The graphical human machine interface (HMI) function enables the operator to view the machine's operation and speed up local/remote diagnosis and troubleshooting.
Large forging presses like Ajax-CECO-Erie Press can use a lot of force to shape workpieces for multiple industries, so it is essential to maintain production uptime and minimize accidental repairs and maintenance.
Although the automotive forging industry has existed for about a century, today's forging press HMIs are improving production uptime and control. Human Machine Interface (HMI) is a user interface or dashboard that connects humans with machines or forging systems. HMI is a software application that graphically displays information about various process states to the operator in a format similar to that of an actual machine or display panel. This information can be accessed locally (on the machine) or remotely (in the factory or remotely) via a PC, laptop or smartphone.
In the automotive forging industry, higher-level HMIs not only enable operators to view the operating conditions of the equipment, but also to predict the performance of the equipment. This is done through dynamic animated models and schematics, real-time trends and charts.
"The cutting-edge HMI is a visual learning tool that allows forging operators to observe the normal operation of the machine and speed up troubleshooting when problems occur," said Bill Goodwin, vice president of sales and engineering at Yili News Systems.
"Even inexperienced personnel can view the well-designed HMI screen, watch the press running, and then understand how it works. When the machine is switched throughout the production cycle, the operator can monitor the press's position and force data in real time. When there is a problem or a sudden stop in the cycle, they can quickly troubleshoot because the HMI provides a graphical window for the machine control system and its processes to identify problem areas," Goodwin added.
Founded in 1895, Erie Press provides a series of standard mechanical forging presses and individually designed hydraulic presses, suitable for most applications, including forging (closed die, open die and annular preform), metal forming, cold extrusion, isothermal Forging, carbon extrusion, compound press and stretch forming machine. The company was acquired by Park Ohio and is now part of the largest forging equipment supplier in North America: Ajax-CECO-Erie Press.
Traditionally, large forging presses need to use a lot of force to shape the workpiece, so it is important to maintain production uptime and minimize accidental repairs and maintenance.
However, for a long time, automakers with forging equipment had to rely on experienced operators to use manual gauges to take instant snapshots of the condition of individual components. Although very useful, it is not comprehensive. If you do not participate in daily maintenance, it will usually lead to problems in development that cannot be diagnosed, until costly production line failures are caused.
"With manual meters, if the pump starts to malfunction, the operator may not notice until the machine cannot complete a cycle," Goodwin said.
Usually, new operators have no experience to identify whether the forging equipment is operating normally. What's more complicated is that if there is a problem, they often waste valuable time looking for experienced operators or technical documents.
"Sometimes, a forging machine stops, but no one knows what went wrong with it, why it stopped, or where an error occurred in [the production cycle]," Goodwin said.
In the forging industry, the next-level HMI of Ajax-CECO-Erie Press not only enables operators to view the operation of equipment, but also uses dynamic animation models and schematic diagrams, real-time trends and charts to predict equipment performance.
HMI in forging Automotive forging presses with the most advanced HMI functions can help operators see and monitor what is happening with sufficient insight, so as to successfully troubleshoot faults and quickly bring equipment back online when needed.
Although HMI is becoming more and more popular in the industry, there are obvious differences in functionality between basic options and advanced options.
The most basic HMI is a visual terminal, where you can enter information and view data, but will not store new information.
In contrast, advanced HMI supports saving/retrieving data, custom search, and historical trend display. Far from primitive, the latest PDF technical documents and schematic diagrams of each component on the machine are searchable and can be displayed quickly as needed. However, the most significant function of HMI is how software applications simplify the operator's understanding and control of the forging press, as well as any necessary troubleshooting.
In fact, the real next-level HMI provides a dynamic animated schematic diagram, allowing the operator to observe it while the forging equipment is running. Operators can quickly "deep" into the performance of specific components (such as valves and pumps) from the top-level animated schematics, as well as find information about part numbers and wiring schemes.
Goodwin said that Erie Press started with a digital SolidWorks model of the printing press, imported it into the HMI software, and then "decomposed it" and animated it on the fly while displaying important operating statistics.
For example, in the case of an animated hydraulic schematic diagram, hydraulic pressure sources from multiple pumps are displayed in one location for instant verification. The operator can monitor the current press status displayed in the text box, as well as the fields indicating the pressure in the master cylinder and the pull back cylinder. Shows the valve command and actual spool feedback of each proportional valve.
According to Goodwin, the press operator can also monitor the main plunger tonnage, main cylinder pressure, moving platen position, last cycle time and current cycle time.
Using this information, the forging staff can more effectively understand the internal operation of the press by observing all these data, because it is cyclically performed during the operation, so as to be able to quickly diagnose and take action when a potential problem occurs.
Whether it is a forging operator or an OEM, the integration of HMI, sensors and online technical support has also made considerable progress in preventive or troubleshooting diagnostics.
For example, Ajax-CECO-Erie Press has developed an online diagnostic system for remote monitoring and support through the remote Ethernet diagnostic connection provided on all new equipment. The Ethernet-based control system provides a platform for OEM engineers to remotely view the health of the machine while it is running.
"The goal is to avoid production downtime by preventing problems and reducing the time to discover, diagnose and resolve problems," Goodwin said. "Remote diagnostics allows us to monitor the forging equipment and solve any potential problems in a timely manner. For example, we can remotely reset a switch that does not activate or fine-tune the target position or precise speed of the press head."
Using a well-designed HMI, the operator can monitor real-time printing press data as the machine transitions to the production cycle. When there is a problem or a sudden stop in the cycle, they can quickly troubleshoot because the HMI provides a graphical window for the machine control system and its processes to identify problem areas.
According to Goodwin, even if the component fails, this capability-and the implementation of some redundant components (such as electronic position sensors) can maintain online production. “If one fails, we can dynamically switch to the good one. Traditionally, a faulty sensor will cause downtime until the technician can obtain the correct part and replace it in the field,” he said.
He pointed out that such a system can also view historical trends and the latest, searchable PDF technical documents and schematics, as well as dynamic animated schematics.
"Based on historical data, if a component starts to fail, maintenance personnel can usually identify and replace it before a catastrophic failure occurs," Goodwin said.
He pointed out that the next level of HMI can conduct a historical review of the operation of the forging equipment on a specific date and time. When the operator simply "fixes" certain types of data or moves a graphical slider representing a time slice (used as an icon on a smartphone), the HMI will display data about the performance of the forging equipment at the exact date and time.
Take Ajax-CECO-Erie Press as an example. Forging equipment with HMI includes its electrical, mechanical and hydraulic equipment data table library. You can view and print electrical schematic diagrams, hydraulic schematic diagrams, and mechanical assembly diagrams from HMI. The data sheet is in PDF format, and keywords can be searched in the document.
"There is no need to spend days searching for the correct technical documentation and reading up to 100 pages of data sheets or wiring diagrams. The data is searchable and immediately available to the operator," Goodwin said.
In fact, the next level of HMI can quickly zero out the required specific data, schematics or drawings by digging deep into the advanced dynamic graphic animation of the device, thereby further improving the search capability.
“For example, on the dynamic animated schematic screen on the HMI, the operator can hover the mouse over the device to find the exact manufacturer part number or click on the device to access its specific data sheet,” explains Goodwin.
Although automotive forging presses have traditionally been regarded as decades-old technology, advanced HMIs are becoming almost as easy to monitor and use as operators’ favorite smartphones, while also providing easy access to key performance data.
The bottom line for manufacturers who rely on the effective use of forging equipment is that new features can significantly increase production uptime and profitability, providing key advantages over competitors.
Please visit the Ajax/CECO/Erie Press website https://ajaxerie.com or send an email to info-sales@AjaxErie.com. Or, if you prefer, please call 814.455.3941.
When designing the enclosure, climate control issues are often overlooked. However, choosing the right cooling equipment is critical to maximizing the efficiency, performance and productivity of the equipment. This white paper explains how to make the right choice.
Use connected worker solutions to support the production of high-quality products. Understanding the long-term patterns, trends, and early reports of quality issues will help drive continuous improvement in your company.
Quality leaders face millions of challenges every day and must make decisions, and these decisions can quickly turn into quality errors, causing the car manufacturing company to lose time, money, and competitive advantage. Many of these companies still use paper forms that require time to check and review to ensure that the team adheres to the compliance of key processes, thereby minimizing quality issues. However, the paper process can be full of errors because employees usually have to check hundreds of items without actually participating in the process or evaluation criteria, leading to quality issues.
Improving product quality is one of the primary goals of every automobile manufacturing company, but without timely and accurate data, this may be difficult. In a market where quality is a key indicator of success, leaders have the opportunity to improve quality control and layering processes and supplier audits by moving from outdated paper handling to digitally connected worker solutions.
Benefits of digitally connected worker solutions for quality management and auditing 1. Unlock key data as early as possible. The last thing the person in charge of key data quality wants to appear is a defective product, which leads to a waste of product, time and money. The connected worker solution makes it easy and possible to capture real-time data and audit trails from frontline workers, which is the key to identifying defects as early as possible. Paper quality management system (QMS) and hierarchical process audits can easily miss key points where the quality is not up to standard or need help. Digital solutions highlight real-time valuable data and provide instant insights into problem areas or processes that need improvement. As a result, problems can be found faster, which means that product defects can be caught before they appear.
2. Ensure process compliance. Digital mobile solutions that collect real-time data from frontline employees help ensure compliance by involving employees. When workers participate in processes and procedures related to achieving and maintaining quality standards, it leads to better quality results. Solutions that provide real-time guidance and prompts to ensure that the job is performed correctly eliminate guesswork and guide workers on the right path. The guided workflow experience helps to get everyone involved to achieve compliance. These flexible, connected employee solutions also provide proactive quality requirements and safety and operating procedures through remote supervision to protect supplier quality.
3. Maintain accountability at all levels. For the paper quality process, it is difficult to know exactly how to end inefficiencies and defects. Digital solutions will not fall into the loop of manually tracking quality issues, but will help keep everyone accountable for the final product. Real-time data analysis across organizations makes it easy to understand who is responsible for different aspects of the workflow and track whether these key projects have been completed. This real-time insight into the data enables quality leaders to take immediate action.
4. Ultimately reduce the cost of quality (COQ). As we all know, the cost of quality is very high. ASQ points out that some organizations have COQs as high as 40% of their sales revenue. The poor quality of a company is often in the range of 10%-15% of sales revenue. The implementation of digitally interconnected employee solutions allows frontline employees to become quality leaders themselves and obtain data in a meaningful and actionable way. This is the key to promoting quality and process compliance improvements, which will ultimately reduce quality costs.
Use connected worker solutions to support the production of high-quality products. Understanding the long-term patterns, trends, and early reports of quality issues will help drive continuous improvement in your company.
About the author: Robin Fleming is the co-founder and CEO of Anvl, an award-winning software company that helps companies unlock real-time data to improve product quality, safety, and productivity. Anvl's easy-to-use connected workforce platform has collected more than 11 million leading data points, and the engagement of its user base is usually over 90%.
No matter which industry you are in, downtime is expensive, but if you find yourself in the automotive industry with large machines running 24/7, the downtime is extremely disruptive and can cause great distress.
Many manufacturers in the automotive industry trust computerized maintenance management systems (CMMS). These systems help simplify the manufacturing process and help achieve a more sustainable, cleaner, smarter and safer manufacturing environment. how? While achieving maintenance goals, they also have a deep understanding of production processes and supply chain operations.
Optimizing preventive maintenance Preventive maintenance refers to continuous daily maintenance to prevent equipment failures. In other words, maintenance is carried out before the equipment fails, and it is still running. This may include simple tasks, such as cleaning filters and only inspecting equipment, or more complex tasks, such as complex investigations to see the condition of parts below the surface.
By correcting small problems in time, you can avoid major component failures or complete machine failures. This not only means that you will pay less to maintain the normal operation and operational status of the manufacturing plant, but also that you will not have to face the loss of revenue and pressure that accompany failures.
Remember, a sudden equipment failure can also mean employee injury. Although no one hopes this will be the case, some machines may explode, cause fires, or burn workers. These situations may bring their own set of confusion.
Instead, the implementation of CMMS completely avoids the possibility of failures and failures. The system notifies you when you should check, and even ensures that work orders are created, technicians are hired, and problems are resolved after integration with the building automation system (BAS).
Simplifying work order tracking As automakers often participate in global supply chain operations, ensuring that everything runs smoothly and the safety and efficiency of each manufacturing plant is a huge challenge.
Many locations mean that work orders may increase every day, and tracking them may get out of control. This makes it difficult to manage maintenance activities, reduce response time, and reduce downtime.
A comprehensive CMMS allows automobile manufacturers to communicate with maintenance technicians, suppliers, operators, and inspectors. Therefore, work orders can be completed on site and offsite. In addition, CMMS can ensure that work order requests are regularly updated, which means that the maintenance team is always in the loop and provides valuable maintenance documentation for the manufacturing plant.
Demonstrating compliance. Multiple regulatory agencies around the world require automakers to comply with certain standards and daily operating protocols. IATF 16949:2016 is an example of such a standard. The standard aims to prevent defects, reduce waste/variation, and improve the quality of the management system of the automotive industry's supply chain.
By integrating CMMS, manufacturers can instantly access data that proves they comply with these standards and comply with other safety, export, import, and environmental standards. When such documents are requested, manufacturers can access their CMMS and immediately provide detailed reports to these regulatory agencies.
Provide key data-driven indicators. Automakers use a large number of parts. For example, the parts of a car are estimated to be between 20,000 and 30,000. The volume is large, the responsibility is great, and the possibility of errors in the production process is also great.
CMMS can set standards for machine productivity to increase productivity in different locations. It is also often used as a maintenance database to provide management visibility across the company. This visibility ensures that the maintenance team identifies key performance trends so that they can make informed decisions about equipment and maintenance requirements.
If you are a 21st century car manufacturer, then you have a great responsibility. Don't forget that the development of technologies such as CMMS takes your needs into consideration-making your manufacturing process easier.
Rockwell Automation’s Cliff Rice demonstrated the importance of digital infrastructure and provided insights on how automakers can begin implementation.
Cliff Rice is an automotive, electric vehicle (EV) and battery industry consultant for Rockwell Automation.
Automakers understand that they must undergo digital transformation to keep up with demand and remain competitive while the demands of the entire industry continue to evolve.
The digital factory promotes connectivity by using a system that can effectively transmit data throughout the production floor. This enables manufacturers to identify optimization opportunities and enables automakers to continuously improve production. In addition, the technology can alert manufacturers to errors or problems that may affect product quality. In order to take advantage of these production capabilities, many automakers are seeking to adjust their current production practices to integrate digital connectivity. However, it may be difficult to know where to start.
Today's Motor Vehicle (TMV): Focusing on the importance of this digital future, how can it help automakers meet the ever-changing needs of the industry?
Cliff Rice (CR): When we talk about changing industry needs, I focus on electric vehicles (EV). This is a huge market shift that we have seen across the board; you seem to hear news about new investments in electric vehicles every day. A unique aspect is that vehicles are a very rich source of data and have an incredibly long lifespan. If we can obtain this data and link it to the manufacturing process, we can learn a lot, such as where quality problems may occur or where they may be missed. We can improve the customer experience by limiting the scope of the recall, and really honed in our operations and production by looking at vehicle data.
TMV: The industry is aware of the need for these technologies. However, there are some minor issues. So what are the challenges faced by automakers when adopting these technologies?
CR: For most people, this is not a completely linear process. I divide the challenges into two broad categories-organizational and technical challenges. From an organizational point of view, I see a lot of lack of consistency. Individual factories and even production lines may have conflicting requirements. The difference between the scale of the challenge and the reward for solving the challenge before a single production line and organization is huge. For example, sometimes the maximum demand for a factory's production line will not be well transformed in all factories. Therefore, you can take individual steps to solve very specific use cases, but you cannot scale or really change the way your business operates.
Then technically, I would say that the biggest concern is network security. This is something we often talk about. Everything is interconnected, which is why we, as a company, have truly expanded our products and product portfolio through remote threat detection, vulnerability monitoring, and secure remote access from suppliers, and we have an end-to-end encrypted communication protocol. We follow IEC 62443-4-1, which defines safety standards for product and process design. Not only does the product need to be safe, but the way it is designed also needs to be safe.
TMV: After realizing these challenges, what advice can you offer to manufacturers who want to incorporate Industry 4.0 technology into their products?
CR: There are three important considerations: one is to start with business value, the second is to ensure that you have organizational consistency, and the third is to build motivation. When I say starting with business value, I mean looking at the problem and defining the rewards for solving the problem. Then look at all the key players, they not only need to participate in that production line, but also need to participate in the entire factory, including the participation of senior management, so that we can expand. We did all of this work even before we even started thinking about the technology, because trying to force a technology to be suitable as a solution is risky. We want to start with a value seminar, where we only look at what the problem is and how it will expand if we solve the problem. Before we start thinking about which technologies will be used to solve the problem, we can examine all of these and define what their success criteria look like. This is about ensuring that we have people from different roles, levels and locations involved in this process. This will help ensure our adoption and availability. We can learn these lessons and deploy them throughout the organization. This is consistent with building momentum. The first digital twin will not be your last, so think about the first specific challenge that can be solved quickly with a truly quantitative return on investment (ROI). Rockwell Automation has FactoryTalk Innovation Suite software, which is expandable and compatible with other products, and can be used as input for other systems. Not only is it a one-time tool you use to build and solve problems, but you can still use the platform to solve the next problem and build the next digital twin. From pilot to enterprise scope is how the real transformation occurs.
TMV: How do manufacturers evaluate their digital readiness before taking the next step in actual implementation?
CR: Evaluation is an important and complicated process because it varies from person to person. But in general, many of these gaps will be discovered from that value seminar. We will look at everything as a whole. So I think most people want to start with the network and infrastructure. But we also want to look at the people, processes, capabilities, and challenges within these organizations. At Rockwell, our approach to assessing the organization's digital readiness and helping them has always been to combine domain expertise first. We will introduce a team focused on digital transformation and advising and guiding the organization. Every organization can adopt some of these digital twin plans, or even completely manual operations, with little automation. There are opportunities through things such as augmented reality (AR), but depending on the challenge at hand, there will be specific things such as network requirements, server infrastructure, or the ability to support these digital twins. If the organization cannot adjust or train it because it does not have the right resources, it is useless to create extremely complex machine learning (ML) algorithms. This is where we will introduce our team of digital transformation consultants to conduct assessments and recommendations based on the company's needs.