It was no coincidence that Bad Neustadt an der Saale was chosen as the setting for the EMO 2017 pre-press conference: Almost two years ago, Siemens began rolling out the topic of digitalization in its own production at the electric motor plant there, which has been in existence for 80 years (see under "The playground of digitalization"). This means that all digital technologies that are relevant in the machine tool environment are being successively implemented here and put through their paces. However, the company does not want to keep the experience it has gained behind the scenes - on the contrary: visitors to Bad Neustadt can also get an idea of how digitalization can work seamlessly from the machine tool to the corporate management level as part of guided tours that now take place almost daily.

It is precisely this topic that will also characterize Siemens' presence at the EMO in Hanover, where the company will be exhibiting on around 1200 square meters of exhibition space. Dr. Wolfgang Heurich, CEO of the Motion Control Business Unit in the run-up to the upcoming industry event: "Digitalization will change the entire machine tool industry dramatically and move it forward. The completely new possibilities offered by linking the digital world with the real world will enable significant productivity boosts and completely new business models." Cloud connectivity will play a central role in this. Among other things, Siemens will be presenting its first MindSphere application for machine tools at EMO with 'Manage MyMachines' - and not just in theory: according to Heuring, around 200 machine tools will be connected to the open IoT operating system via this app throughout the exhibition grounds. Machine operators, for example, can use this new cloud-based approach to obtain an overview of important data and operating statuses of their machines.

Siemens will also be presenting 'Sinumerik Edge', a new high-performance solution for edge computing on machine tools, in Hanover. It is to be launched on the market at the beginning of next year and will enable process data to be processed and analyzed close to the machining process. The decoupling of data processing tasks and process control ensures the necessary safety in the process. In addition to the robust hardware, Siemens will offer tailor-made applications - so-called edge apps - for monitoring and optimizing the machine tool, among other things. Machine manufacturers or service providers can also integrate their own edge apps into the open platform.

As far as the CNC control itself is concerned, Siemens is presenting the 4.8 software version of Sinumerik in Hanover. One new feature in this version is the pitch compensation (NoCo). It is used to compensate for dynamic position deviations in one or more linear machine axes caused by acceleration processes or mechanical compliance within the machine. Specifically, NoCo compensates for the dominant position deviation with a corrective movement in the respective machine axis. The aim is to achieve better machining quality with higher jerk and acceleration values. The pitch compensation can be used for milling, multitasking, tapping, laser machining or water jet machining, for example.

In addition, the 4.8 software version of Sinumerik offers enhanced collision protection: Collision Avoidance Eco and Collision Avoidance Advanced. The Eco version enables simple, reliable machine protection and prevents the machine body from colliding with itself in the work area. To achieve this effect in real time, the assemblies to be protected are calculated as simple geometric bodies. The Eco version of collision monitoring is available in all operating modes - such as JOG, MDA and automatic; the protected areas can be easily configured and visualized as a 3D representation on the control interface.

The Advanced version includes full machine, tool and workpiece protection. The software from Sinumerik product partner ModuleWorks runs integrated on an external computer via an interface. In cooperation with the CNC, it ensures in real time that the machine, tool and workpiece are permanently visible and dynamically protected during material removal. The required workpiece and tool data are made available to the system during set-up.

Last but not least, Siemens is presenting a new version of the Safety Integrated (SI) function for the Sinumerik 840D sI at EMO with the 'Safety Integrated plus' software integrated into the controller. Whereas previously a complete program had to be written for both the NCK and the PLC, in future only one will be required for the PLC. This failsafe program can be created with the Step 7 PLC software, which is integrated into the TIA Portal as standard. Various certified function blocks are available to the user here, which can be transferred directly into the safety program. According to Siemens, Safety Integrated plus reduces the project planning time by up to 50%. Commissioning is also said to be up to 20 % faster - with graphical masks in the Sinumerik user interface making it much easier to parameterize the safety functions.

Motor portfolio supplemented

In the field of direct drive motors, Siemens has further developed its segment motors for large machine tools.

The Simotics M-1FE2, for example, is available in the new size 180. Permanent magnets ensure a particularly high torque density in this built-in spindle motor, which is primarily designed for machining larger workpieces. Its internal diameter of 200 mm and its high performance make the motor ideal for use in turning and milling centers. Siemens has also expanded its portfolio specifically for feed axes with the Simotics S-1FT7 in size 132 with a choice of self-cooling or forced ventilation.

Finally, four new motor modules have been added to the Booksize range of Sinamics drives. At 24 A, 45 A and 60 A, the motor modules run with double overload, and at 24 A with triple overload. New drive functions to compensate for cogging torques and periodic torque ripple also enable even better surface finishes when machining workpieces. Last but not least, the Sinamcis portfolio has been expanded to include the 'Increased tilting power' drive function. According to Siemens, this allows asynchronous spindle motors to brake up to 55% faster, which reduces non-productive times when changing tools, for example.

A 'playground' for digitalization

A key cornerstone of the digital factory: no new machine is purchased in Bad Neustadt without the supplier providing a complete 'digital twin'.

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The Simotics M-1FE2, for example, is available in the new size 180. Permanent magnets ensure a particularly high torque density in this built-in spindle motor, which is primarily designed for machining larger workpieces. Its internal diameter of 200 mm and its high performance make the motor ideal for use in turning and milling centers. Siemens has also expanded its portfolio specifically for feed axes with the Simotics S-1FT7 in size 132 with a choice of self-cooling or forced ventilation.

Finally, four new motor modules have been added to the Booksize range of Sinamics drives. At 24 A, 45 A and 60 A, the motor modules run with double overload, and at 24 A with triple overload. New drive functions to compensate for cogging torques and periodic torque ripple also enable even better surface finishes when machining workpieces. Last but not least, the Sinamcis portfolio has been expanded to include the 'Increased tilting power' drive function. According to Siemens, this allows asynchronous spindle motors to brake up to 55% faster, which reduces non-productive times when changing tools, for example.