The complete recording of the production data for continuous monitoring and evaluation is the basis for the connected production. The different components and sensors of a robot system supply the data which is centrally saved, evaluated and made available for further use. Due to the constant monitoring of set/actual values, deviations from the plan can be recognised directly and corresponding corrections can be made.
The continuous exchange of data and information between the component, the master system and the complete production environment during production allows a constant information flow. Different application areas benefit from this. The exact and direct information about product and process data results in an improved key figures management, immediate change possibilities and a higher system utilisation ratio. Due to the complete and location-independent information availability it is possible to optimise the service and maintenance intervals.
The complete networking of the whole safety technology of a production environment makes it possible that potential causes for a safety-relevant downtime are visible at first sight. The reduction of downtimes results in an increase of the utilisation ratio of a system and in higher quantities at shorter production times. Service and maintenance intervals are optimised by the complete and location-independent information availability.
A constant and continuous acquisition of all production data in a central master system allows the efficient realisation of production processes. When the production data are available for different interest groups, processes can be optimised and company resources can be used optimally. Besides, the service and maintenance intervals can be optimised by the complete and location-independent information availability.
While the robot system is in production, a new program can be simultaneously produced in RoboPlan. The welding, search and travel paths and tools can be programmed using 3D models, and the welding parameters and other functions required for running the program can then be defined. The program is developed in this way before being transferred to the robot controller for optimisation in the workplace. This process is less time-consuming than the generation of a new programme in the system using the TEACH process. In future, further simulation possibilities will be available. At the end the complete production environment as digital twin will be an identical representation of the reality where extensive plannings and optimisations are possible.
A digital twin is a virtual image of the production environment which connects the real and the virtual world. Digital twins use real date of installed sensors which show, for example, the position of the components of a robot system. The coupling of the virtual and real worlds allow an optimum monitoring of the production system and a multitude of visualisation and simulation possibilities.
Sensors supply important data and signals for a profitable further processing. During the 3D measurement in a production line, the welded components are measured three-dimensionally and checked for tolerances and completeness. The sensor compares the actual values of the component with the specified set values and informs about deviations. Thus it is possible to take suitable actions for NOI (not in order) parts.
The continuously rising diversity of product variants with much smaller batch sizes at the same time requires highly flexible production and logistics systems. Instead of rigid transportation systems, intelligent material flow systems are in demand which adapt automatically to the given production conditions because the products to be manufactured can constantly change. An intelligent material flow allows the just-in-time provision of the component groups for the different production steps and the introduction of a chaotic production system.
Due to rising safety requirements the demand for a clear component identification and the corresponding allocation of welding parameters and production data increases. After the quality check, the components are marked with a bar code, an RFID code and/or a component number. The use of measurements for component recognition and identification allows a complete documentation and traceability.
The visualisation of data and results of a robot system on screens inform the employees quickly and directly about the current production state, quantities, error messages, cycle times and much more. Furthermore, targets and degrees of target achievement in different production areas can be displayed with graphics and diagrams. As the employees can see their own progress at any time, the visualisation is an important motivating factor.
Augmented Reality means the computer-supported augmentation of the perception of reality. This information can address all human sense modalities. In manufacturing companies, particularly the visual display of additional information such as graphics, pictures or videos offers many possibilities to optimise the production.
The component-related parameter allocation allows the individual program selection in a robot system which is the basis for the use of a chaotic production system. The parameters can be allocated by different measures of component marking.
Due to the use of a chaotic production system, the number and the order of components do not influence the productivity of a robot system in a negative way. The user can process many component variants without the need to retrofit every time. Thus there are no waiting times and it is possible to produce higher quantities at shorter production times.
In the case of the individual program selection, the welding robot automatically recognises the different component types, for example by means of an RFID code on the workpiece carrier. The robot automatically selects the appropriate processing program. The individual program selection via automatic component recognition allows the use of a chaotic production system. Thus the number of parts and the production order are irrelevant.
A process control system serves to control a production system. Modern process control systems automate process systems and illustrate the process. Thus the system operator can optimally analyse, control and plan the processes. A process control system helps companies to increase the efficiency of their production systems, to ensure the product quality and to react flexibly to market developments.
In a master user management, all users are administered with individual assignment of rights. The administrator can assign a customised rights package to every user. Here the users of all system are centrally managed and can be processed via the internet. Thus, every user has to remember just one access combination.
With the CLOOS User Management System you have direct access to the robots via Ethernet and TCP/IP. The network variant allows to manage the users on a central PC. In the case of the local variant the user logs in and off directly at the robot via the robot operating software. The recording of all user activities allows a complete documentation.
The integration of the production to a database allows an efficient realisation of production processes. Company resources can be used optimally which results in considerable cost savings. Furthermore, data redundancies are avoided because different application areas use a common database. The repair department also benefits from shorter service and check intervals.
Remote service is the external access to production systems and welding machines for information, maintenance and repair purposes. Due to the global, location-independent maintenance and diagnostics possibilities problems can be solved shortly without a visit of a service technician on-site. Maintenance is easier, the system availability increases and the operating costs are reduced.
ERP systems represent all in-house business processes. The aim of the data integration is the access of different application areas to a uniform data model. The complete representation of all in-house business processes enables an efficient use of the available resources. Thus data redundancies are avoided as far as possible.
Mass Customisation means the principles of the customised mass production or the individual production in series. This approach allows a customer-specific solution without giving up the advantages of a process-oriented series production. Due to modern production processes and technologies, the advantages of series and individual production are combined. Thus production companies can react more flexible and without additional efforts to individual customer requirements.
Predictive Maintenance allows the permanent monitoring of the robot system components by means of intelligent software and sensors. The software detects the sensor data, evaluates it and recognises a possible breakdown of the components at an early stage. Damaged components which may cause a system downtime are identified outside the usual maintenance times and can be replaced in time. Maintenance and spare parts procurement can be matched to each other thus reducing the downtimes. Due to the reduction of the downtimes and the increase of productivity the predictive maintenance considerably reduces the operating costs.
