Punching machine

The cause of quality problems with stamped parts can be found when sensor data from all process-critical components is stored over a long period and linked with production data. At the Balluff customer, existing sensors, run times and shift plans were not enough, and the cause of the faults remained unclear. After the retrofit, an analysis application combines the readings with data from MES, ERP and quality assurance. The long-term archive makes it easier to spot patterns and deviations.

Condition monitoring sensors monitor the temperature of a stamping die, and an analysis application continuously checks their values against defined limits. Balluff retrofitted every machine accordingly at a manufacturer of stamped and bent parts that supplies the automotive industry, adding a temperature sensor at the strip infeed. If a tool's temperature rises above the normal range and this has been defined as process-critical, the system issues a warning. Employees can then intervene in time.

Punch press cycle times can be captured with light barriers and shown on dashboards without interfering with the PLC. ZARGES uses Peakboard for this: two light barriers record the products, and the dashboards refresh every two to ten seconds. Additional monitors show SAP order and logistics data. Because the control system remains untouched, the robot manufacturer's warranty and the CE marking remain valid.

Many industrial stamping presses are connected via a central integration platform that addresses all machines via OPC UA or Modbus and clearly separates the shop floor from IT. A maker of electrical connection technology whose machine park consists mainly of metal punching presses used soffico's Orchestra to replace its communication servers at each plant. Systems from around 15 manufacturers and in-house machines are integrated. At the Thuringia plant, around 120 machines were connected in three days.