Digital twins of machine tools

Digital twins optimize processes throughout the entire machine lifecycle

Digital twins of machine tools play a major part in optimizing the machine manufacturer's engineering processes. This is because the digital twin in the automation environment makes it possible to execute process steps in parallel, as opposed to consecutively, as used to be the case. Digital twins also improve processes while the machine is in operation, whether as a digital twin during machining or as a digital twin providing real-time collision protection.

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The digital twin in automation The TIA Portal represents the core component of a seamless digital engineering process. The data from the TIA Portal form the basis for the digital twin. The digital twin in automation – the digital image of the control system, the machine response and the kinematics – offers the chance to test and commission configurations from the TIA Portal in a virtual setting.

Efficient programming

The integrated SIMATIC S7-1500F PLC enables machine manufacturers to take full advantage of the TIA Portal with SINUMERIK ONE. All engineering tasks for machine tools are simplified in the TIA Portal.

Safety Integrated is the uniform solution for safe, standardized automation from Siemens. Only a single failsafe program is required to implement the safe logic. This can be commissioned in the digital twin.

Virtual commissioning

With the digital twin of automation, testing or even commissioning can largely be carried out virtually. The commissioning time on the actual machine is reduced to a minimum and costly prototypes can be avoided.

On request, the Siemens service experts can help you transfer commissioning into the virtual world.

SINUMERIK ONE Digital Twin Engineering Workflow

Integrated engineering

With the integration of the SIMATIC S7-1500 PLC and SINUMERIK ONE in the TIA Portal, an integrated digital engineering process becomes possible for machine tools without having to switch systems. Closed-loop engineering parallelizes mechanics, electronics and automation and brings the disciplines together into a mechatronic development approach. Machine development and commissioning times can thus be reduced.

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The digital twin in machining Thanks to Run MyVirtual Machine – the digital twin of SINUMERIK ONE for machining – NC programs can be programmed and checked offline without needing to use a real machine. Programming, job preparation and process optimization are therefore performed virtually.

Calculate more realistically

Can a component be manufactured at all? And if so, how long will it take? The digital twin answers these questions quickly and precisely. Manufacturers virtually check the suitability of the machine. The program runtime for the workpiece is also accurately calculated at this stage – on the PC in the office, away from the actual production areas.

Virtualize job preparation

Machining programs are prepared on the computer, entirely offline, using the digital twin. This means digital twins of different machines can be stored on a single PC in order to create all programs on a single workstation. Ready-to-run programs are then transferred directly from the PC to the real machine. This can reduce setup time on the real machine by 20%.

Virtual training

New employees can be trained using the digital twin. It is possible to check programming immediately and make errors clearly visible during training - with no risk of damage to real workpieces or machines. And, of course, the real machines can be used in actual production while employees do their training on the digital twin.

Therefore, for us, the prerequisite is to receive a digital twin for each machine in advance.

Peter Leupert, Head of work preparation, Siemens Electric Motor Factory in Bad Neustadt

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The digital twin in production Machine tool collisions are extremely costly and time-consuming. A collision not only damages a machine, it can also jeopardize production order deadlines.

Challenge

Even in well structured processes, operator errors can result in machine tool collisions – for example, manually initiated motions and interventions that cannot be tested offline. Or tool lengths and reference points active on the machines can deviate from specifications. Or if operators are over-cautious when making test cuts, things can take too long, creating a need to speed up operations. However, this can be rather tiresome without a real-time protection system.

Solution-based approach

A digital machine twin can support the machine tool user – even if the machine tool is being manually operated. A digital twin provides reliable real-time collision protection for machines. It stops axis motion before a collision can occur.

Our solution

The Protect MyMachine /3D Twin Edge app facilitates creation of 3D models of tool components, fixtures and workpieces as well as their associated positions. This digital twin in a machining environment not only displays the current positions of all components, but also their future positions in the form of lookahead graphics (ghost images). This represents a practical way of visualizing the position that the machine will soon assume. As a consequence Protect MyMachine /3D Twin plays a key role in ensuring maximum productivity and availability for machine tools.

Tip: If you are already using the digital twin for machining – Run MyVirtual Machine – you can simply import the job setup in Protect MyMachine /3D Twin and reuse it.

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Digital twins of machine tools

Digital twins optimize processes throughout the entire machine lifecycle

The digital twin in automation

The digital twin in machining

The digital twin in production

Reducing machine engineering and commissioning times while increasing quality