Machining centre
A connected machining centre gives its manufacturer secure remote access to error messages, control data and machine condition. Faults are analysed from a distance, and data flows into MES, ERP or the cloud.
Machining centre at a glance
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Solution examples featuring Machining centre
ZEISS: new integration level regulates data heterogeneity and sets group-wide data standards
Digital transformation at Groupe Renault
Smart and remote services: machine connectivity is the foundation
Connected machining centre: remote access and data for MES and ERP
In the solution examples, a router or gateway provides access to the machine. At CHIRON Group, an MRX 5 router from INSYS icom is permanently installed in every machine. Using the icom Connectivity Suite VPN service, the customer dials in with the affected machine, and the data travels encrypted. For entire plants, Groupe Renault relies on OPC UA: legacy equipment receives adapters and an IoT box that translate its protocols into the OPC UA standard, and sensor data reaches Google Cloud Platform via MQTT. At ZEISS, soffico's Orchestra integration platform absorbs the different data formats, from an older handheld screwdriver to a modern machining centre with an OPC UA interface, and passes them on to ERP and MES.
The examples come from mechanical engineering, the automotive industry and metal and electronics. CHIRON Group, a Tuttlingen-based maker of mill-turn machining centres, accesses machines remotely when faults occur and builds its ConditionServices on top: wear parts are replaced according to actual wear rather than at fixed intervals. Groupe Renault uses OPC UA at 17 of its 38 production sites with 3,300 OPC UA-enabled devices. ZEISS has used its structured data basis to improve processes and reduce scrap. In podcast episode #54, Daniel Fritz of INSYS icom and Johannes Strobel of CHIRON Group discuss the solution.
Podcast episodes featuring Machining centre
Connected machining centres: frequently asked questions
How does remote service work for mill-turn machining centres?
With remote service, a service engineer from the manufacturer accesses the customer's mill-turn machining centre directly via an encrypted VPN connection. CHIRON Group permanently installs the MRX 5 router from INSYS icom in its machines for this purpose. Customers no longer have to pass on error messages, control backups or the machining program in use by phone or photo. The engineer analyses the problem remotely and can intervene in the control if necessary.
What is needed for remote maintenance of a machining centre?
Remote maintenance of a machining centre requires a router or gateway in the machine and a VPN service that connects the customer and manufacturer networks with encryption. At CHIRON Group, the built-in MRX 5 is given a fixed IP address, and the access data is stored in the higher-level system. After registration with the icom Connectivity Suite, the machine becomes visible to the service team. Cooperation with the customer's IT department is usually required.
How can machining centre maintenance become predictable?
Machining centre maintenance becomes predictable when wear parts are replaced according to actual wear rather than at fixed intervals. CHIRON Group determines wear limits through measurements at control level, which it accesses via the remote connection. This shows whether a limit has been reached or when it will be. With its ConditionServices, customers get higher machine availability at predictable costs.
How is a machining center connected to MES and ERP?
A machining center is connected to MES and ERP via a standardised interface such as OPC UA and an integration layer. At ZEISS, soffico's Orchestra forms this layer and has to handle a modern machining centre with an OPC UA interface as well as an older handheld screwdriver. Groupe Renault equips legacy equipment with adapters and an IoT box that translate their protocols into the OPC UA standard and collects the data in Google Cloud Platform.
More assets in “Machinery and Equipment”
Pump
Pump monitoring with IoT records vibration, temperature, pressure and energy consumption of running pumps. Operators detect damage and faults before a pump fails and plan maintenance by condition rather than at fixed intervals.
Electric motor
Motor condition monitoring with IoT continuously measures the vibration, temperature and current draw of electric motors. Operators detect imbalance, bearing damage or winding faults early and replace motors based on condition rather than after a failure.
Packaging machine
OEE software automatically records run times, downtime, speed and rejects on packaging machines from the machine signals. Operators see where their lines lose performance, and machine builders use the same data for remote access and digital services.
Compressor
With IoT, compressor maintenance follows actual condition: sensors record current consumption, pressure, temperature and running times. Operators detect creeping damage and unused running time early and cut energy and service costs.
Refrigeration system
A refrigeration monitoring system makes service plannable: temperatures, refrigerant circuit pressures, compressor status and energy consumption flow into a platform in real time. Operators and service partners detect faults early, avoid unnecessary site visits and reduce excess consumption.
Air conditioning system
Commercial air conditioning systems in offices, retail branches and data centres can be monitored remotely with IoT. Operators see energy consumption, temperatures and faults in one place, detect failing compressors or refrigerant shortages early and plan service visits precisely.
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