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Sanayii 4.0 ın yeni bir 3 boyuta ihtiyacı var.

Промышленность 4.0 нуждается в размере следующего поколения 3.

Industry 4.0 is a new paradigm for the structure, planning, and execution of production processes through the use of modern IT and communication methods. It is yielding completely new ideas and concepts in which IT solutions are crucially blazing the trail from two main perspectives.

Sanayii 4.0, modern BT ve iletişim yöntemlerinin kullanımı yoluyla üretim süreçlerinin yapısı, planlanması ve yürütülmesi için yeni bir paradigmadır. BT çözümlerinin iki ana perspektiften çok önemli bir şekilde çığır açtığı tamamen yeni fikirler ve kavramlar üretiyor.

Индустрия 4.0-это новая парадигма для структуры, планирования и выполнения производственных процессов с использованием современных информационных технологий и коммуникационных методов. Это дает совершенно новые идеи и концепции, в которых ИТ-решения решающим образом прокладывают путь с двух основных точек зрения.

First, 3D-based simulation software allows visualization and validation of processes and production tasks. This is important, because production plants are seldom established from scratch, but are often replanned while production is running. That in itself is nothing new appropriate solutions for the digital factory have long been in use. But what is new is this: To transform the ideas and concepts of Industry 4.0 into reality, virtual factories and model plants must now be an exact representation of the real production systems.

İlk olarak, 3B tabanlı simülasyon yazılımı, süreçlerin ve üretim görevlerinin görselleştirilmesine ve doğrulanmasına olanak tanır. Bu önemlidir, çünkü üretim tesisleri nadiren sıfırdan kurulur, ancak genellikle üretim devam ederken yeniden planlanır. Bu kendi başına yeni bir şey değil, dijital fabrika için uygun çözümler uzun süredir kullanılıyor. Ama yeni olan şudur: gerçeğe fikirleri ve Sanayi 4.0 kavramlarını dönüştürmek için, sanal fabrikalar ve model bitkiler artık gerçek üretim sistemlerinin kesin temsilcisi olmalıdır.

Во-первых, программное обеспечение для 3D-моделирования позволяет визуализировать и проверять процессы и производственные задачи. Это важно, потому что производственные предприятия редко создаются с нуля, но часто перепланируются во время производства. Что само по себе не является чем-то новым, соответствующие решения для цифровой фабрики уже давно используются. Но что нового, так это то, что для воплощения идей и концепций Индустрии 4.0 в реальность виртуальные фабрики и модельные заводы теперь должны быть точным отображением реальных производственных систем.

Not just geometrically and kinematically, but also in regard to the logical behavior and control of the manufacturing units. They therefore represent a sort of virtual twin or shadow factory. This is the only way to get from stiff, prescribed processes to agile, self-organized production units. Secondly, a digital factory allows implementation of new manufacturing processes, plant concepts, and technologies that would be too expensive or even impossible without simulation-based solutions. The more robotic applications that are used not only for simple handling tasks, but also for complex production steps the greater the need will be for programming and simulation tools. IT solutions are leading the way to these complex applications, becase they give the operator the necessary programming and simulation environment to make applications that were previously represented through a manual teach in or would not show the necessary process quality.

Sadece geometrik ve kinematik olarak değil, aynı zamanda üretim birimlerinin mantıksal davranışı ve kontrolü açısından da. Bu nedenle bir tür sanal ikiz veya gölge fabrikasını temsil ederler. Katı, önceden belirlenmiş süreçlerden çevik, kendi kendini organize eden üretim birimlerine geçmenin tek yolu budur. İkinci olarak, bir dijital fabrika, simülasyon tabanlı çözümler olmadan çok pahalı ve hatta imkansız olacak yeni üretim süreçlerinin, tesis konseptlerinin ve teknolojilerin uygulanmasına izin verir. Yalnızca basit işleme görevleri için değil, aynı zamanda karmaşık üretim adımları için kullanılan robotik uygulamalar ne kadar fazlaysa, programlama ve simülasyon araçlarına olan ihtiyaç o kadar büyük olacaktır. BT çözümleri, operatöre daha önce manuel öğretme yoluyla sunulan veya gerekli süreç kalitesini göstermeyen uygulamaları yapmak için gerekli programlama ve simülasyon ortamını sağladığı için bu karmaşık uygulamalara öncülük ediyor.

Не только геометрически и кинематически, но и в отношении логического поведения и управления производственными единицами. Таким образом, они представляют собой своего рода виртуальный близнец или фабрику теней. Это единственный способ перейти от жестких, предписанных процессов к гибким, самоорганизующимся производственным подразделениям. Во-вторых, цифровая фабрика позволяет внедрять новые производственные процессы, концепции и технологии, которые были бы слишком дорогими или даже невозможными без решений, основанных на моделировании. Чем больше роботизированных приложений используется не только для простых задач обработки, но и для сложных производственных этапов, тем больше будет потребность в инструментах программирования и моделирования. ИТ-решения прокладывают путь к этим сложным приложениям, поскольку они предоставляют оператору необходимую среду программирования и моделирования для создания приложений, которые ранее были представлены с помощью ручного обучения или не демонстрировали необходимого качества процесса.

Cyber-physical systems are indispensable However, it is important to understand that a virtual copy of a plant or production line by itself does not add value to intelligent manufacturing. The production won’t be smart until all component s in the virtual manufacturing process communicate with each other exactly as they will in the real environment. This network of components the Internet of things is the core of Industry 4.0 and opens the way to “cyber-physical” systems. Smart manufacturing brings a change from the normally rigid automation lines and robotic systems creating flexible, cooperating, agile automation solutions. It involves the transition from uncompromising tools to flexible production systems that cover a diversity of product variants, and the ability to react quickly to changing production plans. The resulting environment can even produce small batches efficiently.

Siber-fiziksel sistemler vazgeçilmezdir Ancak, bir tesisin veya üretim hattının sanal bir kopyasının tek başına akıllı üretime değer katmadığını anlamak önemlidir. Sanal üretim sürecindeki tüm bileşenler gerçek ortamda olduğu gibi birbirleriyle tam olarak iletişim kurana kadar üretim akıllı olmayacaktır. Nesnelerin İnterneti bileşenlerinden oluşan bu ağ, Endüstri 4.0'ın özüdür ve “siber-fiziksel” sistemlerin yolunu açar. Akıllı üretim, esnek, işbirliği yapan, çevik otomasyon çözümleri yaratan normalde katı otomasyon hatlarından ve robotik sistemlerden bir değişiklik getiriyor. Ödün vermeyen araçlardan, çeşitli ürün çeşitlerini kapsayan esnek üretim sistemlerine geçişi ve değişen üretim planlarına hızlı tepki verme becerisini içerir. Ortaya çıkan ortam, küçük partileri bile verimli bir şekilde üretebilir.

Киберфизические системы необходимы, однако важно понимать, что виртуальная копия завода или производственной линии сама по себе не добавляет ценности интеллектуальному производству. Производство не будет разумным до тех пор, пока все компоненты в виртуальном производственном процессе не будут взаимодействовать друг с другом точно так же, как в реальной среде. Эта сеть компонентов Интернет вещей является ядром индустрии 4.0 и открывает путь к “киберфизическим” системам. Интеллектуальное производство позволяет отказаться от обычно жестких линий автоматизации и роботизированных систем, создавая гибкие, сотрудничающие, гибкие решения для автоматизации. Это предполагает переход от бескомпромиссных инструментов к гибким производственным системам, охватывающим разнообразие вариантов продукции, и способность быстро реагировать на изменение производственных планов. В результате окружающая среда может эффективно производить даже небольшие партии.

Do these high demands mean that intelligent manufacturing and In- dustry 4.0 is only for large companies?

No, in fact it’s the opposite. Because the methods and ideas of Industry 4.0 are applied to smaller quantities and sub-processes, or to products with low production volume, advantages can be more clearly recognized and often more quickly implemented. The sample applications below will show how a new generation of digital manufacturing tools has become the trailblazer for progressive manufacturing technologies and future production processes.

Bu yüksek talepler, akıllı üretimin ve Sanayi 4.0'ın sadece büyük şirketler için olduğu anlamına mı geliyor?

Hayır, aslında tam tersi. Endüstri 4.0'ın yöntem ve fikirleri daha küçük miktarlara ve alt süreçlere veya düşük üretim hacmine sahip ürünlere uygulandığından, avantajlar daha net bir şekilde fark edilebilir ve çoğu zaman daha hızlı uygulanabilir. Aşağıdaki örnek uygulamalar, yeni nesil dijital üretim araçlarının nasıl ilerici üretim teknolojileri ve gelecekteki üretim süreçleri için öncü haline geldiğini gösterecektir.

Означают ли эти высокие требования, что интеллектуальное производство и производство 4.0 предназначены только для крупных компаний?

Нет, на самом деле все наоборот. Поскольку методы и идеи Индустрии 4.0 применяются к меньшим количествам и подпроцессам или к продуктам с низким объемом производства, преимущества могут быть более четко распознаны и часто быстрее реализованы. Примеры приложений ниже покажут, как новое поколение цифровых производственных инструментов стало первопроходцем в области прогрессивных производственных технологий и будущих производственных процессов.

Demands on “digital factory” software

“Sayısal fabrika” yazılımına yönelik talepler

Требования к программному обеспечению “цифровой фабрики” 

The first question is what properties “digital factory” software must provide to help companies efficiently break into smart manufacturing. First, the software must be compatible with all CAD systems and work with any manu- facturer’s robots and machines. This is a mandatory prerequisite for customer relationships that are becoming more and more diverse with more complex and demanding systems.

İlk soru, şirketlerin akıllı üretime verimli bir şekilde girmesine yardımcı olmak için “dijital fabrika” yazılımının hangi özellikleri sağlaması gerektiğidir. İlk olarak, yazılım tüm CAD sistemleriyle uyumlu olmalı ve herhangi bir üreticinin robotları ve makineleriyle çalışmalıdır. Bu, daha karmaşık ve talepkar sistemlerle giderek daha çeşitli hale gelen müşteri ilişkileri için zorunlu bir ön koşuldur.

Первый вопрос заключается в том, какие свойства должно обеспечивать программное обеспечение “цифровой фабрики”, чтобы помочь компаниям эффективно перейти на интеллектуальное производство. Во - первых, программное обеспечение должно быть совместимо со всеми системами САПР и работать с роботами и машинами любого производителя. Это обязательное условие для взаимоотношений с клиентами, которые становятся все более и более разнообразными в связи со все более сложными и требовательными системами.

Industry 4.0 needs a new generation of 3D tools.

Sanayi 4.0 ın yeni nesil 3Boyutlu araçlara ihtiyacı var.

Индустрия 4.0 нуждается в новом поколении 3D-инструментов.

At the same time, a program is needed that supports all relevant technologies, applications, and system designs. It must also be easily expanded when new technologies come into play. This requires an adequately generic, scalable software structure. Additionally, the soft- ware must bring along the necessary openness for harmonically integrating into existing system landscapes, data structures and customer processes.

Aynı zamanda, ilgili tüm teknolojileri, uygulamaları ve sistem tasarımlarını destekleyen bir programa ihtiyaç vardır. Ayrıca yeni teknolojiler devreye girdiğinde kolayca genişletilmelidir. Bu, yeterince genel, ölçeklenebilir bir yazılım yapısı gerektirir. Ayrıca yazılım, mevcut sistem ortamlarına, veri yapılarına ve müşteri süreçlerine uyumlu bir şekilde entegre olmak için gerekli açıklığı da beraberinde getirmelidir.

В то же время необходима программа, которая поддерживает все соответствующие технологии, приложения и системные проекты. Он также должен быть легко расширен, когда вступают в игру новые технологии. Для этого требуется достаточно общая, масштабируемая структура программного обеспечения. Кроме того, программное обеспечение должно обеспечить необходимую открытость для гармоничной интеграции в существующие системные среды, структуры данных и процессы клиентов.

And last but not least, the project must show initial success quickly. To start with small projects and get quick, concrete results, but also to achieve a high level of expansion for automation and process integration, the “digital factory” software must be modular and scalable. It must allow setup for the specific application and grow along as the company’s needs change. On top of all the characteristics mentioned, it should also be cost-efficient and very user-friendly.

Ve son olarak, proje hızlı bir şekilde ilk başarıyı göstermelidir. Küçük projelerle başlamak ve hızlı, somut sonuçlar elde etmek, aynı zamanda otomasyon ve süreç entegrasyonu için yüksek düzeyde genişleme elde etmek için “dijital fabrika” yazılımının modüler ve ölçeklenebilir olması gerekir. Spesifik uygulama için kuruluma izin vermeli ve şirketin ihtiyaçları değiştikçe büyümelidir. Bahsedilen tüm özelliklere ek olarak, aynı zamanda uygun maliyetli ve çok kullanıcı dostu olmalıdır.

И последнее, но не менее важное: проект должен быстро продемонстрировать первоначальный успех. Чтобы начать с небольших проектов и получить быстрые конкретные результаты, а также достичь высокого уровня расширения для автоматизации и интеграции процессов, программное обеспечение “цифровой фабрики” должно быть модульным и масштабируемым. Он должен позволять настраивать его для конкретного приложения и развиваться по мере изменения потребностей компании. Помимо всех упомянутых характеристик, он также должен быть экономичным и очень удобным в использовании.

Virtual manufacturing tools in use: A system integrator

A look at the everyday work of a system integrator makes it clear what benefits new-generation “digital factory” soft- ware brings to the table. In early project phases sometimes even during the pre-sales phase system integrators are expected to document the efficiency and functionality of their offerings with case studies, accessibility tests and feasibility studies. These tasks must be performed very quickly and with the most extensive resources possible.

A digital catalog of mechatronic resources makes definition and validation of high-quality 3D layouts quick work. Also, a comprehensive range of 3D layout and simulation tools is available as well. The only question is this:

Does the IT solution also ensure that the process simulation reflects the actual behavior of the manufacturing cells to be built later?

 Industry 4.0 needs a new generation of 3D tools Made to fit: Simulated and real behavior Instead of building a quick layout with 3D CAD components from the catalog, and then programming the scripts and macros for simulating the material flow and behavior of the cell, it would be much easier to use mechatronic com- ponents and resources for the layout definition and at the same time to define a schematic logic for the production island. In this way, it can be ensured that the simulated and real behavior match because the simulation is based on the same logic used during the PLC programming and therefore corresponds to the real system behavior later on.

This means that no manufacturing layout is limited to standard components. Now it pays off when “digital factory” software solutions provide user-friendly functions for integrating new, project-specific components in the layout. This process must be quick and easy for users without programming knowledge to complete.

At the same time, the software infrastructure of new solutions is no longer based on proprietary formats, but on open standards. Consistent use of AML (Automation Markup Language) as a descriptive language for system models, for example, allows considerably simpler interaction with engineering partners through standardized, system-neutral exchange of complete system data or equipment data, including kinematic and logic definitions.

In addition, PLCOpen ensures that the system logic at the basis of the first simulation concepts can also be used for later PLC programming. The most important requirement for virtual commissioning should be supported by the software architecture. 

The software FASTSUITE Edition 2, which is CENITs next generation product, for example, uses a shared memory in which the controls write the simulation data and from which the 3D visualization then reads the simulation data.

Virtual commissioning

This shared memory approach also allows control emulators to replace real control components during the acceptance phase. In such cases, we refer to a virtual production start, or virtual commissioning.

This is possible because the entire layout consists of cyber-physical simulation models or mechatronic resources, providing the virtual link to software in the loop or hardware in the loop. This allows the virtual model to be tested against the real controls before the real system is put into operation. Virtual commissioning supports parallel workflows and reduces risks, errors and downtimes in production. It’s no surprise that demand is getting stronger all the time among automotive manufacturers.

It is also a mandatory prerequisite for integration of new production processes with robot safety, cooperating robots, etc., for which realistic reproduction of ever more complex, self-organizing behavior through macro programming and scripts is no longer possible. As soon as the production islands have been started, the same virtual layout can be used to introduce new parts and products. The time-consuming teach-in and the production interruptions that go with it are no longer needed.

New manufacturing technologies require 3D

The advantage of a high-performance digital factory is not just limited to offline programming of a robot cell while the real cells are operating. Development of modern robotic technologies and applications bring the advantage of 3D solutions for offline programming and simulations even more into play. This is because the complex 3D movements now in demand can no longer be taught manually.Digital Factory Solutions Industry 4.0 needs a new generation of 3D tools 

Production processes like roll hemming, sealing, adhesion or painting require a virtual programming and simula- tion environment, so that they can also be efficiently operated when small batches come through or conversion is required often. Then there is another aspect that shows the advantage of a modern “digital factory”: It is far more efficient to reuse not only the CAD data, but also the metadata provided by engineering (such as for fasteners) instead of redefining them in production every time.

Other application scenarios

The advantages mentioned above are relevant to all manufacturing industries, as shown by a look at the aircraft industry. In aircraft construction, we are seeing increasing use of robot cells for manufacturing composite materials and the associated technologies, such as laying bands, placing patches and cleaning molds. For this, special, often highly complex machines and robotics systems are being used in the airframe construction departments.

The aircraft industry also places stringent requirements on administration of fastener data and process automation.

Here also, a virtual 3D factory solution is becoming a prerequisite for introducing automation concepts with the goal of making manual processes superfluous and achieving better production performance.

Software providers must become project partners

Providers of the right software solutions must increasingly see themselves as project and implementation partners for the manufacturing industries, and also as bridge builders between engineering and production. There are often major system discrepancies between CAD systems on the one hand and manufacturing on the other. Software partners must help close these gaps efficiently.

Aside from that: Manufacturing technologies and processes are becoming more and more complex, while system and component variants become ever more flexible. This requires software providers to offer solutions that make complex things simple and easy to control again.

The bottom line

The growing trend toward greater flexibility in manufacturing processes through standardized machine- and robot-based applications is unstoppable. The result will be highly adaptable manufacturing processes with which batches of any size including just one can be produced efficiently.

We know that Industry 4.0 provides us with the concepts and ideas necessary for this paradigm change. However, the transformation also forces IT system integrators and software companies to create the mechatronic systems with a 1-to-1 relationship to real production conditions. “Digital factory” solutions are therefore the core of making Industry 4.0 a reality.

Sayısal Fabrikaların Verimliliği

ЭФФЕКТИВНОСТЬ ДЛЯ ЦИФРОВОЙ ФАБРИКИ

The software integrates all robots, machines and tool components

into a single, unified, intuitive simulation environment. FASTSUITE

Edition 2 can build a bridge between development, engineering and production, because the program’s functionality embraces the entire process. From early layout studies, to process engineering and simulation to virtual commissioning and production optimization.

• compatible with all common CAD systems

• open for robots, machines, technologies and controls from all manufacturers

• supports nearly every production process in a unified application environment

• modular and scalable

• a continuous infrastructure for moving flexibly between

planning, validation, simulation and programming

• innovative, efficient operating concept

Yazılım tüm robotları, makineleri ve alet bileşenlerini entegre eder

tek, birleşik, sezgisel bir simülasyon ortamına dönüştürün. HIZLI SUİT

Sürüm 2, programın işlevselliği tüm süreci kapsadığı için geliştirme, mühendislik ve üretim arasında bir köprü kurabilir. Erken yerleşim çalışmalarından proses mühendisliğine ve simülasyona, sanal devreye alma ve üretim optimizasyonuna kadar.

• tüm yaygın CAD sistemleriyle uyumlu

• tüm üreticilerin robotlarına, makinelerine, teknolojilerine ve kontrollerine açık

• birleşik bir uygulama ortamında neredeyse her üretim sürecini destekler

• modüler ve ölçeklenebilir

• arasında esnek bir şekilde hareket etmek için sürekli bir altyapı

planlama, doğrulama, simülasyon ve programlama

• yenilikçi, verimli işletim konsepti

Программное обеспечение объединяет всех роботов, станки и компоненты инструментов

в единую, унифицированную, интуитивно понятную среду моделирования. БЫСТРЫЙ ЛЮКС

Издание 2 может создать мост между разработкой, проектированием и производством, поскольку функциональность программы охватывает весь процесс. От ранних исследований компоновки до проектирования технологических процессов и моделирования до виртуального ввода в эксплуатацию и оптимизации производства.

• совместимость со всеми распространенными системами САПР

• открыт для роботов, машин, технологий и средств управления всех производителей

• поддерживает практически все производственные процессы в единой среде приложений

• модульная и масштабируемая

• непрерывная инфраструктура для гибкого перехода от

планирования, валидации, моделирования и программирования

• инновационная, эффективная концепция работы