With its renowned brands KraussMaffei, Netstal and KraussMaffei Berstorff, the KraussMaffei Group is currently promoting its networking solutions, reunited by the Plastics 4.0 concept, at K 2016 show. A new online E-Service platform that traces future optimization routes for customer/service processes is being highlighted. Many other solutions, e.g. APC plus function, DataXplorer technology and Euromap 77 computer interface, are on display.
The future is now? A tailored online customer service
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E-Service by KraussMaffei Group, available soon, will support day-to-day service cases processing |
Worldwide, plastic processors often face urgent needs regarding spare parts. In order to avoid extended downtimes, measures must be taken quickly should a machine component has to be replaced. Precise part designation and reference number, cost, terms of delivery and installation need to be identified ASAP. Netstal’s CEO Renzo Davatz, also serving as the Group’s Vice President for Service in the IMM segment, is confident about what he has to offer: “With the future E-Service of the KraussMaffei Group, processes such as these will soon be able to be managed much more efficiently. This will facilitate the processing of service cases in day-to-day business and increase system availability of our machines.”
In response to any immediate concern, future users of KraussMaffei equipment are expected to log in to the new online E-Service platform. The start screen will welcome them with a complete overview of their machine fleet. Every single manual, service data or related video will as well be stored in the platform. “Part finder app on a smartphone or a tablet will enable reliable identification of the required component using QR codes. Availability and price can be determined in a database, where an ordering function will also be integrated. A service ticket can also be opened directly from the app,” explains Davatz. By pressing dedicated buttons of the digital console, the user will quickly access a large number of services: the ticket system, current machine performance data, or remote maintenance.
Benjamin Müller, E-Service Project Manager, leads a team that works meticulously on implementing the new service for all the three KraussMaffei brands. Its strong potential and benefits are currently shown to K 2016 visitors on a demo version. The new portal represents the Interactive Services category, which together with Integrated Production and Intelligent Machines are the three pillars of Plastics 4.0 concept. IMM President of KraussMaffei Group, Dr. Hans Ulrich Golz, states, “This 4th industrial revolution will radically change the working world — for instance, by self-optimization of smart machines, and thus achieving stable processes.”
APC plus: Weight consistency for cascade injection molding
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APC plus makes the user benefit from new smart features for a better injection molding precision and repeatability |
The new machine function, APC plus (for Adaptive Process Control), already embodies Müller’s auspice. Since the previous version of the system (APC, successfully launched two years ago), extra functions with more specific response to process variations — e.g. fluctuating ambient conditions, downtimes, or recyclate use — were implemented. APC plus can account for particular property patterns of twenty basic materials and assume corrective measures during the holding-pressure phase. Melt characteristics such as compressibility can thus be fully taken into account. Following the cascade injection process, APC plus sets opening times of needle shut-off nozzles so that they are actuated repeatably, i.e. at the same mold fill level. This way, an extreme weight consistency of finished products is guaranteed.
The new DataXplorer: A microscope for process datamining
For KraussMaffei Group, “Integrated Production” equals seamless machinery networking along the whole production chain. A simple example would be communication of an injection molding machine and a dryer, aimed at optimizing material flow and avoiding idle times.
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The new DataXplorer system displays and evaluates up to 500 high-resolution signal paths, depending on machine model. |
The new DataXplorer system provides a meticulously detailed view of the process, making it possible to rectify errors even if their patterns are not clear at first. The system displays and evaluates up to 500 high-resolution signal paths, depending on machine model. Dr. Reinhard Schiffers, Head of Machine Technology at KraussMaffei, believes that another important application for DataXplorer is process documentation: “For safety-related components or medical technology, it is important to be able to retrieve all quality-relevant process data for each individual injection cycle.”
A FiberForm application of this technology is being shown at K 2016: parts labeled with a QR code allow for direct access to specific production parameters. These can include injection pressure curves or those for heating organic sheets. Thus, tracing any product/process data for individual components online via a smartphone, tablet, or PC becomes smooth and natural.
Euromap 77: A standard IMM/host interface
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Live demonstration at the K Show: QR code on a FiberForm component allows for a direct access to individual production parameters such as injection pressure or heating curves. |
In order to break a path for integrated production, the leading manufacturers of injection molding equipment gathered to design a new host network interface named Euromap 77. Based on OPC-UA protocol, the interface serves to provide standardized communication between injection molding machines and a computer network. Euromap 77 is being premiered at K 2016 at the booth of German Engineering Federation (VDMA). Real-time production data transferred by the machines of various exhibitors in several exhibition halls, including Netstal and KraussMaffei, is visualized to visitors’ satisfaction.
Analytics: Smart KPI for any mobile device
Another prototype demonstrated by KraussMaffei Group at its K 2016 booth shows benefit generation opportunities for future production. Modern IMMs provide data abundantly, and the decisive question is how to optimize the process based on information gathered. New web application by KraussMaffei, simply called Analytics, will use various process data and key performance indicators collected from Netstal and KraussMaffei machines. The generated analytic information will allow for a more efficient work, e.g. with early detection of faults.
Three pillars for Industry 4.0 implementation
Plastics 4.0 is not a mere umbrella term but a three-part concept intended to bundle each and every new solution offered by the Group. The three pillars it leans on are Intelligent Machines, Integrated Production, and Interactive Services. The first pillar represents self-optimizing smart machines that improve productivity and part quality. The second one means seamless networking of individual machines and components with relevant autonomous process control. Finally, the third pillar is systems built on the latest sophisticated communication technologies for a quick world-spanning customer service.
