PROJECT DESCRIPTION
This project arises from the collaboration between Izkan Componentes S.L., a company specialising in the manufacture of components for the railway sector, and Arratiako Zulaibar Lanbide Ikastegia, with the aim of monitoring and optimising the CNC manufacturing process in its machining workshop.
To this end, a detailed analysis of the use of production resources will be carried out, evaluating the level of use of the machines in order to determine the degree of optimisation of the process, identify possible bottlenecks and detect opportunities for improvement.
The project includes the installation of network analysers to record energy consumption data, the implementation of energy management modules and real-time monitoring of the information obtained. The necessary material resources will be provided by the company.
From the data collected, Izkan Componentes S.L. will be able to optimise its manufacturing process through more efficient management of its resources, improving the productivity and sustainability of its operation.
Methodology
The project was based on monitoring real CNC machining processes. An initial analysis of the production processes and how the machines could be monitored was carried out, and the system was then implemented in parallel with the production processes. A secure remote connection was established via VPN, and the control dashboard was designed using the machines in actual operation and real production data.
Requirements from the company
Production based on CNC machines
A server installed at the company
VPN access to the server
An internet access switch accessible in the main electrical panel
Resources
Material Resources:
- THREE-PHASE NETWORK ANALYZER CVM-E3-MINI-ITF-485-IC RAIL 6 units
- TD5 50/5A CURRENT TRANSFORMER, 15×15 MM PLATE 6 units
- FW2 SURFACE DISTRIBUTION BOX WITH 3 ROWS AND 24 MODULES 1 unit
-LINE-EDS-PSS PRO ENERGY MANAGEMENT SYSTEM, WITH POWERSTUDIO AND
INTEGRATED WEB SERVER 1 unit
-TCPRS1+ RS-485 / ETHERNET / WI-FI CONVERTER 1 unit
Human Resources:
- 170 hours of the technical teacher specialising in the data monitoring project
Results & Achievements
A solution has been provided for monitoring the machines indirectly from the main electricity supply panel, to provide the production manager with a useful tool for making production decisions and balancing the use of the workshop’s CNC resources.
Development of a CNC machine monitoring system
Development of a solution that goes beyond software solutions dependent on each machine’s control system
Produce automated reports on the status of machines on a monthly, weekly, daily or shift basis…
Monitor the amount of electrical energy consumed in manufacturing processes.
Be able to monetise the manufacture of parts based on electricity consumption
