Networking reduces downtime
The core of Industry 4.0 is networking: machines and products collect, analyze, evaluate, and continuously communicate with each other. The unique potential of cell-based management lies precisely in the fact that die-casting units can quickly return to production readiness after a shutdown and achieve self-optimization even in the final expansion phase. This continuously improves the availability of equipment units. After all, approximately 47% of production interruptions today are caused by peripheral equipment (Figure 1).
The root cause is usually a lack of communication between subsystems. The consequence is data loss within the system, leaving operators unable to determine the cause of the problem or its solution. Overarching, unit-based management can effectively improve this situation. However, truly establishing intelligent, self-optimizing units still requires further development and the definition of standards.
Three steps to achieve intelligent die-casting unit
For Bühler, the development of the cell management system is a crucial step in making die casting a part of Industry 4.0. The transformation to intelligent die casting cells can be achieved in three phases. These three phases can be established independently or expanded continuously (Figure 2).
The first phase involves identifying and eliminating existing weaknesses in the die-casting unit. The key to this is installing a central control system, also known as a unit management component. Currently in the die-casting industry, if equipment malfunctions, operators typically have no choice but to start troubleshooting from the periphery of the equipment. This usually requires manually resetting each piece of equipment within the unit and restarting the process from its initial position. With a central control system, manual operation by operators can be eliminated, easily achieving automated resets. This allows operators to focus on other important tasks.
The second phase enables production optimization: In this phase, the central unit control system identifies deviation parameters and provides information on how to improve the production process. Furthermore, it can offer suggestions to prevent accidental shutdowns of the die-casting unit and make preventative maintenance possible. Another feature of the unitized management system is its support for visual operation, which helps operators analyze data and find solutions more easily. This interactive management model involving machines, operators, and process experts makes optimizing the die-casting process effortless. The availability of unit equipment is significantly improved.
The third stage aims to achieve the ultimate goal of intelligent manufacturing. This step can be fully automated and can prevent errors and quality fluctuations in production early on. Specifically, this is achieved through "predictive analytics." The control unit, based on calculations, can predict in advance which parts require maintenance and then propose targeted countermeasures. Maintenance can be planned and executed at the optimal time.
The central control system acts as the "brain" of the equipment units.
“We are currently implementing the first phase,” explains Laszio Jud, head of automation at Bühler Die Casting. In this phase, the unit control acts as the “brain” of the die casting unit, as it communicates directly with peripheral systems such as trimmers and marking machines (Figure 3). It works with the subsystems to control and monitor the entire unit. Unit control is performed by a central operating unit. The user interface is internet-connected and can be operated using mobile devices. Particularly noteworthy is the system's intuitive interface: clear and concise instructions, accurately pinpointing fault information, and maintenance assistance features. All relevant information during the production process is stored in a database, facilitating easy component traceability.
In the event of a production interruption, another advantage of the unit management system becomes apparent: fault reports from all equipment can be displayed centrally. This means that operators not only receive information about the fault itself, but the system also provides specific troubleshooting suggestions. This significantly shortens the failure cycle of the die-casting unit, enabling the equipment to be quickly restarted after a failure.
Traceability and quality assurance
Many industries require product traceability, especially the automotive industry, which emphasizes comprehensive traceability. However, achieving full traceability requires significant resources and financial investment. Cellular management can record detailed production data, thereby enabling product traceability.
Interface Standard
To achieve unitized management, interfaces need to be standardized and unified data formats and transmission protocols need to be established so that components from different manufacturers can be compatible. However, the interfaces of die-casting equipment to date do not meet the requirements of universality. Bühler adopts the IEC standard, which is widely recognized in the industry and is a prerequisite for communication between machine control and production management systems (Figure 4).
Compared to the universality of interfaces, intra-cell communication is more difficult to implement, and the challenge lies in establishing the exchange of deterministic signals. Currently, commonly used interfaces are Profinet and Ethernet/IP. Switching to new communication protocols will take time. "That's why we keep trying to use all interfaces in our cell management projects," explains Laszlo Jud. "However, we believe that IEC standards will soon become the standard for intra-cell communication."
Target data analysis at the unit level
To implement a unit management system, another task needs to be completed: data analysis and interpretation of process data. “Today, we have acquired a large amount of data from the die-casting machine. However, the most important thing is how to extend data collection to all other subsystems, how to interpret this data, what conclusions to draw, and what actions to take,” emphasized Laszlo Jud. The information collected by the unit equipment should be used to maximize the improvement of the die-casting process. For example, the current status of the equipment can be analyzed through data, thereby rationally planning the maintenance of the equipment unit. This marks another important step towards a digital future for the die-casting process: intelligent data collection can help people accurately analyze the causes of failures and optimize the production process accordingly. Jud said, “Experience tells us that building such a comprehensive database will bring endless benefits to our customers.” Undoubtedly, the correct use of production data can significantly improve the availability of die-casting units.
