020 65 to reduce RTF maintenance in favor of a more proactive maintenance plan. If, in the past, the maintenance of machines and equipment were based on failures, it is feasible to start introducing a CMMS to collect important data to help predict future outages. CMMS is Figure 3: Data Logging at a Forging Manipulator. It is interesting for users of such machinery to perform comprehensive data analysis in order to reduce downtime and maintenance costs, but an even greater benefit lies in the increased product quality through better reproducibility, better mechanical properties of the forgings, and better documentation for the end customer. Machine and plant failures can be considerably reduced by the right maintenance strategy. The following terms must be distinguished: Run-To-Failure (RTF) Maintenance: The machine or system is running until an error occurs. A simple example would be the replacement of a burnt-out light bulb. An important goal of a computer-aided maintenance management system (CMMS) is to reduce RTF maintenance in favor of a more proactive maintenance plan. If, in the past, the maintenance of machines and equipment were based on failures, it is feasible to start introducing a CMMS to collect important data to help predict future outages. CMMS is characterized by its support in maintenance planning, preventing plant failure, and extending Preventive maintenance, PM for short, is triggered by timings, measurements, or events. This type of maintenance is common in a lot of maintenance departments already. One general example is the regular car inspection: oil change per 30,000 km or every 24 months (Figure 5). Condition-BasedMaintenance (CBM): A condition-oriented maintenance, CBM, makes it possible to connect meters and measuring devices from machines and trigger work orders when certain limits are achieved. Figure 3: Data Logging at a Forging Manipulator. It is interesting for users of such machinery to perform comprehensive data analysis in order to reduce downtime and maintenance costs, but an even greater benefit lies in the increased product quality through better reproducibility, better mechanical properties of the forgings, and bett r docume tation for the end customer. Machine and plant failures can be considerably reduced by the right maintenance strategy. The following terms must be distinguished: Run-To-Failure (RTF) Maintenance: The machine or system is running until an err r occurs. A simple ex mple would b the replacement of a burnt-out light bulb. An important goal of a computer-aided maintenance management system (CMMS) is component life cycle (Figure 4). Preventive Maintenance (PM):

n

Figure 2: Rail bound Forging Manipulator. Cylinders, valves, pumps/motors, transmissions, and oil-filters are conceivable. Subsequently, it has been proposed to monitor the oil quality or to predict the optimal time for an oil change. Since a SSM 1000 contains around 3,600 l of hydraulic oil, an oil change costs about $4,000 (for just the oil). In addition, a clean oil requires a longer service life of all components. Figure 2: Rail bound Forging Manipulator. Cylinders, valves, pumps/motors, transmissions, and oil- ilte s are conceiv ble. Subsequently, it has been proposed to monitor the oil quality or to predict the optimal time for an oil change. Since a SSM 1000 contains around 3,600 l of hydraulic oil, an oil change costs roundabout 4,000 $ (for just the oil). In addition, a clean oil requires a longer service

d