DMG Mori de­liv­ers soft­ware so­lu­tions to dig­i­talise Porsche parts

Auto components India - - ALLIED INDUSTRIES -

Per­for­mance, re­li­a­bil­ity and pre­ci­sion are fac­tors that de­ter­mine suc­cess or de­feat in the world of mo­tor sport, both on the rac­ing track and in man­u­fac­tur­ing. And this is pre­cisely where Thomas Hauer, Pro­duc­tion Man­ager at DECKEL MAHO See­bach, a sub­sidiary of DMG Mori, sees the chal­lenge for DMG MORI as a parts sup­plier. He said, “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.”

“As an App-based man­age­ment and op­er­at­ing soft­ware pack­age, DMG MORI en­ables con­sis­tent man­age­ment, doc­u­men­ta­tion and vi­su­al­iza­tion of or­der, process and ma­chine data as well as the man­age­ment of the ma­chine on the shop floor. In a unique way, CELOS, the soft­ware so­lu­tion from DMG Mori, com­bines pro­duc­tion plan­ning and work­shop into a highly ef­fi­cient con­trac­tual ser­vice part­ner­ship,” Hauer said.

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.


For DMG MORI and the Porsche team, CELOS, which sim­pli­fies and ac­cel­er­ates the process from the ideation to the fin­ished prod­uct, has proven to be a cor­ner­stone of their part­ner­ship. In the Mo­tor­sport CNC Com­pe­tence Cen­tre, 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 pro­grammes, the set-up 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 Cen­tre. 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 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 ana­lyis 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.

DMG MORI process chain

The 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 pro­gramme 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 Hauer.

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