Now often used as an argument in the context of marketing strategies, sustainability is seen as a quality criterion for fair trade and production under environmentally friendly and resource-conserving conditions. Accordingly, this way of doing business is one of the guiding principles of Industry 4.0: Exploiting potential savings, increasing productivity and reducing emissions. Innovative technologies are driving the expansion of sustainable solutions. "Contrary to the widespread assumption that it compromises the principle of environmental compatibility due to its high energy consumption, digitalization is actually proving to be a key driving force," emphasizes Martin Dreher, Managing Director of Drehertec. "Particularly in the field of machining, it holds considerable potential for sustainable production if implemented intelligently."

Harvesting energy

The latest developments in the field of tool and mould making are moving towards predictive methods and the optimization of measuring techniques. Preventing damage and reducing wear and tear are the primary objectives, compliance with which ensures a smooth process flow.

Martin Dreher, Managing Director of Drehertec. © Kukla, Drehertec

During tool holding, for example, sensors inside the machine monitor vibrations and process forces. However, as the sensors are permanently active due to their monitoring function, they usually require additional energy. This is where digitalization offers a solution: energy harvesting is a process for reducing overall energy requirements by generating small amounts of electricity for low-power mobile devices. "By collecting the power generated by vibrations, ambient temperature or air currents and transferring it to the sensors of the tool system, batteries are no longer needed," explains the expert for turning machines. By pooling surplus resources with the help of a collection system, savings can be made at the same time.

Thinking tools

In addition to reducing energy consumption, the trend towards sustainable machining is characterized by preventive technologies. For example, measures such as the regular switching of maintenance intervals promote longer tool life. Digital sensors inside the machine inform the system about the machine's condition: By determining characteristic values, control loops can be set up, which in turn enable tool service life to be increased.

The link between measurement technology and machines not only reduces rejects, but also enables feedback on potential process obstructions to be determined at an early stage. "To prevent possible damage to components or tools, the system provides information about the position of the cutting elements. However, the key technology in terms of sustainability and tool efficiency is the digital twin, which provides an exact image of the production equipment," explains Dreher. A combination of collected real-time data and algorithms depicts the digital twin in a virtual space. This centrally accessible platform receives all data on the condition of the tools and can be successively expanded with further information on production. This means that machining and product information is available to the user at all times. In addition to recording disruptive factors or possible damage to the tools, manufacturing processes can also be planned, tested and optimized virtually.

Maintenance from the cloud

Against the backdrop of Industry 4.0, the networking of individual machines to create a smooth overall cycle is one of the main objectives. Cloud-based software solutions provide a digital remedy for tool management, for example. As the program takes care of setting, preparing and optimizing the production equipment, a large part of the user's time, which is usually spent on these tasks manually, can be saved. The cloud stores process data and also acts as an interface for different users by making the values available to everyone on one platform. "However, the platform not only provides digital twins, but also information such as cutting data or the number of reprocessings," says Dreher. Cloud solutions also enable networking across company boundaries and bring tool manufacturers, service providers and machining companies closer together, thus optimizing cooperation between the various players. "As a link between smart machines and users, the cloud combines modern technologies with proven manufacturing methods and serves as the basis for sustainable machining in the digital age of Industry 4.0," concludes Dreher.

According to documents from Drehertec / ag