|8分钟阅读

Composites 4.0:从哪里开始?

传感器,物联网平台,数据分析 - 更智能化,高效制造的工具比比皆是,但开始的地方实际上更简单。
#specialReport.#composites101#composites4_0

这是7月2020年7月的在线侧栏,“Composites 4.0:数字转换,自适应生产,新范式“。在该文章中,我定义了Composites 4.0,然后讨论各种应用程序和含义。在这里,我想出为什么要关心的原因,然后通过两家拥有如何开始经验的公司的一些实际建议来行走。

Composites 4.0:为什么重要

Already the change has started. Companies are using digital technologies, sensors, data analytics and artificial intelligence to improve quality, reduce cost, boost production rates and cut lead times. Within the next 10 years, suppliers who can’t match these metrics will find it increasingly difficult to compete.

但肯定不适用于每个人?我在主要文章中讨论的例子范围从灯丝绕组到树脂输注,用于航空航天和工业,碳和玻璃纤维,热固性和热塑性塑料。

在去年的碳纤维2019年会议上,我领导了Composites 4.0的小组讨论。以下是来自小组成员的总结的利弊:

Composites 4.0 panel discussion challenges and opportunities

来源|CW

“公司在意识到他们需要开始数字转型之旅,但在哪里开始?”

从你的数据

“We’re seeing growing business activity and more composites companies involved with edge-computing, cloud-computing, AI [Artificial Intelligence] and 5G communications,” says Avner Ben-Bassat, president ofPlataine(沃尔瑟姆,质量。,美国和特拉维夫,以色列),作为复合材料制造业的工业4.0软件供应商。他指出,作为一家公司,柏拉托人每年看到大约200家工厂。“几年前,我们必须解释Edge-Computing和AI。现在,我们的讨论更加升高。所有这项活动都是成本降低和生产增加,目标更快,更好,更便宜。“

With this increased activity, however, there also comes a plethora of opinions. “Everybody now is talking about the data and you have to have 5G to collect the data,” says Ben-Bassat. “But there is already so much data being collected that companies are not using. You don’t need 5G or a massive investment to just start with the data you have.”

柏拉托克复合材料4.0应用程序

Many Plataine customers start with Composites 4.0 apps that enable more efficient use of data they are already collecting, such as prepreg out-time, ply kits per part and tool maintenance schedules. Source | Plataine

他说,真正的问题,“你是怎样的数据?我的指导是首先从你的问题开始。如果您需要增加速度,瓶颈在哪里?你需要收集什么样的数据以推动解决方案?“

Many companies begin by looking at software and Industry 4.0 platforms, which can be overwhelming. “First, you have to understand your parts, processes and customer demands versus what you can do as an organization,” Ben-Bassat advises. “Then you get to which software and platform might work to achieve the necessary solutions.”

“我们有涵盖复合材料谱的案例历史,但我们也在复合材料之外工作,”他指出。“一些公司拥有目标,KPI(关键绩效指标)和”数字转型计划“,其中包括变革管理和培训的要素。然后柏拉兰人成为其中的一部分。但我们也有公司试图弄清楚该做什么以及在哪里开始。所以,我们走进,做面试和过程分析。问'你想做什么?'如果他们不确定,我们会分配作业。“

数字转换一步一步

虽然主要文章具有较紧凑的Dynexa故事版本,但它缺乏一些有趣的观察和建议我认为值得分享的房间。

1. “Many players in the composites industry are not large R&D institutes with millions of dollars to spend on this.”

Dynexa长丝绕组碳纤维

Dynexa采用湿丝绕组生产高质量的碳纤维复合管和轴。查看Dynexa的CFRP输出轴“Composite output shaft ready for automotive proving ground“。来源|Dynexa.

Christian Koppenberg是董事总经理Dynexa.(德国Laudenbach),使用湿丝绕组制作复合管和轴。“我们是零部件制作人,”他补充道。“所以,它不像我们有幻想机器人或灯光工厂。其他生产者可能面临着与数字转型面临的同样的问题。“

如何制作第一步?“我们理解不要被术语不堪重负,我们对此知之甚少,”Koppenberg说。“但我们确实知道复合材料。向复合材料迈出4.0有点舒适区域,但我们明白我们在工人投入的一切,这是一个代码,这是数字转型的一种基础。“

As noted in the main article, the next step was still a struggle. But one thing Dynexa had in its favor was the German government’s commitment to manufacturing. Germany is already a global leader in developing Industry 4.0 standards and technologies. Committed to supporting its small and medium enterprises (SMEs, orMittelstand.),德国经济和能源部(BMWI)资助大学为他们的地理区域提供免费数字化咨询。全国,26Mittelstand 4.0.competence centers provide practical support and cover all topics along the value chain.

Mittelstand 4.0.network in Germany competence center Chemnitz

德国的Mittelstand 4.0能力中心为中小企业提供免费数字化咨询。来源|Mittelstand 4.0-poldence Center Chemnitz

“The University of Darmstadt is local to us and was a partner in this government network,” notes Koppenberg. “We began to work with them and found their approach was hands-on and very simple. Their goal was to just help us make the first steps. It was key that they were not trying to sell anything, but instead worked with us to find therightsolutions.”

2. “Begin with several key questions: Where is my problem? Where do I need the data? How do I need to measure and communicate that data?”

Dynexa长丝绕组碳纤维

Dynexa在其数字转换中的第一步是长丝绕组期间树脂拾取的监测系统。来源|Dynexa.

与柏拉托克的建议类似,大学团队鼓励Dynexa提出问题。“我们在哪里工作,这是质量相关的和工人技能依赖性的,并花费了美国金钱和时间?这是我们的第一次理解,“Koppenberg说。“他们表示不担心架构 - 即服务器,云计算,边缘计算等。部分是简单的。我们必须决定的是我们想要做的事情。他们说,“不要过度补充,”他们说。“看起来更需要衡量的东西以及如何做到这一点。”这些决定将指导我们最终的架构。“

如主要文章所述,Dynexa的开始是开发一种数字系统,以测量在绕组期间拾取了多少树脂并用干纤维施用。先前的过程需要操作员停止机器,测量管的厚度,记录该测量,然后重新启动卷绕机。随着达姆施塔特大学的帮助,Dynexa开发了一种连接到校正表和决策算法的数据库的相机系统,使机器能够知道目标应该是用于缠绕的每个阶段并自动响应的目标。

3.“这不是用机器人取代人员;这是关于改变这个过程。“

因此,他们能够将手工工作转移到数字系统中。“这不是为了摆脱运营商,”笔记Koppenberg“,而是关于更改过程。我们取得了更好的过程控制,因此我们的生产更快,更高效。但这不是降低人员成本。相反,操作员仍在那里,但现在他/她可以专注于不同的东西,让机器手柄调节树脂含量。操作员可能会看看下一个部分或监督多个机器。这将让我们通过所有机器更具成本效益并实现更高的质量。效率是我们的主要目标。之前,我们的零件含有变化,这是我们生产的主要问题之一。“

4.解决问题,然后使用数据进一步改进过程。

“另一个问题,”Koppenberg说,“真正需要多少数据?我们可以不断运行相机,但这不是必需的。我们只衡量该过程对产品质量一致可靠。“

He continues, “Now that we have digitized the process, we can gain experience and further develop it. We have all of the winding machines connected. They are creating data which we can now correlate. Some said, ‘just measure it all of the time and let the AI find the correlations and tell you what to do.’ But this was hard for us to put into action. However, the way we have done it, we can analyze the data offline for correlations to further improve the process, but also to apply this approach to other production processes. We are doing this now,” Koppenberg points out, “which is a digital transformation for us.”

5. True digital transformation will transform not just your production, but your business.

并且这种转变仍在继续,通过Dynexa的销售和营销负责人,Matthias Bruckhoff,称之为“为客户提供新的生态系统的逐步过程”。这个新的生态系统包括客户的在线门户网站(见main article:“改变范式”),但也是一个新的数字标签系统,响应其客户对所有零件数据的要求放入一个地方,包括质量控制表和处理指南(参见“数字线程与数字双胞胎”).

“I would advise companies that are beginning this journey to consider, 'what keeps me from offering this service or product flexibility to my customer?’ We used to spend so many hours on labelling, now we are not only making our customers more efficient, but us as well. The real value in digitization is if it enables a transformation in the processes behind your business,” says Koppenberg, “and open up new possibilities and maybe, longer term, new business models.”

相关内容