DIGITAL TOOL MANAGEMENT & MOULD MONITORING

DIGITAL TOOL MANAGEMENT& MOULD MONITORING

INNOVATIVE SOLUTIONS FOR PLASTIC INJECTION MOLDING, PUNCHING & FORMING TOOLS

2 CONDAMOS

OUR VISION & STATUS QUO

As a lively medium-sized technology company, we want to actively shape the future of the injection moulding, stamping and forming industries. Our motivation is the development of efficiency potentials and their imple-mentation in the value chain of our customers. The key to accomplish this vision are our employees, who know our customers‘ daily challenges and develop the right techno-logies.

As a tool making company, we are the link between pro-duct development and series production. We therefore pursue a holistic approach for our customers, so that we can support them along the entire value chain, from starting from the product development process to the se-ries production. Together with our customer, we want to make the implementation of tool projects more efficient and make both tools and the production processes safer

and more efficient by using software and hardware solu-tions.

We have founded the CONDAMOS (connected data moul-ding solutions) business unit out of our mould technology business unit. With CONDAMOS we want to make in se-ries production transparent, by capturing, analysing and visualizing all relevant process data. The data enable us to take targeted measures to optimize the series production process in all relevant areas and thus increase productivi-ty and quality, while at the same time reducing costs. Due to the modular structure of our self-developed software and hardware solutions, we can respond precisely to the individual requirements and challenges of our customers. This is how we create a new, sustainable added value di-mension.

CREATING A NEW VALUE-ADDED DIMENSION

DIGITAL TOOL MANAGEMENT & MOULD MONITORING 3

The current isolated solutions in the injection molding, stamping and forming production process are the deci-sive hurdle when it come to optimize the series produc-tion process. So far, (process) data have been recorded, but this is mainly used for process control and molded part quality.

Tool making and tool data have so far generally been left

out. Tool availability, tool life and the possibilities offered by machine learning and AI have so far not been consi-dered.

The linking and analysis of the existing process data, as well as the expansion with data from tool and tool construction form the basis for the possibilities of a new value creation dimension.

As toolmaker, with a tool service & support division, we precisely know the problems our customers face in their series production:

• Tool failures and production breakdowns• High scrap rates• Service & maintenance costs that are too high• Fluctuating quality of the produces parts• Imprecise communication between production and tool maintenance department • Insufficient quality assurance in the production and tool maintenance department• Increasing competitive and price pressure for the production facilities

WE ARE AWARE OF YOUR DAILY CHALLENGES

STATUS QUO PROBLEM

• Tool failures • Long production downtimes• High maintenance costs of the tools

• Process data and process informa-tion partly available

• Lack of know-how in tool making

• Inaccurate capacity reserve for ser-vice orders

• Difficult scheduling of rush orders• Strong competition in service &

support

• Know-how only in tool making• Lack of process data and process

information of the tools

• Diametrically opposite requirements between serial production and tool making

• Inefficiencies, since process data and knowledge are not shared between serial production and tool making

MISSING INTEROPERABILITY

4 CONDAMOS

WHAT DOES THE NEW ADDED VALUE DIMENSION LOOKS LIKE?

VALUE ADDED WITH DATA

Source: WZL/WBA AAchen / Sauer & Sohn Dieburg

The new dimension of added value should link and make more efficient the individual processes between product development and series production, by analysing and sharing knowledge and information of the entire value chain.As a link between series production and product development, tool making offers great potential regarding oppor-tunities for optimization. By analysing the entire process data, tool making can provide the knowledge for targeted optimisation of product development and series production.Therefore, the „classic analogue tool making“ must be developed into „digital toolmaking“. The missing process data can only be sensibly recorded, linked and analysed using the „Digital Tool Building“.


AND HOW DOES THE BUSINESS MODELL LOOKS LIKE?

DIGITAL TOOLING AS A BUSINESS MODEL

With CONDAMOS, we are gradually refining the collection and analysis of the key process data and the analysis options. In this way, the production process can be monitored transparently and the data-based optimization of the components, the tools, the production and predictive maintenance is made possible.This enables us to increase the productivity as well as quality of our customers‘ manufactured part.At the same time, we also increase the cost-effectiveness of our customers‘ production facilities, in which tooling costs, production downtimes and maintenance costs can be reduced in a targeted manner.

AKTUELLER STAND CONDAMOS

PRESCRIPTIVE ANALYTICS

PREDICTIVE ANALYTICS

DIAGNOSTIC ANALYTICS

DESCRIPTIVE ANALYTICS

What happened?

Why does it happen?

What will happen?

How can we automaticallyreacted to it?

TSM-Platform (2016-2019)Exemplary service:• Networked tool monitoring

TSM-Plattform untill 2020 (incl. Werkprima)Exemplary service:• Data-supported tool start-up• Data-based component and tool optimization

(retrospective)

CONDAMOSfrom 2020 with research project„FutureMould“Exemplary service:• Smart tool start-up• Data-based production optimiza-

tion

CONDAMOSfrom 2020 with research project „FutureMould“Exemplary service:• Data-based component and tool• optimization (proactive / forward looking)• Predictive Maintenance

Source: WZL / WBA AAchen / Sauer & Sohn Dieburg

6 CONDAMOS

THE MODULES

OVERVIEW

Our modules are designed and developed in such a way that they can capture process data form the entire value chain of the various types of tools. The data collected by our modules are sent to the TSM platform and analysed there. The processed data can then be viewed in the TSM platform.

Software solution

• Basic module (platform)• Digital order management• Digitales tool (service) book• Visualization platform for:

– Service & Support – Process data from the produc-tion process – Analysis of the process data

Hardware solution

• Digital switch• Process monitoring based on

cycle times: – Maschines & plant monitoring

Hardware solution

• Records tool-based process data during the production process

• Sends the captured data to the CONDAMOS backend for data storage & analysis

Backend solution

• Acquisition of production machine and tool peripheral data via IO-Link & OPC-UA

• Analysis of the data from own data collection and the other modules• Transfer of the processed data to the TSM platform (interface) for visuali-

zation


APPLICATIONS& BENEFITS

CONDAMOS can already be used effective-ly in tool support, as a reactive process, to in-crease tool availability by using the module TSM .

• The digital documentation of the repair and maintenance measures as well as the system-atic recording of the problems, error patterns and repair measures carried out on the tool ena-ble recurring problems and weak points to be identified and suitable measures to be taken.

In series production, emerging process errors, partial or full system failures, lower part quality or, in the worst case, production downtime can be identified and prevented.

CONDAMOS can monitor the tool process data in the production process in real time and react to deviations in the reference parameters. Deviations in parameters can be recognized and preventive measures can be initi-ated even before critical deviations in parameters arise.

In order to enable analysis and predictive maintenance, CONDAMOS accesses the various historical and current tool and sensor data. Through the use of different ana-lysis methods, such as correlation analyses, potential pro-duction failures and problems on your tool can be identi-fied more quickly and reacted to more quickly.

REALIZATION OF THE NEW VALUE ADDED DIMENSION

BENEFITS TSM TSM & Sparrow TSM & EAGLE

Digital order management and digital tool (service)booklet

Analysis and measures take via tool management function

Reduction of the repair and maintenance costs by identifying weakness and problems of the tool during service & support

Quality assurance

Reduction of unplanned downtime

Higher productivity in series production

Production and process view

Overview of the activity of the plants and the machine park (cost-effective tool based MES)

Constant and reproducible quality of the moulded parts

Demand-based, predictive maintenance instead of static maintenance intervals

8 CONDAMOS

FUNCTIONALITYOVERVIEW

DATA COLLECTION, ANALYSIS & VISUALISATION

Thanks to its modular structure and the various software and hardware solutions, CONDAMOS can be specifically adapted to customer needs.The data are transferred to CONDAMOS via various solutions and the analysis is visualised on the TSM platform.

Process data:

• Capture of tool based process data via EAGLE

• Capture of machine and tool peri-pheral data via IO-Link & OPC UA

Analysis:

• Analysis of the recorded data with CONDAMOS

Input and visualization of the data in the TSM platform

• Capture of data regarding tool support via direct input

• Data entry by the machine ope-rator

• Visualization of the processed data


THE MODULES

ALL RELEVANTDATA FROM ONE SOURCE

10 CONDAMOS

TSM PLATFORM DIGITAL TOOL BOOK

The TSM platform is both an input and visualization plat-form. It serves as an interface for the CONDAMOS system. The platform is web-based and can be accessed and used with any browser via the Internet or intranet thanks to the responsive design.

The platform has various tasks within the overall system:

• In tool support, it is used for control, processing, pro-cessing and the detailed documentation of all orders.

• In series production, it enables the machi-ne operator to provide quick and easy feed-

back on tools, machines and components.

• At the same time, the platform visualizes and saves the live data from the production process (process data from the sensor system of the tool, tool periphery & machine) as well as the proces-sed and analysed data from service & support. *

• It also gives an overview of the current status of the systems and machinery. **

DAS FRONTEND DER NEUEN WERTSCHÖPFUNGSDIMENSION

THE FUNCTIONS AT A GLANCE

* (In combination with the Eagle module for tool process data and the IO-Link & OPC-UA interface for peripherals & machines)** (Process monitoring of systems & machines in combination with the Sparrow or Eagle module)

Tool Service book

• Tool management• Order management• Documentation of tool service & support• Prepared service history

Analysis & visualization of data from

• Service & Support• Production – Tool process parameters – Machine & tool peripherals – Plant & machine status


TSM PLATFORM FUNCTIONS

TOOL MANAGEMENT

Digital management of tools and service orders of the tool maintenance department

All relevant data, documents and deadlines are stored centrally• Work instructions• Plans (Parts list, CAD data, etc.)• Measurement results

e.g. Hot runner, flow rates of the cooling circuit etc

Tool-based evaluations of support & service events

ORDER MANAGEMENT

Easy creation of service orders• Problem description and / or work order• Delivery date back to production

Digital recording of the tasks carried out and errors found on the tool

The process status of the tool support can be follow up live at any time:• Order creation• Incoming check• Repair• Outgoing check• Delivery of the tool back to the production

12 CONDAMOS

TSM PLATTFORM FUNCTIONS

DOKUMENTATION VON SERVICE & SUPPORT

Transparent documentation of the entire service process• Tool and order references • Repair and approval status • Before-and-after media (pictures, videos, documents)• Order position• Data inventory• Pictures of the damages / visual markers• Recording of the fault patterns & repair measures

carried out

Export function of the order as PDF and Excel

Automatic notifications

PREPARED SERVICE HISTORY

Analysis & evaluation function• Global evaluation of all tools

– Identification of repair and maintenance intensive tools

• Tool based evaluation – Identification of recurring problems and weaknes-ses of the tool

Clear visualization of the evaluation using understandable graphs and diagrams• Service history: date / cycles / errors• Overview of orders and error patterns• Service history over time• Detailed error images according to the error catalo-

gue


TSM PLATTFORM FUNCTIONS

MACHINE STATUS AND CYCLE TIMES

In combination with Sparrow, the TSM platform provides a live overview of the current machine status and the current cycle time.

The current status of the machine is highlighted via diffe-rent colours:• Green: Machine is running – the cycle times corre-

spond to the specification• Red: Machine is down• Orange: Problem / malfunction of the machine

The machine park can be easily monitored and the cycle times can be tracked. An early correction, in the event of deviations in the cycle times and a possible the reduction in quality differences of the produced moulded parts, is possible.

MODULAR AND WEB BASED

Extension of the TSM with new modules :• Personal home screen• Sensor module (visualisation)• Process module (touch optimized user interface)

New features• Multi-client capability • Role administration • Direct messaging• And counting…

Quality notification in production directly and easily via tablet

14 CONDAMOS

EAGLE

Eagle is the CONDAMOS module for mould monitoring, i.e. the capture and monitoring of the process data of the tool during series production. Eagle is connec-ted directly to the tool and can then record the para-meters of the integrated tool sensors during the pro-duction process. It transfers the recorded tool process data directly to the TSM platform for the purpose of process monitoring and analysis. All tool process data is visualized and archived live via the TSM platform.

A reference parameter or reference intervals can be set for each sensor. If there is a deviation, you can react im-mediately. Uncritical parameter deviations are recognized and preventive measures can be initiated immediately

before critical deviations occur that lead to damage to the tool, poorer part quality or to production failure.

Thanks to the TSM platform, the tool process data is not exclusively available for series production, but also be shared with the tool maintenance and product develop-ment department. The information obtained enables tar-geted tool optimization, not only through tool support, but also in the engineering of new tools.

EAGLE can be configured individually to suit the number of sensors in the tool. With our know-how, we are your ideal partner for equipping tools with sensors.

TOOL SENSOR DATA

Technical details:

Analoge & digitale Eingänge

Integrated measuring amplifier :• Piezo elements with peak detection• Strain gauges with peak detection• Thermocouples

Connection via WIFI or Ethernet

Internal memory in case of connection loses


EAGLE

ÜBEBRLICK DER SENSORIK AM WERKZEUG

Supported sensor technology:• Piezoelectric pressure sensors• Strain gauge pressure sensors • Thermocouples • Analog sensors (0-10VDC)• Limit switch • All the sensor comes with OPC/UA

Depending on the configuration:• Up to 48 analogue sensors• Up to 16 limit switches• Unlimited sensors connection via OPC/UA

EXAMPLE PLASTIC INJECTION MOULDING TOOL

acceleration sensor

ultrasonic sensor

position sensor

strain gauge sensor temperature sensor

Pressure &temperature

sensor

piezoelectric sensor

16 CONDAMOS

SPARROW

Sparrow is a digital switch to monitor the machine park and the production process on the respective machine. Sparrow is connected directly to the tool and monitors the cycle time of the each individual cycles during the production process on the corresponding machine.

The recorded cycle times are visualized in the TSM plat-form. Default times can be set for each individual tool.

These are compared with the current cycle times during the manufacturing process. Machines with inconsistent cycle times are highlighted in the TSM platform.An early correction of inefficient cycles is possible. In this way, the productivity of tool and the machine can be in-creased and the quality differences of the produced parts can be reduced.

DIGITAL SWITCH

Note: Depending on the type of tool, the illustration can differ from Sparrow.


SPARROW

COST-EFFECTIVE & INTELLIGENT TOOL-BASED MES

Alle Produktionsmaschinen werden digital in der TSM-Plattform abgebildet.

The current status of the machine is highlighted via different colours:• Green: Machine is running – the cycle times correspond to the specification• Red: Machine is down• Orange: Problem / malfunction of the machine

Relevant information can be called up for each machine, such as:• Machine number• Tool number• Produced parts• Order• Start of production• Production progress• Malfunction information

Through its design, Sparrow enables the machine park to be monitored easily and efficiently and to react quickly to any faults or problems that may arise.

18 CONDAMOS

www.condamos.com

Sauer & Sohn GmbH & Co. KG Geschäftsbereich CONDAMOS Groß-Zimmerner Straße 51 64807 Dieburg Phone: +49 6071 206-140 [email protected]

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DIGITAL TOOL MANAGEMENT & MOULD MONITORING