Digitalization in Aerospace
Transcript of Digitalization in Aerospace
Digitalization in Aerospace
www.siemens.com/aerospace Dominik Riehle
Confidential / © Siemens AG 2016. All Rights Reserved.
Aerospace – the healthiest industry
Confidential / © Siemens AG 2016. All Rights Reserved.
High Pressure for production increase
Increased complexity
Boeing 787 Airbus A350 Airbus A380
Aluminium Composites/Titanium
Source: Internet
Market Growth Heavy backlog
Confidential / © Siemens AG 2016. All Rights Reserved.
Beside Pressure for production increase - Technology Transforming Business
Models defined
Confidential / © Siemens AG 2016. All Rights Reserved.
Challenges for the manufacturing industry are growing worldwide
Manufacturers need to transform
Enhance flexibility Individualized production with higher productivity
Reduce time to market Shorter innovation cycles
with more complex products
Increase efficiency Energy and resource efficiency
with global operations
Confidential / © Siemens AG 2016. All Rights Reserved.
The End Customer requirements in Aerospace Manufacturing
Product Design
Production Planning
Production Engineering
Production Execution
Service
Confidential / © Siemens AG 2016. All Rights Reserved.
The Digital Enterprise
TIA
Production
Totally Integrated Automation
Product design
Automation design
PLM
Product Lifecycle Management
Design and virtual production Real production
cPDM
Digital Production
MES
CNC
TIA Portal 3D Process Design
CAD + CAE
Production Planning
Confidential / © Siemens AG 2016. All Rights Reserved.
Feeding Back Insights from Realization and Utilization Makes a Smart and Agile Value Chain
Confidential / © Siemens AG 2016. All Rights Reserved.
Portfolio Alignment – Covering the Aerospace Supply Chain
SIEMENS
PLM products and
Services Totally Integrated Automation
Manufacturing Executions
Systems Customer Services
• Retrofit
• Service Contracts (incl. Data driven services)
• Training
Machine Builder
End
customer
Confidential / © Siemens AG 2016. All Rights Reserved.
Machine Tool builder / System Integrator Primes and Tier 1
Our Sales force passion - Partnerships with end users and Machine Tool builders / System Integrators
Global Siemens Aerospace Team
• Develop productivity advantages with machine tool builders and
System Integrators
• System solutions for technology leadership
• Standardization of leading edge technology
Balanced
triangle
Confidential / © Siemens AG 2016. All Rights Reserved.
Digitalization will not work without people A dedicated Account Team supports the end customers in Aerospace
Global Aerospace Account Management Team
Confidential / © Siemens AG 2016. All Rights Reserved.
Aerospace Key Account Management
Key account managers
Confidential / © Siemens AG 2016. All Rights Reserved.
Communication concept www.siemens.com/aerospace
Manual
Internal
PR & Media Cooperation
Brochures
Social Media
Newsletter, PPT
Video, Trailer
Online, external
Meeting presence
Siemens One Meetings
Marketing Manager Meeting
Website set up Key visual
www
Application Manual Reference Manual
360° communication
Confidential / © Siemens AG 2016. All Rights Reserved.
The End Customer requirements in Aerospace Manufacturing
Product Design
Production Planning
Production Engineering
Production Execution
Service
Confidential / © Siemens AG 2016. All Rights Reserved.
One Digital Backbone Homogenous program management and systems engineering
Challenges
• One homogenous platform
is required to conduct the
complete product lifecycle
management
Advantages
• Integrated verification
process
• One single source for
product information on a
global base
Teamcenter
Confidential / © Siemens AG 2016. All Rights Reserved.
Design, engineering and manufacturing solution help Aerospace manufacturer to deliver better products faster and efficient
Product Design
Challenges
• Openness and modularity approach
to product development
Advantages
• End to end from design to
production based on one integrated
Siemens toolset
• This toolset coordinates disciplines,
preserves data integrity and
streamlines the entire product
development process
NX CAD/CAM
Confidential / © Siemens AG 2016. All Rights Reserved.
NX Design Flexibility
Flexibility to use the best tool for your design task in a single environment delivers maximum productivity
Parametric feature based modeling
• Sketch Based Workflows
• Feature Based
Synchronous Technology
• Fast design evolution
• Increased data reuse from other CAD systems
• Fully integrated with feature modeling
Freeform modeling
• Flexible approaches to generate complex shapes
“It was up to our engineers to select the system they wanted and they chose
NX. Soon we began to understand that it was new technologies rather than just
new tools”
Evgeny Savchenko
Head of Mechanical CAD
Sukhoi Design Bureau
Confidential / © Siemens AG 2016. All Rights Reserved.
A complete CAM solution for aerospace parts
• High quality surface finish
• Increased machining productivity
Fast and accurate programming
• Prismatic parts – milling, turning, mill-turn
• Complex parts – advanaced 5-axis
• Forms – high speed machining
• Programming automation
Production-ready output
• Integrated G-code driven machine tool simulation
• Optimized output for Sinumerik controlled machines
• Directly connect CAM to CNC
NX CAM for Aerospace Machining
Confidential / © Siemens AG 2016. All Rights Reserved.
Optimize the Speed and Efficiency Using High-Fidelity Simulations of Complex Automation Systems
Production Planning
Challenges
• Verification of the error free CNC
program
• Downloading of the optimized
program to the CNC machine
Advantages
• Reduction of process prove-out
time due to a full digital model
• Containing all parameters and
restrictions of the real machine
(dynamic and geometric dimensions)
VNCK
Confidential / © Siemens AG 2016. All Rights Reserved.
Future: all use-cases supported on NX platform
Tool Path Verification
part & tool
Machine Simulation
tool path driven
Machine Simulation
G-code driven
Generic
OOTB ready-to-use for tool path based
verification & simulation
Machine Specific
controller integrated virtual machining environment
for final NC code validation, synchronization & optimization
Machine Simulation
controller driven
VNCK
inside
Virtual Machine
VNCK / HMI
based
Confidential / © Siemens AG 2016. All Rights Reserved.
Siemens 840D VNCK Support
NX CAM
Sinumerik VNCK
Post-processing
NC Programming
Integrated Simulation
Siemens Virtual NC Controller
3D machine tool and tooling models with kinematics
Unique machine tool characteristics - from real controller
Verification Cut motion and material removal
Machine Simulation Common Simulation Engine driven
Machine Simulation Virtual NC Controller driven
Optimized for Sinumerik 840D
Tool path
NC Code
NC Code
Confidential / © Siemens AG 2016. All Rights Reserved.
Extend the Digital Thread to the Shop Floor With an integrated CAD-CAM-CAE Chain for Hybrid Manufacturing
Production Engineering Hybrid Manufacturing:
Think it. Model it. Make it.
Confidential / © Siemens AG 2016. All Rights Reserved.
The End Customer requirements in Aerospace Manufacturing
Product Design
Production Planning
Production Engineering
Production Execution
Service
Confidential / © Siemens AG 2016. All Rights Reserved.
Security Integrated
Safety Integrated
Diagnostics
PROFINET
Common Data Management
HMI Controller Distributed I/O Motion Control Drives
WinCC Step7 Scout Startdrive
Totally Integrated Automation Portal
Challenges:
• Flexibility, reliability, security, and
safety
• Standardizing engineering platforms
to cover all applications in aerospace
manufacturing for maximum
efficiency
Advantages:
• Unique and consistent user interface
concept for all technologies provides
a connectivity standard
• Common and centralized services
for PLC- and CNC driven applications
TIA Portal
Production Engineering
Intuitive Efficient Proven
Minimize engineering cost by using one platform for all engineering applications
Confidential / © Siemens AG 2016. All Rights Reserved.
Communication in Manufacturing Real-time performance and open Ethernet communication in one system
PROFINET – communication from field to management level
Horizontal integration
on machine level
Full TCP/IP in parallel
to real-time
Industrial Standards
e.g. OPC, Safety,
Energy Management
Maintenance
and service
IT level
TIA
Machine level
M2M
Quality
Data
Motion
Energy
Data
BoM
Diagnostic
Data
Remote
Service
Production Engineering
Confidential / © Siemens AG 2016. All Rights Reserved.
PROFINET interconnectivity
Interconnectivity by PROFINET PROFINET interconnectivity in production plant
CL
ICK
TO
PL
AY
Confidential / © Siemens AG 2016. All Rights Reserved.
How can safety engineering be easily integrated in the machine?
All from a single source
Integrated safety solutions for
recording, evaluating, all the
way to responding
Reduce complexity
by means of an integrated
safety solution
Integrate machine safety directly
Easy fulfillment of machine
directives
due to standard-conformant
evaluation and certified products
Confidential / © Siemens AG 2016. All Rights Reserved.
Production Execution
Advcanced Controller - SIMATIC S7-1500 T-CPU
Integrated web server
Communication
High Speed
Archives & recipes
Confidential / © Siemens AG 2016. All Rights Reserved.
The compact PC-based controller SIMATIC ET 200SP Open Controller
for serial machine builders Unique combination of a failsafe controller and modular I/Os
Feature / Function Benefit
• compact system with integrated
safety functionality
• No additional safety controller
necessary less space
• Controller, visualization, central
I/Os and Windows applications
on one device
• Decreased spares inventory
• Decreased effort for evaluation
and service
• Powerful PC-based controller
with complete engineering in the
TIA Portal
• Increased productivity and
reduced engineering effort
Production Execution
Confidential / © Siemens AG 2016. All Rights Reserved.
Production Execution
Mobile Panels 2nd Generation
Performance like a Comfort Panel +
Sturdy and brilliant at once +
PROFINET / PROFIsafe +
Unique emergency button +
Compact connetivity +
Confidential / © Siemens AG 2016. All Rights Reserved.
Code-Reading and RFID systems
RFID Systems Code-Reading Systems
High-performance code-reading systems for
1D/2D-codes, text and form-recognition Compact and high-performance RFID systems for
HF-range (short range)
UHF-range (long range)
Production Execution
Confidential / © Siemens AG 2016. All Rights Reserved.
Tool Identification with SIMATIC Ident for machine tools
SIMATIC RF250R with ANT8 SIMATIC RF210R
SIMATIC RF180C/
RF182C
SIMATIC RF160C/
ASM456
SIMATIC RF250R with ANT8 SIMATIC RF210R
PROFINET/Ethernet TCP/IP
PROFIBUS
RS232
RS422
SINUMERIK SIMATIC
Integration into the machine tool controller
Confidential / © Siemens AG 2016. All Rights Reserved.
SIMATIC Energy Manager PRO ISO 50001 certified Energy Management System for industry and production
Feature / Function Benefit
TÜ V audited Energy Management
System in accordance with ISO
50001 and energy efficiency
projects
Efficient compliance of legal
requirements
Identification of savings potential
by using flexible and automated
analyses and reports with energy
key figures
Reduction of operating costs and
ensuring the competitive advantage
Seamless connection to SIMATIC
Energy Suite and open interfaces
for the connection of additional
systems
Linkage between energy data,
production data, security of
investment and scalability
Consumption forecast for all
media
Efficient energy purchase
Confidential / © Siemens AG 2016. All Rights Reserved.
The End Customer requirements in Aerospace Manufacturing
Product Design
Production Planning
Production Engineering
Production Execution
Service
Confidential / © Siemens AG 2016. All Rights Reserved.
Challenges
• Standardize the CNC automation
concept with highest performance
and quality throughout the lifecycle of
the partfor all technologies: (5 axis
machining, Composite, additive
manufacturing, robotics)
Advantages
• One single platform for all
technologies
• The open SINUMERIK kernel allows
imple-mentation of aerospace
specific functionalities
SINUMERIK
Cover all Aerospace technologies by one CNC Controller Achieve highest performance in machine operation
Production Execution
Confidential / © Siemens AG 2016. All Rights Reserved.
Modern touch technologies
and intelligent structures make work quicker at the
machine
Siemens offers first touch technology for intuitive operation
Confidential / © Siemens AG 2016. All Rights Reserved.
Challenges
• Optimum milling results are crucial particularly
in the aircraft industry. The SINUMERIK
MDynamics Milling technology package is the
ideal tool for such applications.
Advantages
• Advanced operation and unique technology
cycles
• Ultimative shopfloor programming and high-
quality CNC simulation
• SINUMERIK MDynamics sets up new records
regarding the surface quality, precision and
speed
SINUMERIK MDynamics
Aerospace specific functionalities Improve surfaces through optimization of the CAM data and intelligent milling
Production Execution
Confidential / © Siemens AG 2016. All Rights Reserved.
Top Surface - the enhancement of Advanced Surface
Improved surface quality:
With diagonal programmed toolpaths for finishing
With poor data quality and/or irregular point
distribution in NC programs from the CAD/CAM
system
Improved machining speed:
Improved observation of acceleration and jerk
limits
Improved contours perfectly :
• Preset standard values for contour and orientation
tolerance for nearly all
Formerly Formerly Formerly
Top Surface Top Surface Top Surface
Confidential / © Siemens AG 2016. All Rights Reserved.
Each Aerospace parts characterized their own requirements, but all have one
common property 5-axis machining
Velocity Accuracy Surface
+++/
+ (Ti) ++ +
Velocity Accuracy Surface
++ +++ +++
Velocity Accuracy Surface
+++ ++ +
Velocity Accuracy Surface
++ ++ +
Aero
str
uctu
res
Co
mp
osit
e
pro
cessin
g
En
gin
e
Co
mp
on
en
ts
Lan
din
g g
ear
ORIVECT
Great Circular Interpolation
Tol
TRAORI
Transformation Orientation
COMPCAD
Smoothing by Compressor
Look Ahead
Speed profiles over blocks
Confidential / © Siemens AG 2016. All Rights Reserved.
ORIVECT Great Circular Interpolation
Task • Machining of structural parts, esp. Thin-walled pockets
Solution • Using vector interpolation within in a plane by using the function ORIVECT
Advantages • Programming longer linear sets w/o infringing the contour
• Describing an inclined wall exactly by one sentence
• Easy-to-use by the preconfigured function
Confidential / © Siemens AG 2016. All Rights Reserved.
TRAORI 5-Axes transformation orientation
Without Transformation
With Transformation
Task • Position transformation to machine coordinate system from a workpiece
based NC program
Solution • Using the integrated TRAORI functionality to adjust automatically the path
due to the position related Tool Tip (TCP)
Advantages • Program independent of tools (orientation and length)
• Program independent of machine kinematics
• Highly complex workpieces can be manufactured on different machines with different cinematic characteristics w/o a specific postprocessor run
Confidential / © Siemens AG 2016. All Rights Reserved.
COMPCAD Smoothing by Compressor
Tol
Task • Highly requested surface qualtiy, accurancy and speed
Solution • The function COMPCAD converts the complete polygon into a series of spline
blocks
Advantages • Creation a user defined tolerance band
• Smooth curves ensures high surface quality
• Automatically optimized speed profiles to meet the surface quality.
Confidential / © Siemens AG 2016. All Rights Reserved.
Look-Ahead function Path guidance “sees”
Feed
Block N1 N12
G64 Look Ahead
Task • Requests in reducing machining time
Solution • Look Ahead function „sees“ into a numbers of traversing sets in advance and
calculates a speed profile over all.
Advantages • Activated functions ensure the best balance between machining time and
suface quaity
• Smooth velocity profile at maximum speed
• Avoiding braking at block transition improves surface quality
Confidential / © Siemens AG 2016. All Rights Reserved.
Rotary technology without borders:
Full extent in technology cycles and measuring cycles
for rotary operations
Maximum process security:
Unlimited simulation of rotary operations in any levels
and tool orientations
SINUMERIK Multi-Tasking-uses – revolutionary Mill/Turn
SINUMERIK-Multitasking
Confidential / © Siemens AG 2016. All Rights Reserved.
Drilling and milling Turning
Turning on milling centers - an additional technology field in the machine
With turning on milling centers the existing milling center kinematics is used in a different interaction of the axis and spindles involved.
Orientation axis (B)
Rotary axis in position control
Milling spindle
Spindle in speed control
Rotary table (C)
Rotary axis in position control
Rotary table (C)
Spindle in speed control
G18
+Z
+ X WCS
+Z
WCS + X
+Y
G17
Orientation axis (B)
Rotary axis in position control
Milling spindle
Rotary axis in position control
Example: milling center with B/C-kinematics
3
Confidential / © Siemens AG 2016. All Rights Reserved.
SINUMERIK- The special 5-axes functions are also available for turning
Confidential / © Siemens AG 2016. All Rights Reserved.
Recording of measurement results - quality transparency in JOG and Automatic
CSV-format
Text format
Measurement in JOG
Measurement in Automatic
From system software 4.7 the measurement results can be stored in standardized protocol files with a minimum of effort – in the setup-mode as well as in
Automatic.
Confidential / © Siemens AG 2016. All Rights Reserved.
EES - Execution from External Storage - memory without frontiers
EES extends the CNC-memory on external storage media such as network drives– without limitations in the functionality (elimination of the EXTCALL-command).
EES – CNC-memory without restrictions
PCU50 SSD
SINUMERIK 840Dsl
User CF-card
SINUMERIK 828D
SINUMERIK
sytem CF-card
Industrial Ethernet
Server
Network drive
CNC-memory on SINUMERIK
NCU/PPU
Confidential / © Siemens AG 2016. All Rights Reserved.
Enhance already accurate machines with CNC based VCS compensation
Yesterday: Mechanical adjustment of machine components and
highly-developed craftsmanship
TCP positioning error
Ma
nu
fac
turi
ng
eff
ort
Today: Mechanical adjustment of
machine components and highly-
developed craftsmanship combined with
CNC based VCS compensation
CNC based
Compensation
VCS
Yesterday
“Scraping”
Today
“Programming”
Confidential / © Siemens AG 2016. All Rights Reserved.
Compensate for the Geometric Errors in a Machine Tool and make
accurate portal milling machines even more accurate
Six errors for each linear axis plus three squareness errors (3-axes machine tool: 6 + 6 + 6 + 3 = 21 possible errors)
Note:
geometric errors may vary
with temperature
Confidential / © Siemens AG 2016. All Rights Reserved.
Complete Compensation for SINUMERIK-controlled 3/5 axes machine tools
VCS File Format
[XTX]
AXIS_LENGTH [mm] = 1800
LINEAR_CORRECTION [mm/m] = 0.0
INTERVAL [mm] = 25
DEVIATION [mm]
GRIDPOINTS = {
-75.0 -0.012193623479
-50.0 0.000000000000
-25.0 0.012193623479
…
21 Geometric Errors + SINUMERIK 840D sl = Higher Accuracy
Error of linear axes
Error of rotary axes
CNC based Compensation
VCS
Activation of VCS Benefit for machine tool user : accurate results
Measure
Activation of TRAORI
Error saved in VCS file
Errors saved in TRAORI-MD Rot. Comp. Swivel Head
CYCLE 996 All Mechanism
6 pts
25~30 pts
Confidential / © Siemens AG 2016. All Rights Reserved.
Ensure and increase machine tool availability One central platform provided by SINUMERIK Integrate for Production
Production Execution
Client
Server
Industrial Ethernet
Client Client Client Client
SINUMERIK Integrate
Company Level
• Manage MyPrograms (MMP)
• Manage MyTools (MMT)
• Analyze MyPerformance (AMP)
• Analyze MyCondition (AMC)
• …
Machine Operator station Tool store Tool setting station
• Enterprise Resource Planning (ERP)
e.g. SAP
• Manufacturing Execution System (MES)
e.g. SIMATIK IT
• PLM software (for example: TEAMCENTER)
Machine
Confidential / © Siemens AG 2016. All Rights Reserved.
SINUMERIK Integrate for production Digitalization for production with machine tools
Tecno-
matix
Manage MyTools
Analyze MyPerformance
Manage MyPrograms
Analyze MyCondition
SINUMERIK
Integrate
N10 G17
N20 G54
N30 T= “CUTTER_63“
N40 M06
N50 T= “CUTTER_20“
N60 S1200 M03
N70 G0 X-20 Y-20 Z-5
N80 Z-3
N90 G94 F1000 X100
CNC program
N05 G54
N10 G17
N15 T=“CUTTER_20“
N20 M6
N25 S2000 M3
N30 G0 X10 Y10 Z-5
N35 G1 G94 F1200 X100
N40 Y100
N45 X0
N50 Y0
Machine statuses
x x OEE = Avail-
ability
Perfor-
mance Quality
AMP Clients
AMP Server ist
soll
Evaluation of
machine status
Determination of
OEE figures
Acquisition of
machine status
Test results Measuring series Reports
Status
analysis
Initiation of
actions
Status
monitoring
CNC
program
N05 G54
N10 G17
N15
T=“CUTTER_20“
N20 M6
N25 S2000 M3
N30 G0 X10 Y10 Z-5
N35 G1 G94 F1200
X100
N40 Y100
N45 X0
N50 Y0
CNC
program
N05 G54
N10 G17
N15
T=“CUTTER_20“
N20 M6
N25 S2000 M3
N30 G0 X10 Y10 Z-5
N35 G1 G94 F1200
X100
N40 Y100
N45 X0
N50 Y0
CNC
program
N05 G54
N10 G17
N15
T=“CUTTER_20“
N20 M6
N25 S2000 M3
N30 G0 X10 Y10 Z-5
N35 G1 G94 F1200
X100
N40 Y100
N45 X0
N50 Y0
Confidential / © Siemens AG 2016. All Rights Reserved.
Conclusion - Closed Loop Manufacturing is the factory of the future
Production Resources Production Process Product Structure
Virtual
Product Design
Production Planning
Production Engineering
Production Execution
Service
technical domains in
one data model
Virtual
Confidential / © Siemens AG 2016. All Rights Reserved.
Thanks a lot for your attention
Digitalization will become
a revolutionary step
to a new level
in manufacturing!