Integrated Production System

The FMS solutions from Starrag provide users with a production system from a single source that is customised, offers process reliability and – not least because of its dependability – is profitable.

A cell controller developed by Starrag serves as a core element that monitors all processes. The cell controller controls the entire process – from the automatic loading and storage of the raw material to the unloading of the finished components, depending on requirements. The controller manages all data and resources such as tools, pallets, fixtures, etc. The orders are automated by the cell controller, accepted by the primary ERP system and reported as complete once the process is finished.

The cell controller guarantees digital transparency in the factory through measures such as visualisation of the plant status because the cell controller centrally manages all of the FMS information, which it forwards on as required via standard interfaces to primary computer systems or to control rooms and display overviews.

Starrag is working together with other key players on solutions that use the IoT.

Rapid development in the field of cloud-based data storage offers great future potential for the analysis and optimisation of machines and processes, thus paving the way for even greater availability and productivity.

The MQS combines the most important components for status monitoring and diagnostics on machines.
Fingerprint: Starrag has developed a process that can help with measuring the actual status of all feed drives in a machine, which enables the amount of wear to be ascertained.

Maintenance: The maintenance module offers a compact overview of the current maintenance status of a particular machine and thus indicates the maintenance work required at an early stage.

Integrated sensors: When it comes to complex and highly productive machine tools, sensor-supported monitoring of all media (e.g. coolant and lubricant, hydraulics, thermal stabilisation of the machine) is an important task.

Starrag machines are equipped with methods for using energy efficiently. These methods are combined in a comprehensive concept for each machine.

Energy-saving measures such as minimising friction by using high-quality bearing systems or FEM-optimised reduction of moving masses. In addition, modern energy-saving electronic components with low heat dissipation are being used, thus further increasing the lifetime of machines. Methods such as recovering energy to feed it back to the mains when motors are braked and dynamic reactive power compensation across an entire machine are also being implemented to reduce operating costs. Electrical and pneumatic energy consumption are recorded and users can use the information to tackle internal corporate energy management.
In addition to shutting down the entire machine at the end of the machining cycle, it is also possible to configure the machine to restart independently so that it warms up before production begins.

The Starrag PQS system supports users when it comes to recognising and avoiding process instabilities via intelligent evaluations on the integrated sensors.

Damage to the machine spindle must be avoided effectively. A system for automatic recognition of chatter vibrations has been developed to support the user with this task. This "chatter monitor" indicates the process status to the user using simple colour signals and warns against exceeding the process limits.

The electronics identify tool imbalances, the absolute vibration level of the spindles and process instabilities. This entire process depends on close interaction with the monitoring camera and the data from the CNC.

The HMI is the interface between a human and a machine.

In the past, usage in the consumer sector has developed rapidly in relation to smartphones and tablets, but until now machine tools have conventionally been operated via keys and command prompts. The main objective when developing the Starrag HMI was to transfer the modern-day possibilities of mobile end devices in terms of ergonomics, interactivity and flexibility to a production scenario.

By adapting state-of-the-art user prompts from contemporary smartphone programs, the safety of your manufacturing process can be increased because faults caused by incorrect operation are eliminated.