Smart Engineering and Productions 4.0

An important role for the efficiency of production cycles is played by Software solutions, the pillar of the infrastructure of a functional, innovative and “Digital” project. How will a manufacturer of automation systems have to move in order to industrialize an equipment using an automated and digital production process in 4.0 key? Through five steps, we will illustrate how to automate a process to realize automation electrical panels, starting from engineering to production and testing.

by Gruppo Meccatronica – ANIE Automazione

Is it possible to improve efficiency within production cycles? The current technological proposals allow us to find the right solutions for any kind of process. However, everything depends on companies and their desires to want to see their company faster, more flexible, innovative and protagonist in a market increasingly oriented towards listening and satisfying the needs of their customers. In this direction an important and priority role is exercised by the Software solutions, a real pillar around which it is possible to build the infrastructure of a functional, innovative and above all “Digital” project. Digital is the definition that will have to be assimilate in current and future visions for those who want to continue to be market trend-setters.
Why digital? With traditional methods it is impossible or extremely difficult to realize design engineering quickly and then be able to adapt it in real time to the needs of customers without having to face obstacles caused by bad communication between operational departments, suppliers or customers. We also consider the complexity of projects storage, production inputs and the high risk associated with errors with consequent loss of quality of the finished product. Why a digital future? If we analyze a normal product life cycle we realize that it is more and more like a “spot”, very fast market introduction times and the need to immediately think about its future, the needs of its users and how its production technology will evolve. Today we can safely say that the real impulse given to technological innovations has been generated by solutions coming from the IT world with the software, IoT, secure data storage and all the digital solutions connected to them. Let now try to think of how an automation systems’ manufacturer can industrialize an equipment using an automated and digital production process in 4.0 key, which possesses high productivity indexes, sustainable and easily implemented. An articulated process that develops within the value chain: from the digital choice of the components, the project engineering to the development and study phase of the “Digital Twin” to provide accurate and reliable production data. Data that can be replicated over time with absolute reliability, flexibility and adaptable to future changes in the market. Through five steps we will illustrate how it is possible to automate a process to create electrical control panels starting from engineering phase to the production and the final testing phase.

Digital descriptions of the items as a prerequisite
The digital description of the items is requested as a prerequisite to automate the processes without these necessarily being identical over time. The correct description allows you to accurately design the project by highlighting the components characteristics and the related technical data sheets. The components will be cataloged and positioned on the mounting plates and subsequently provided the connection and cable entry indications. In this phase the thermal calculation linked to the dissipation of the components can also be realized, designing, if it is requested, the correct conditioning system. All the project data will be saved in order to be reused in future projects, to create the order lists for suppliers and the construction specifications requested by the customer.

Virtual engineering of the control cabinet
Digital data is now the focus for developing the product and giving the right inputs to production. Before starting to program all the construction phases, it is possible to add a simulation phase called “Virtual Prototype”. This prototype allows to verify all the constructive parameters of the cabinet through a product’s virtual visualization in its entire production cycle. In this phase it will be possible to check all the compatibility indicators between project, materials/components management and production. The virtual development of the control cabinet can be visualized in 3D together with the whole digital technical description and presented to the customer for the appropriate technical approvals. It can also provide additional value within a commercial presentation concept designed to make the proposal professional and reliable.

Connected digital production project units/operational units
This approach is an important link between the project units and the operational units. Digital data, consolidated in the previous phase, will make possible to transform the virtual phase into reality by providing all the elements for an integrated production. In this phase, specific machining centers, fed in an automated manner, can in total autonomy perform the operations related to the mechanical machining of the flat parts of the cabinets and the mounting plates that will be machined with holes and threads to facilitate and speed up the subsequent assembly steps and the components’ electrical connection. All machining operations can be carried out in total automatism, reducing intermediate steps of machining and number of errors. In this way, the whole production chain will be fed with process continuity ensuring safety and quality.

The smart control system analyzes the data coming from the digital model
Through a digital process control it is possible to insert in-line smart check stations able to perform specific setups to identify errors and manage the stages of the production cycle progress. The intelligent control system analyzes the data coming from the digital model and determines the subsequent production steps. In constant dialogue with the work centers, it dictates the parameters related to the production capacity of the process line.
Online operators will be assisted digitally and guided through tablets in all the implementation phases related to electrical connections.
This digital cycle greatly reduces the complexity and errors, inserting the operator fully into a production cycle 4.0.

The future landscape includes augmented reality
Many features of the products can be controlled digitally even before they are assembled, so this aspect can be used as a pre-certification element. The verification of standardized models can be achieved by processing digital models. For example, these models can be integrated into standard modules within software tools or stand-alone software solutions. Today many tests can be done digitally, even if not all. Currently the functions can be tested only at the end of the production cycle. With the help of the digital model and the aid of augmented reality technology, it will be possible to guide the final approval process through a simulation activity able to lead us to the end of the final standardization process.