Bühler’s "Fusion" three-platen diecasting system will be able to optimally apply the future machine-learning and artificial-intelligence capabilities of the new Smart CMS concept, making it the platform for the digital diecasting concept. Fusion offers closed-loop control and Industry 4.0-standard automation, and its servo-driven hydraulics can cut cycle time and reduce energy consumption.
Overall equipment effectiveness
"Fusion" was developed by Bühler, "designed to deliver exceptional OEE," — overall equipment effectiveness. With closed-loop control, modular energy frame, and Industry 4.0-automation capability, Fusion is a flexible system for aluminum and magnesium diecasting.
The SmartCMS collects and manages data drawn from every component and peripheral of the production cell, to improve process performance and make it possible to increase OEE.
Initially available at the cell level, SmartCMS delivers improvements through equipment connectivity, cell automation and operation, centralized alarms, data collection, flexible part flow, and recipe management.
“If we think of a diecasting cell like a human body, with lots of different tasks carried out by different parts, the SmartCMS is the brain, ready to coordinate all of that activity in the most effective way,” explained Bühler managing director Jonathan Abbis. SmartCMS lays a foundation for “smart” management of entire diecasting cells, with the ability to collect information from multiple data sources in a single control system.
Learning to improve
The Bühler Digital Cell’s Predictive Analytics uses machine learning from sensor data on each cell, anticipating system breakdowns and calculating the “engineering parameters” of key machine parts to propose scheduled interventions. In the future this will include even more critical processes, to cover the components typically responsible for around 80% of unexpected downtime in a diecasting machine.
Cloud-based failure-analysis tool
Each hour of downtime on a diecasting cell loses revenue opportunities and puts pressure on delivery schedules. Understanding more about what is causing downtimes and applying proactive fixes can save significant sums. The Bühler Digital Cell’s Downtime Analysis capability is a comprehensive, cloud-based failure-analysis tool, providing root-cause reporting from the diecasting machine. Analysis can help to reduce downtime on a single machine, and it can inform changes on other machines, to drive best practice. While data is provided on several diecasting machine parameters, an extension to cover the entire cell is planned in the near future. All data is stored securely in the Bühler Insights IoT platform, powered by Microsoft Azure.