digitalization in aerospace

Digitalization in Aerospace

www.siemens.com/aerospace Dominik Riehle

Confidential / © Siemens AG 2016. All Rights Reserved.

Aerospace – the healthiest industry


High Pressure for production increase

Increased complexity

Boeing 787 Airbus A350 Airbus A380

Aluminium Composites/Titanium

Source: Internet

Market Growth Heavy backlog


Beside Pressure for production increase - Technology Transforming Business

Models defined


Challenges for the manufacturing industry are growing worldwide

Manufacturers need to transform

Enhance flexibility Individualized production with higher productivity

Reduce time to market Shorter innovation cycles

with more complex products

Increase efficiency Energy and resource efficiency

with global operations


The End Customer requirements in Aerospace Manufacturing

Product Design

Production Planning

Production Engineering

Production Execution

Service


The Digital Enterprise

TIA

Production

Totally Integrated Automation

Product design

Automation design

PLM

Product Lifecycle Management

Design and virtual production Real production

cPDM

Digital Production

MES

CNC

TIA Portal 3D Process Design

CAD + CAE

Production Planning


Feeding Back Insights from Realization and Utilization Makes a Smart and Agile Value Chain


Portfolio Alignment – Covering the Aerospace Supply Chain

SIEMENS

PLM products and

Services Totally Integrated Automation

Manufacturing Executions

Systems Customer Services

• Retrofit

• Service Contracts (incl. Data driven services)

• Training

Machine Builder

End

customer


Machine Tool builder / System Integrator Primes and Tier 1

Our Sales force passion - Partnerships with end users and Machine Tool builders / System Integrators

Global Siemens Aerospace Team

• Develop productivity advantages with machine tool builders and

System Integrators

• System solutions for technology leadership

• Standardization of leading edge technology

Balanced

triangle


Digitalization will not work without people A dedicated Account Team supports the end customers in Aerospace

Global Aerospace Account Management Team


Aerospace Key Account Management

Key account managers

http://omed.gatech.edu/redux/wp-content/uploads/2013/12/NorthropGrumman-blue.jpg

/wikipedia/en/c/c7/MTU_Aero_Engines.svg


Communication concept www.siemens.com/aerospace

Manual

Internal

PR & Media Cooperation

Brochures

Social Media

Newsletter, PPT

Video, Trailer

Online, external

Meeting presence

Siemens One Meetings

Marketing Manager Meeting

Website set up Key visual

www

Application Manual Reference Manual

360° communication

http://www.siemens.com/aerospace



Product Design

Production Planning



Service


One Digital Backbone Homogenous program management and systems engineering

Challenges

• One homogenous platform

is required to conduct the

complete product lifecycle

management

Advantages

• Integrated verification

process

• One single source for

product information on a

global base

Teamcenter


Design, engineering and manufacturing solution help Aerospace manufacturer to deliver better products faster and efficient

Product Design

Challenges

• Openness and modularity approach

to product development

Advantages

• End to end from design to

production based on one integrated

Siemens toolset

• This toolset coordinates disciplines,

preserves data integrity and

streamlines the entire product

development process

NX CAD/CAM


NX Design Flexibility

Flexibility to use the best tool for your design task in a single environment delivers maximum productivity

Parametric feature based modeling

• Sketch Based Workflows

• Feature Based

Synchronous Technology

• Fast design evolution

• Increased data reuse from other CAD systems

• Fully integrated with feature modeling

Freeform modeling

• Flexible approaches to generate complex shapes

“It was up to our engineers to select the system they wanted and they chose

NX. Soon we began to understand that it was new technologies rather than just

new tools”

Evgeny Savchenko

Head of Mechanical CAD

Sukhoi Design Bureau


A complete CAM solution for aerospace parts

• High quality surface finish

• Increased machining productivity

Fast and accurate programming

• Prismatic parts – milling, turning, mill-turn

• Complex parts – advanaced 5-axis

• Forms – high speed machining

• Programming automation

Production-ready output

• Integrated G-code driven machine tool simulation

• Optimized output for Sinumerik controlled machines

• Directly connect CAM to CNC

NX CAM for Aerospace Machining


Optimize the Speed and Efficiency Using High-Fidelity Simulations of Complex Automation Systems

Production Planning

Challenges

• Verification of the error free CNC

program

• Downloading of the optimized

program to the CNC machine

Advantages

• Reduction of process prove-out

time due to a full digital model

• Containing all parameters and

restrictions of the real machine

(dynamic and geometric dimensions)

VNCK


Future: all use-cases supported on NX platform

Tool Path Verification

part & tool

Machine Simulation

tool path driven

Machine Simulation

G-code driven

Generic

OOTB ready-to-use for tool path based

verification & simulation

Machine Specific

controller integrated virtual machining environment

for final NC code validation, synchronization & optimization

Machine Simulation

controller driven

VNCK

inside

Virtual Machine

VNCK / HMI

based


Siemens 840D VNCK Support

NX CAM

Sinumerik VNCK

Post-processing

NC Programming

Integrated Simulation

Siemens Virtual NC Controller

3D machine tool and tooling models with kinematics

Unique machine tool characteristics - from real controller

Verification Cut motion and material removal

Machine Simulation Common Simulation Engine driven

Machine Simulation Virtual NC Controller driven

Optimized for Sinumerik 840D

Tool path

NC Code

NC Code


Extend the Digital Thread to the Shop Floor With an integrated CAD-CAM-CAE Chain for Hybrid Manufacturing

Production Engineering Hybrid Manufacturing:

Think it. Model it. Make it.



Product Design

Production Planning



Service


Security Integrated

Safety Integrated

Diagnostics

PROFINET

Common Data Management

HMI Controller Distributed I/O Motion Control Drives

WinCC Step7 Scout Startdrive

Totally Integrated Automation Portal

Challenges:

• Flexibility, reliability, security, and

safety

• Standardizing engineering platforms

to cover all applications in aerospace

manufacturing for maximum

efficiency

Advantages:

• Unique and consistent user interface

concept for all technologies provides

a connectivity standard

• Common and centralized services

for PLC- and CNC driven applications

TIA Portal


Intuitive Efficient Proven

Minimize engineering cost by using one platform for all engineering applications


Communication in Manufacturing Real-time performance and open Ethernet communication in one system

PROFINET – communication from field to management level

Horizontal integration

on machine level

Full TCP/IP in parallel

to real-time

Industrial Standards

e.g. OPC, Safety,

Energy Management

Maintenance

and service

IT level

TIA

Machine level

M2M

Quality

Data

Motion

Energy

Data

BoM

Diagnostic

Data

Remote

Service



PROFINET interconnectivity

Interconnectivity by PROFINET PROFINET interconnectivity in production plant

CL

ICK

TO

PL

AY


How can safety engineering be easily integrated in the machine?

All from a single source

Integrated safety solutions for

recording, evaluating, all the

way to responding

Reduce complexity

by means of an integrated

safety solution

Integrate machine safety directly

Easy fulfillment of machine

directives

due to standard-conformant

evaluation and certified products



Advcanced Controller - SIMATIC S7-1500 T-CPU

Integrated web server

Communication

High Speed

Archives & recipes


The compact PC-based controller SIMATIC ET 200SP Open Controller

for serial machine builders Unique combination of a failsafe controller and modular I/Os

Feature / Function Benefit

• compact system with integrated

safety functionality

• No additional safety controller

necessary less space

• Controller, visualization, central

I/Os and Windows applications

on one device

• Decreased spares inventory

• Decreased effort for evaluation

and service

• Powerful PC-based controller

with complete engineering in the

TIA Portal

• Increased productivity and

reduced engineering effort




Mobile Panels 2nd Generation

Performance like a Comfort Panel +

Sturdy and brilliant at once +

PROFINET / PROFIsafe +

Unique emergency button +

Compact connetivity +


Code-Reading and RFID systems

RFID Systems Code-Reading Systems

High-performance code-reading systems for

1D/2D-codes, text and form-recognition Compact and high-performance RFID systems for

HF-range (short range)

UHF-range (long range)



Tool Identification with SIMATIC Ident for machine tools

SIMATIC RF250R with ANT8 SIMATIC RF210R

SIMATIC RF180C/

RF182C

SIMATIC RF160C/

ASM456

SIMATIC RF250R with ANT8 SIMATIC RF210R

PROFINET/Ethernet TCP/IP

PROFIBUS

RS232

RS422

SINUMERIK SIMATIC

Integration into the machine tool controller


SIMATIC Energy Manager PRO ISO 50001 certified Energy Management System for industry and production

Feature / Function Benefit

TÜ V audited Energy Management

System in accordance with ISO

50001 and energy efficiency

projects

Efficient compliance of legal

requirements

Identification of savings potential

by using flexible and automated

analyses and reports with energy

key figures

Reduction of operating costs and

ensuring the competitive advantage

Seamless connection to SIMATIC

Energy Suite and open interfaces

for the connection of additional

systems

Linkage between energy data,

production data, security of

investment and scalability

Consumption forecast for all

media

Efficient energy purchase



Product Design

Production Planning



Service


Challenges

• Standardize the CNC automation

concept with highest performance

and quality throughout the lifecycle of

the partfor all technologies: (5 axis

machining, Composite, additive

manufacturing, robotics)

Advantages

• One single platform for all

technologies

• The open SINUMERIK kernel allows

imple-mentation of aerospace

specific functionalities

SINUMERIK

Cover all Aerospace technologies by one CNC Controller Achieve highest performance in machine operation



Modern touch technologies

and intelligent structures make work quicker at the

machine

Siemens offers first touch technology for intuitive operation


Challenges

• Optimum milling results are crucial particularly

in the aircraft industry. The SINUMERIK

MDynamics Milling technology package is the

ideal tool for such applications.

Advantages

• Advanced operation and unique technology

cycles

• Ultimative shopfloor programming and high-

quality CNC simulation

• SINUMERIK MDynamics sets up new records

regarding the surface quality, precision and

speed

SINUMERIK MDynamics

Aerospace specific functionalities Improve surfaces through optimization of the CAM data and intelligent milling



Top Surface - the enhancement of Advanced Surface

Improved surface quality:

With diagonal programmed toolpaths for finishing

With poor data quality and/or irregular point

distribution in NC programs from the CAD/CAM

system

Improved machining speed:

Improved observation of acceleration and jerk

limits

Improved contours perfectly :

• Preset standard values for contour and orientation

tolerance for nearly all

Formerly Formerly Formerly

Top Surface Top Surface Top Surface


Each Aerospace parts characterized their own requirements, but all have one

common property 5-axis machining

Velocity Accuracy Surface

+++/

+ (Ti) ++ +


++ +++ +++


+++ ++ +


++ ++ +

Aero

str

uctu

res

Co

mp

osit

e

pro

cessin

g

En

gin

e

Co

mp

on

en

ts

Lan

din

g g

ear

ORIVECT

Great Circular Interpolation

Tol

TRAORI

Transformation Orientation

COMPCAD

Smoothing by Compressor

Look Ahead

Speed profiles over blocks


ORIVECT Great Circular Interpolation

Task • Machining of structural parts, esp. Thin-walled pockets

Solution • Using vector interpolation within in a plane by using the function ORIVECT

Advantages • Programming longer linear sets w/o infringing the contour

• Describing an inclined wall exactly by one sentence

• Easy-to-use by the preconfigured function


TRAORI 5-Axes transformation orientation

Without Transformation

With Transformation

Task • Position transformation to machine coordinate system from a workpiece

based NC program

Solution • Using the integrated TRAORI functionality to adjust automatically the path

due to the position related Tool Tip (TCP)

Advantages • Program independent of tools (orientation and length)

• Program independent of machine kinematics

• Highly complex workpieces can be manufactured on different machines with different cinematic characteristics w/o a specific postprocessor run


COMPCAD Smoothing by Compressor

Tol

Task • Highly requested surface qualtiy, accurancy and speed

Solution • The function COMPCAD converts the complete polygon into a series of spline

blocks

Advantages • Creation a user defined tolerance band

• Smooth curves ensures high surface quality

• Automatically optimized speed profiles to meet the surface quality.


Look-Ahead function Path guidance “sees”

Feed

Block N1 N12

G64 Look Ahead

Task • Requests in reducing machining time

Solution • Look Ahead function „sees“ into a numbers of traversing sets in advance and

calculates a speed profile over all.

Advantages • Activated functions ensure the best balance between machining time and

suface quaity

• Smooth velocity profile at maximum speed

• Avoiding braking at block transition improves surface quality


Rotary technology without borders:

Full extent in technology cycles and measuring cycles

for rotary operations

Maximum process security:

Unlimited simulation of rotary operations in any levels

and tool orientations

SINUMERIK Multi-Tasking-uses – revolutionary Mill/Turn

SINUMERIK-Multitasking


Drilling and milling Turning

Turning on milling centers - an additional technology field in the machine

With turning on milling centers the existing milling center kinematics is used in a different interaction of the axis and spindles involved.

Orientation axis (B)

Rotary axis in position control

Milling spindle

Spindle in speed control

Rotary table (C)


Rotary table (C)

Spindle in speed control

G18

+Z

+ X WCS

+Z

WCS + X

+Y

G17

Orientation axis (B)


Milling spindle


Example: milling center with B/C-kinematics

3


SINUMERIK- The special 5-axes functions are also available for turning


Recording of measurement results - quality transparency in JOG and Automatic

CSV-format

Text format

Measurement in JOG

Measurement in Automatic

From system software 4.7 the measurement results can be stored in standardized protocol files with a minimum of effort – in the setup-mode as well as in

Automatic.


EES - Execution from External Storage - memory without frontiers

EES extends the CNC-memory on external storage media such as network drives– without limitations in the functionality (elimination of the EXTCALL-command).

EES – CNC-memory without restrictions

PCU50 SSD

SINUMERIK 840Dsl

User CF-card

SINUMERIK 828D

SINUMERIK

sytem CF-card

Industrial Ethernet

Server

Network drive

CNC-memory on SINUMERIK

NCU/PPU


Enhance already accurate machines with CNC based VCS compensation

Yesterday: Mechanical adjustment of machine components and

highly-developed craftsmanship

TCP positioning error

Ma

nu

fac

turi

ng

eff

ort

Today: Mechanical adjustment of

machine components and highly-

developed craftsmanship combined with

CNC based VCS compensation

CNC based

Compensation

VCS

Yesterday

“Scraping”

Today

“Programming”


Compensate for the Geometric Errors in a Machine Tool and make

accurate portal milling machines even more accurate

Six errors for each linear axis plus three squareness errors (3-axes machine tool: 6 + 6 + 6 + 3 = 21 possible errors)

Note:

geometric errors may vary

with temperature


Complete Compensation for SINUMERIK-controlled 3/5 axes machine tools

VCS File Format

[XTX]

AXIS_LENGTH [mm] = 1800

LINEAR_CORRECTION [mm/m] = 0.0

INTERVAL [mm] = 25

DEVIATION [mm]

GRIDPOINTS = {

-75.0 -0.012193623479

-50.0 0.000000000000

-25.0 0.012193623479

…

21 Geometric Errors + SINUMERIK 840D sl = Higher Accuracy

Error of linear axes

Error of rotary axes

CNC based Compensation

VCS

Activation of VCS Benefit for machine tool user : accurate results

Measure

Activation of TRAORI

Error saved in VCS file

Errors saved in TRAORI-MD Rot. Comp. Swivel Head

CYCLE 996 All Mechanism

6 pts

25~30 pts


Ensure and increase machine tool availability One central platform provided by SINUMERIK Integrate for Production


Client

Server

Industrial Ethernet

Client Client Client Client

SINUMERIK Integrate

Company Level

• Manage MyPrograms (MMP)

• Manage MyTools (MMT)

• Analyze MyPerformance (AMP)

• Analyze MyCondition (AMC)

• …

Machine Operator station Tool store Tool setting station

• Enterprise Resource Planning (ERP)

e.g. SAP

• Manufacturing Execution System (MES)

e.g. SIMATIK IT

• PLM software (for example: TEAMCENTER)

Machine


SINUMERIK Integrate for production Digitalization for production with machine tools

Tecno-

matix

Manage MyTools

Analyze MyPerformance

Manage MyPrograms

Analyze MyCondition

SINUMERIK

Integrate

N10 G17

N20 G54

N30 T= “CUTTER_63“

N40 M06

N50 T= “CUTTER_20“

N60 S1200 M03

N70 G0 X-20 Y-20 Z-5

N80 Z-3

N90 G94 F1000 X100

CNC program

N05 G54

N10 G17

N15 T=“CUTTER_20“

N20 M6

N25 S2000 M3

N30 G0 X10 Y10 Z-5

N35 G1 G94 F1200 X100

N40 Y100

N45 X0

N50 Y0

Machine statuses

x x OEE = Avail-

ability

Perfor-

mance Quality

AMP Clients

AMP Server ist

soll

Evaluation of

machine status

Determination of

OEE figures

Acquisition of

machine status

Test results Measuring series Reports

Status

analysis

Initiation of

actions

Status

monitoring

CNC

program

N05 G54

N10 G17

N15

T=“CUTTER_20“

N20 M6

N25 S2000 M3

N30 G0 X10 Y10 Z-5

N35 G1 G94 F1200

X100

N40 Y100

N45 X0

N50 Y0

CNC

program

N05 G54

N10 G17

N15

T=“CUTTER_20“

N20 M6

N25 S2000 M3

N30 G0 X10 Y10 Z-5

N35 G1 G94 F1200

X100

N40 Y100

N45 X0

N50 Y0

CNC

program

N05 G54

N10 G17

N15

T=“CUTTER_20“

N20 M6

N25 S2000 M3

N30 G0 X10 Y10 Z-5

N35 G1 G94 F1200

X100

N40 Y100

N45 X0

N50 Y0


Conclusion - Closed Loop Manufacturing is the factory of the future

Production Resources Production Process Product Structure

Virtual

Product Design

Production Planning



Service

technical domains in

one data model

Virtual


Thanks a lot for your attention

Digitalization will become

a revolutionary step

to a new level

in manufacturing!

digitalization in aerospace

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