IPS

“集成制造系统”是对实现数字化目标的重要贡献，它为应对即将到来的挑战提供了平台。当斯达拉格生产系统和机床的用户、操作者在使用数据执行复杂任务时，它为其提供支持，并为网络化生产世界增加价值。

Highlights

Industry 4.0 Statement

“Industrie 4.0” and the Starrag Integrated Production System (IPS)

The internally developed IPS from Starrag offers customers a modular system of solutions tailored to their needs within the context of “Industrie 4.0”.

Customers receive networked manufacturing solutions that are completely tailored to their needs using customer-specific modular systems, living up to the claim "Engineering precisely what you value". The impressive results include increased profitability, improved safety and higher growth.

But what exactly does “Industrie 4.0” mean? We have moved through Industry 1.0 (mechanisation), 2.0 (mass production) and 3.0 (automation), and we are now on our way to “Industrie 4.0”. This new stage of development will shape the future of industry like never before. Ultimately, it is about forming an integral link throughout the entire value chain, from developing initial ideas right up to final recycling, including the customer services that are connected to each stage of this process.

By developing IPS, Starrag has made a crucial contribution towards achieving this aim. It allows customers to gradually automate their production processes so that they can ultimately take full advantage of all the options provided by the system. This begins with individual machines with add-on functions and moves on to flexible manufacturing systems (FMS) and even entire production lines. At each stage of expansion, modules are available that are adapted for the respective specialised task.

The unique selling point and basis for reliable production planning is the cell controller technology that Starrag has developed in house, and that is used to control manufacturing systems and lines with maximum process reliability. The cell controller monitors all the processes, thus ensuring digital transparency. It manages all the information relating to the production system centrally and passes this on, if necessary, to higher-level data processing systems via standard interfaces.

If a customer operates at the final stage of expansion, all they need to do is feed the parts for processing into a material accumulator. The rest happens fully automatically: from loading and storing the raw material, to various machining steps and, finally, to unloading the finished workpieces. All the data and resources are managed by the cell controller, which receives the orders directly from the end customer's ERP (Enterprise Resource Planning) system.

Communication between the individual components provides invaluable benefits. For example, it can safeguard production reliability by monitoring the condition of machines, greatly reducing costs relating to maintenance and downtime. It also provides an opportunity to monitor and control energy requirements and consumption throughout the manufacturing process, optimising energy management. By better utilising their capacities and controlling production, companies can greatly increase their profitability or generate growth.

单元控制器

斯达拉格的柔性制造系统解决方案为用户提供了一个定制化的一站式生产系统，具有出色的工艺可靠性（可靠只是其中的一个原因）和盈利能力。

斯达拉格单元控制器是监控所有过程的一个核心元件。单元控制器可根据要求控制从自动装载和原材料存储到卸载成品件的整个过程。控制器管理着所有数据和资源，如刀具、托盘、夹具等。单元控制器自动生成指令，主 ERP 系统接受指令，并在过程完成后发送报告。

单元控制器集中管理着所有 FMS 信息，可以根据需要通过标准接口将信息转发至主计算机系统或者控制室，并显示概览，因此能够通过设备状态可视化等措施保证工厂的数字透明化。

物联网

斯达拉格与其他关键企业一同着力打造 IOT 解决方案。

云数据存储领域的飞速发展为机床及工艺流程的分析和优化带来了巨大的未来潜力，从而为更高的适用性和生产力创造了前提条件。

机床认证系统

MQS结合了最重要的部件，用于机床的状态监控和诊断。

指纹：斯达拉格开发了一个可以帮助测量机床内所有进给驱动实际状态的工艺流程，从而实现磨损程度的测定。

维护：维护模块可针对特定机床提供一个紧凑的当前维护状态概览，从而指示早期阶段需要的维护工作。

集成传感器：对于复杂且高产的机床而言，通过传感器监控所有介质（例如冷却液和润滑剂、液压系统、机床热稳定性）是一项重要任务。

效率控制

为实现能源的高效利用，斯达拉格机床采取了一系列方法，并将这些方法整合为一个综合概念，以适应每台机床的情况。

采取节能措施，比如通过使用优质轴承系统减少摩擦，或者通过有限元优化减少运动重量。另外，还使用了低散热的现代节能电子元器件，进一步延长机床的使用寿命。还实施了电机制动时回收能源并将其反馈到电源，以及全机床动态无功补偿等方法，降低运营成本。记录电气系统和气动系统能耗，用户可以利用该信息来解决企业内部能源管理问题。

除了在加工循环结束后关闭整个机床外，还可以配置机床单独重启，以便在生产开始前进行热机。

过程质量控制

斯达拉格过程质量控制系统 (PQS) 支持用户通过集成传感器的智能评估来识别和避免过程不稳定性。

我们必须有效避免机床主轴的损坏。为达到这一目的，斯达拉格专门开发了一个自动识别颤振的系统。该“颤振监测器”通过简单的彩色信号向用户指示过程状态，并在超过过程极限时发出警告。

电子器件可识别刀具不平衡、主轴的绝对振动水平和过程不稳定性。整个过程依靠与监控摄像头和数控系统数据的紧密交互。

人机界面

人机界面是人与机床之间的对话接口。

在过去，智能手机和平板电脑在消费者领域的的使用发展迅速，然而时至今日，机床的操作仍然依靠钥匙和指令提示等传统方式。斯达拉格开发人机界面的主要目的是把现代移动终端设备在人机工程学、交互性和灵活性方面的可能性转移到生产场景中。

通过利用当代智能手机程序中最先进的用户提示，消除误操作故障，可使制造过程的安全性得以提升。

机床保护系统

通过使用斯达拉格机床保护系统 (MPS)，可以避免您和您的机床承担因人为失误导致的不良结果。

无论您是需要启动新的数控程序、调节刀具还是手动操作机床，斯达拉格 MPS 系统都能可靠地防止各种类型的碰撞。

防撞保护装置使用机床、工件和刀具的 3D 模型，并实时对比其在加工区内的位置。如果控制系统检测到即将发生碰撞，人机界面 (HMI) 将以 3D 视图显示危险情况，并且机床会提示操作者进行校正。

The components in the Starrag IPS system also address issues like mobility by making information available on mobile end devices or state-of-the-art human-machine interfaces such as "smart operation". Humans play a central role when it comes to “Industrie 4.0”. They are, after all, the ones who ultimately control and monitor the production.

The "Integrated Production System" is a crucial contribution towards achieving the aim of digitalisation, as it provides a platform for meeting the upcoming challenges. It offers support for users and operators of Starrag production systems and machines as they carry out the complex task of using data in a way that adds value in a networked world of production. Starrag IPS allows customers to gradually automate their production process so that they can ultimately take full advantage of all the options provided.

On linked large machines, sheet metal forming tools can be completely machined in one clamping operation. The result is a 31% reduction in processing time.

Flexible manufacturing system for chinese aircraft industry

Chengdu Aerospace: Industry 4.0 at its finest

Chengdu / China

While others are still romanticising Industry 4.0, the Swiss-based Starrag is already realising digitally networked production in Southwest China. With a completion date of summer 2019, six ECOSPEED F 2060 are to be installed at Chengdu Aerospace‘s aircraft factory in China to create one of the most productive and efficient plants in the world. The plant will be used for the complete processing of aluminium structural components. A high level of investment is being made in the Chinese aviation industry. The industry plans to build over 1900 new aircraft by until 2025 at a total cost of around 300 billion US dollars and is investing heavily in new production technology. Chengdu Aerospace Plane Aviation Machinery Equipment Ltd. has now ordered a digitally networked flexible manufacturing system (FMS) with cell controllers from the Starrag.

Work will take place between January 2018 and summer 2019 to install an FMS comprising six ECOSPEED F 2060 and a total of 20 pallets, two set-up stations, a transfer car and 17 storage locations. The ECOSPEED machining centres are characterised by 120-kW high-performance spindles (30,000 rpm), a pallet size of 6,000 mm x 2,000 mm and Sprint Z3 parallel kinematic machining heads. Thanks to its unique patented kinematic process, the Sprint Z3 head greatly exceeds the position speed of a multi-axis milling head. In addition to standard components such as angular milling and drilling heads, the FMS also contains two new highlights: The Sonic Eye measuring head significantly reduces the effort required to take measurements during the production of structural components which require documentation. The ultrasonically measured data (measuring accuracy: ± 20 μm) is wirelessly transmitted via radio antenna to the CNC, which also controls the use of the Sonic Eye.

Digital, networked, productive

With a completion date of 2019, six ECOSPEED F 2060 are to be installed at Chengdu Aerospace‘s aircraft factory to create one of the most productive and efficient Industry 4.0 plants in the world for the complete processing of aluminium structural components.