Don’t bite off more than you can chew
DISA was facing different challenges with customers demanding completely optimized molding machines on the one hand, and the ongoing digitalization on the other hand. How to start with digitalizing machine building, and how to transfer the benefits into added value for the customer? The answer: Take it in small steps!
After starting with simulating a certain aspect if the machine development process, this success was the foundation for the simulation of another small aspect and so on. This way DISA managed to minimize both risk and effort of digitalization and was also able to test new machines in a virtual environment. When the physical machine was built, many flaws and errors had already been eliminated and commissioning at the customer’s site took less time and corrections.
We are challenged always with lead times on machines and installation at customers, so therefore it has been important for us to establish a new way to test our software and equipment before going on the physics of machines.Jan Hemmingshøj, Electrical Automation Department Manager at DISA Industries
From brake discs to kitchenware
With high quality solutions for molding machines in foundries, DISA has made its way to the top suppliers in the industry. Products that are made using DISA’s technology range from brake discs for cars to premium kitchenware.
DISA’s focus has always been on higher quality and less energy consumption. Being a long-time user of Siemens technology, DISA integrated the Digital Enterprise solution portfolio step by step in order to implements virtual commissioning for new machines.
Simulations drive availability
Downtimes in foundries are extremely expensive. So, DISA was looking for new ways to test their software and machines before they are shipped to the customer. The company started with one part of a new machine, simulated it in detail, and then moved on to the next part.
This way, DISA is now able to simulate the whole molding line. There’s a huge advantage over testing a physical machine in the real world: It sparks the creativity of the engineers, because they can try everything imaginable without having to be afraid of possibly damaging an expensive machine. It’s more like computer gaming and makes them more confident and more thorough.
Integrating a digital twin
DISA relies on automation hardware and software from Siemens. Having everything they need from a single vendor is a huge benefit, which becomes even more important as the local Siemens subsidiary in Denmark support DISA can easily establish the contact between DISA engineers and Siemens experts.
It all started with SIMIT, when DISA connected the physical PLC to the simulation. Now they also use PLCSIM Advanced to simulate the controller and to use higher processing speeds. DISA is able to create digital twins of their machines, which helps them to offer new business models like better aftersales support. In addition, it offers them the opportunity to present their technology virtually to customers and prospects, e.g. on trade fairs, thus saving them the need to transport heavy machines. The digital twin is just as functional and impressive.
It’s big for us to have all from the same supplier, so that you know everything works together.Lukas Theisen, R&D Engineer Electrical Design at DISA Industries
Everything can be simulated. We had difficulties finding something that we couldn’t do.Lukas Theisen, R&D Engineer Electrical Design at DISA Industries
