both on the racing track and in manufacturing. And this is precisely where Dr Thomas Hauer, production manager at DECKEL MAHO Seebach, sees the challenge for DMG MORI as a parts supplier: “Like in motor racing events, component manufacturing is also all about being faster and better than the others.” And that can only be achieved by using the latest technologies. By the end of 2015, more than 60 different components with a total quantity of over 2,300 individual pieces had been manufactured by DMG MORI for the Porsche team. The parts range, amongst other items, includes complex housings for pumps and electric motors as well as sophisticated mounting elements for the innovative braking system. The developers from the racing team supply the necessary CAD data, while the machining experts in Seebach are responsible for the entire process through to the finished workpiece. For DMG MORI and the Porsche team, CELOS® in particular has
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proven to be a cornerstone of their partnership. In the Motorsport CNC Competence Center, all machine tools are equipped with CELOS®. Moreover, the CELOS® PC version is available to the team. The CELOS® PC version serves as the central planning and management software. The individual jobs are completely detached from the machines by a control console. The Job Manager combines NC programs, the setup plan and the tools into one job. Accordingly, no technical drawings or documentation in paper form can be found in the Porsche Motorsport CNC Competence Center. The Job Scheduler then plans the job in detail and assigns it to a specific machine. The current status, as well as the effects of last-minute changes, can be viewed using the CELOS® control console. Here CELOS® helps to prioritise the work processes of the machine according to the respective delivery date. “In
DMG MORI process chain – with 1:1 simulation on the racing track One highlight of component production is the DMG MORI process chain. It includes design and programming as well as a subsequent 1:1 simulation of the NC program in the DMG MORI Virtual Machine. As the components for the LMP1 are produced “from a solid block”, the implementation of the milling strategy takes on central importance. On the one hand, the required programming strategy is available for every task in the process chain, no matter how complex, and, on the other, the virtual machine monitors feasibility as well as 100% collision safety. The importance of the DMG MORI Virtual Machine is comparable to that of the racing simulator for the pilots. “It enables 1:1 simulation of real machining on the PC – including machine kinematics and real control. This allows us to precisely adjust the machining process to the requirements of the individual component in order to continuously reduce ‘our lap times.’” explains Dr Hauer.
the fast moving area of motor sport, extremely short-term manufacturing jobs are simply a part of daily business. In addition to planning and management tools, as a control console CELOS® can retrieve data from all connected machine tools in real time. The
stored data can then be used to carry out operational analyses in order to optimise production in the short and medium terms. The networking of the machines in combination with the continuous recording of real-time data is an important step towards Industry 4.0.
August 2016