Efficient process chain boosts productivity in metal working

At this year’s Metav trade show, running from February 23 to 27 in Düsseldorf, the Siemens Division Drive Technologies exhibited products, applications and services aimed at improving productivity and efficiency in all sectors of the metal working industry.

In Hall 16 Siemens presented new products for its Sinumerik CNC system platform, demonstrating the functionalities for milling and turning operations based on a specimen workpiece from the aerospace industry. Product highlights included the new Compact-CNC Sinumerik 828D, the Premium-CNC Sinumerik 840D sl system and the Sinumerik MDynamics technology package for milling applications. The new, easy-to-operate Sinumerik Operate interface simplifies and speeds up CNC programming. The new models illustrated how energy-efficient solutions can be put together around the CNC platform with drives and motors for all technologies and sectors. The Sinumerik Manufacturing Excellence service portfolio offers greater productivity for machine tools, with the focus on the topics “Machine Retrofit” and “Manufacturing IT”. Visitors were also able to get the latest information on Service and Support for the Sinumerik CNC system.

In conjunction with its partners from the machine tool sector DMG, Index, Iscar, Renishaw, Schütte, Star and Zoller, Siemens put on the special show “Metal meets Medical” in Hall 9, which presented the entire production process for medical components. There, visitors were able to see for themselves how medical engineering products are processed using machine tools equipped with the Sinumerik 840D sl CNC. By examining processing technologies such as 5-axis grinding, rotary milling, HSC milling and swiss turning, attendees had the opportunity to find out about the use of machining technology in the medical engineering field. The Sinumerik 840D sl CNC enables precise and rapid processing, even of complex implants. Because of the high machining speeds involved, the oil cooling methods employed and owing to particularly hard materials, fire protection plays a major role in medical engineering. On show was the Sinorix al-deco STD local application extinguishing system, featuring a fire sensor which is actuated as soon as its ambient temperature exceeds 110°C.

A digital factory was used as an example to demonstrate the entire process chain for the manufacture of medical engineering products. The focus here was on the integrated planning and realization of the major production steps in association with the work piece, the efficient use of resources, as well as standardization of the process and its continuous improvement. The process chain was demonstrated with the Siemens software products Teamcenter and NX CAM. The sample object, which was design-engineered using NX CAM, was milled on a tool machine.

Siemens’ “Blue Competence” display in Hall 16 showcased energy efficiency with the drive system Sinamics. An exhibit featuring the Sinamics G120 frequency inverter demonstrated how feeding back electricity generated during braking could cut energy costs. Class IE2 energy-efficient low voltage motors reduce energy costs too. One example featuring the Sinamics S120 drive system illustrated energy balancing in multimotor drives through the regenerative feedback of current between servo drives having simultaneous acceleration and braking phases. Kinetic buffering increases system availability and ensures continued operation in the event of failure of the main supply and external disruptions.

As part of a special presentation aimed at younger visitors in Hall 7, Siemens provided information on the training and continuing education of specialist CNC personnel, with the focus on the Sinutrain training system. By comparing the latter with practical work on a lathe using the Sinumerik 840D sl controller, visitors were able to confirm for themselves that operating and programming the actual machine and the training system activities were practically identical.

The Siemens Industry Sector (Erlangen, Germany) is the worldwide leading supplier of environmentally friendly production, transportation, building and lighting technologies. With integrated automation technologies and comprehensive industry-specific solutions, Siemens increases the productivity, efficiency and flexibility of its customers in the fields of industry and infrastructure. The Sector consists of six divisions: Building Technologies, Drive Technologies, Industry Automation, Industry Solutions, Mobility and Osram. With around 207,000 employees worldwide (September 30), Siemens Industry achieved in fiscal year 2009 total sales of approximately €35 billion.

The Siemens Drive Technologies Division (Nuremberg, Germany) is the world's leading supplier of products and services for production machinery and machine tools. This includes standard products but also encompasses industry-specific control and drive solutions. Integrated technologies along the entire drive train with electrical and mechanical components offer highest potential to reduce energy consumption in industrial plants. The services provided by the Division include mechatronics support in addition to online services for web-based fault management and preventive maintenance. With around 36,000 employees worldwide (September 30), Siemens Drive Technologies achieved total sales of €7.5 billion in fiscal year 2009.

Reference Number: IDT2010022311e