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What were the challenges to be solved and what specific benefits were achieved?
The networking of quality management allows for faster identification and elimination of quality issues. Processes need to be monitored, in particular in the areas of production and quality monitoring, factory automation and assembly lines or condition monitoring of machinery and systems. The system guides, warns and supports the operator, thus enabling less qualified personnel to be used.
Implementing the solution requires very little effort due to state-of-the-art control, web technologies and standardized programming techniques. Once it has been installed, the PMX solution enables the entire production measurement chain to be monitored and controlled. Anomalies, defective sensors and unnecessary features can be identified, reported and avoided. The system offers variable configuration and flexible, standardized control for universal use, as well as seamless networking of production and manufacturing.
One of the challenges was to develop CPS functionalities in the field of sensors and test and measuring equipment. An integrated platform strategy was required as the basis for product development as a whole and its global implementation. In addition, specific roles needed to be assigned to users and developers.
“The IIoT is a global business driver. Germany and Europe will only survive through their innovative capacities. HBM sensors and test and measuring systems are the ideal solution for use in production processes that require maximum quality and efficiency.” Michael Guckes, Product Manager for Industrial Amplifiers and Software at HBM
How can the Industrie 4.0 approach be described?
“Plug and Measure” eliminates the need to calibrate sensors. 'Integrated intelligence' enables the amplifier to run quality-critical algorithms and calculations by itself, during production monitoring. This results in web-based control and diagnostics functions and easier and more efficient preventive maintenance.
What could be achieved?
Series manufacturing of products and components is facing a new 'industrial revolution.' Production systems are working in a way that is increasingly flexible and networked. Production processes are becoming ever more efficient through the use of cyber-physical systems; however, at the same time, they are becoming more complex and multi-faceted. The choice of suitable metrological systems plays a key role in implementing new production concepts: Using test and measuring equipment that matches modern production systems is the only way to achieve seamless quality control and efficient and cost-saving production.
What measures have been taken to achieve the solution?
Production systems can be networked via an integrated Industrial Ethernet connection to implement seamless real time production monitoring. Integrated TEDS (Transducer Electronic Data Sheets) enable the PMX to automatically identify the transducers, thus facilitating “Plug and Measure” technology. When TEDS sensors are installed or replaced the measuring amplifier automatically parameterizes the measurement chain and is then again immediately ready for operation. In addition, defective sensors can be identified. The measuring amplifier system features smart sensor monitoring as the basis for various functionalities. These include autonomous decisions as well as quality monitoring and computation using “smart functions”. The system teaches itself, thus enabling self-optimization through predefined parameters. A PMX measuring amplifier platform supported by web server technologies is used as hardware. The main interface is TCP/IP. Remotely managed browser and server standards allow for fast service and start-up. Furthermore, many interfaces enable data to be linked to the product and its value stream along the entire measurement chain.
What can others learn from it?
HBM offers an integrated concept for sensors and measurement data acquisition in both development and production. In addition to providing suitable sensors, modern measurement electronics are a crucial factor in the measurement chain in production.
Existing systems often can neither meet the requirements nor cope with the amounts of data to be handled in modern, highly dynamic production lines. Important criteria for successfully using this type of measurement system include data transfer in real time, high computing capacities and simple parameterization and visualization of measurement data for different groups of staff and operators. Another important aspect of the PMX system is that it can be used for both development and production tasks. A 'cross-department' platform facilitates more efficient structures and shorter times to market. HBM offers a wide range of sensors for measuring force strain and temperature. Various designs and measuring ranges ensure that the sensor type that matches a specific test is always available.
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