Intelligent automation on the path to factory of the future

As has become tradition, the focus of the DMG MORI Open House event at DECKEL MAHO Pfronten from 14 to18 February 2017 has been on the latest innovations and ground-breaking technologies. On an exhibition area of over 8.500 m² the machine tool manufacturer showcased 80 high-tech machines live in operation, including three world premieres – the LASERTEC 75 Shape, the 3rd generation DMU 50 and the CLX 350 – as well as highlights from the die & mould, aerospace and medical branches.

The tone was set by the omnipresent topic “Digital Factory” at this year’s event in Pfronten. For DMG MORI Industry 4.0 in process and product means supporting customers with software in every process step. In the showcase CELOS® Factory DMG MORI presented the complete process chain – from the idea to the finished product. Highlights of power tools, CELOS®, and Industry 4.0 machine demonstrated the production of a component right through to the intelligent machine. Additionally, new automation solutions were showcased like Robo2Go and a flexible production system with LPP linear pallet pool.

“Industry 4.0” is dominating the discussion of the future like no other topic. As the world’s leading manufacturer of machine tools, DMG MORI supports its customers on their path to consistent digitalisation based on the app-based control and operator system CELOS® with intelligent software solutions and a lot of digital products and services. By now every fourth machine is thanks to CELOS® compatible with the future.

Due to continuous development of further future-orientated applications CELOS® ensures the seamless introduction of software solutions for Industry 4.0.The CELOS® CONDITION ANALYZER, for example, captures the status data of the machine tool. When combined with diverse Industry 4.0 sensor packages in turning and milling the user has, on the one hand, perfect software tools for monitoring the machine status and machining process which can analyse performance and status in real time directly on the machine control or externally via the CELOS® PC. On the other hand, can derive decisive knowledge for a reliable “predictive maintenance” solution from longterm evaluation based on APPs. This means customers save maintenance costs and have an effective tool for preventing unplanned downtimes to the greatest possible extent as well as boosting the efficiency of their production systems.

Integral solutions for automated production

Automation belongs to the key elements of a holistic CELOS® factory of the future. With its new loading and unloading system Robo2Go DMG MORI shows how this hurdle can be overcome already now.

The mobile Robo2Go system excels, on the one hand, through its flexibility. Within a very short time it can be used on different lathes of the customer if required with the aid of a lifting device, which of course maximises investment security. The system also allows permanent free accessibility to the machine tool.

After adaption to the lathe the system, on the other hand, can be programmed easily with a few entries via a special CELOS® APP right at the control. This keeps setup times to a minimum and optimises the utilisation rate. This completely parameter-based and therefore very simple way of programming the robot enables especially smaller firms entry into flexible automation.

Production system with an LLP linear pallet pool

Another highlight at the Open House with regard to automation is a flexible automated production system. The centrepieces of the impressive production system are the two horizontal machining centres NHX 5000 and DMC 60 H linear plus the LPP 24 linear pallet pool system, from which the two horizontal centres are fed with workpieces automatically.

The LPP-24 system on show in Pfronten offers storage space for 24 pallets on two levels. Thanks to the modular design of the LPP system, storage can be expanded optionally to accommodate 99 pallets, whereby several standardised configuration options ensure a high level of individual adaptability. Up to eight machines, for example, combined with maximum five setup stations can be connected even in the standard version. Further modifications are also available as special customised configurations. This makes the pallet pool systems of the LPP family the key to flexible automation for small and medium-sized series. Where necessary, one-off orders can be incorporated easily into the automatic process flow without reducing the overall productivity of the system as a whole.

Sophisticated laser texturing on a compact footprint

With its LASERTEC 75 Shape DMG MORI expands its portfolio in laser texturing of defined, technical surface structures by means of layer by layer material removal using a 3D laser. The machine is equipped with a 100 W fibre laser and CELOS® for simplest operation and full integration in the company organization.

With a footprint of just 8 m² the LASERTEC 75 Shape is ideally suited for the tightest of production environments but nevertheless offering a work area that can handle workpieces with diameters of ø 650 mm and heights of 500 mm. The NC swivel-rotary table is designed for components weighing up to 600 kg. The LASERTEC 75 Shape masters fast texturing, even in 3D free-form, with no problem at all thanks to contour-parallel laser shaping, which in turn does away with the need for any expensive, environmentally harmful etching. The modern control philosophy based on the SIEMENS 840 D solutionline plus user-friendly LASERSOFT software features round off the offer of the new model.

With enhanced technology for 5-axis applications now in its third generation

The new DMU 50 3rd Generation from DMG MORI combines more 20 years of experience in 5-axis milling with unique future technologies and sets new standards in simultaneous 5-side to 5-axis machining. With its enlarged swivel range, more powerful spindle and its innovative cooling concept, the world premiere ensures competitive ability in many areas of application for demanding branches such as the aerospace, medical and automotive industries.

A travel path of 650 x 520 x 475 mm and workpiece weights of up to 300 kg mean the new 3rd generation DMU 50 covers a wide range of components. Its new NC swivel-rotary table with an enlarged swivel range of -35°/+110° boosts this versatility. A rapid traverse of 42 m/min and 30 rpm in the swivel-rotary axis ensure the dynamics for simultaneous 5-side to 5-axis machining. The user has the choice of motor spindles with speeds up to 20,000 rpm in addition to the 12,000-rpm inline spindle. Also available as an option is an expanded tool magazine with up to 120 pockets. There are 30 tool pockets in the standard version. The 3rd generation DMU 50 achieves a degree of precision that is unbeatable in this segment thanks to its one-piece machine bed on the one hand and on the other its innovative cooling of the guides and drives.

Highly-productive universal turning center for a broad range of applications

As the latest model in this segment, the CLX 350 universal turning center expands the portfolio of high-performance basic machines from DMG MORI. In its standard version this compact model, with a footprint of less than 5 m², machines bar material of Ø 51 mm – with Ø 65 mm also available as an option. The maximum turning diameter of the CLX 350 is 320 mm. It has travel paths of 242.5 mm in the X-axis and 530 mm in the Z-axis. The VDI 30 servo turret has space for twelve tools – powered as an option. This all adds up to make the CLX 350 an efficient and highly-productive universal turning for a multitude of different applications.

With a speed of 5,000 rpm the highly-dynamic spindle can machine complex, high-quality components and guarantees maximum precision and accuracy of the workpiece. The labyrinth structure and air cooling prevent the penetration of coolant thus promising a high level of productivity and a long life cycle. The replacement cartridge means the spindle can be changed quickly and simply, even during servicing. The ball screw, with a tolerance class of IT 1, also plays a key role where precision and outstanding surface quality are concerned. The compact and stable design of the machine ensures maximum rigidity, even in the boundary areas of machining, as well as optimum chip removal. Thanks to its 19” multi-touch control from SIEMENS, the CLX 350 also offers the user fast and simple operation combined with perfect ergonomics and compact dimensions.

Best surface quality thanks to the integration of grinding technology

After setting standards in technology integration with mill-turn technology for almost two decades, the machine tool manufacturer has now expanded its portfolio in this field to include a new variant with milling, turning and grinding (F-mill D-turn S-grind) capabilities. So as of now the integration of grinding technology is available for all machines in the DMU / DMC FD duoBLOCK® series, thus guaranteeing top surface qualities of up to 0.4 µm. Milling, turning and grinding are carried out in a single setup, so deviations resulting from retooling are also eliminated.

DMG MORI supports the grinding process of the FDS models in the duoBLOCK® series with DMG MORI technology cycles for internal, external and face grinding. Truing cycles expand the range of functions. Also new is an AE sensor (Acoustic, Emission) that guarantees maximum reliability and accuracy by detecting the first contact between the grinding wheel and the truing unit. The first contact between the grinding wheel and the component is also determined via the spindle load factor. DMG MORI has equipped the 1,300-liter coolant unit of the FDS machines with a centrifugal filter that catches even the finest particles (> 10 µm) from the grinding process.