UAC tests domestic predictive service for machine tools

2024: Predictive Service Module Testing

Aviastar implemented a pilot project to introduce a domestic predictive service from the Zyfra Group of Companies to prevent the failure of production equipment and extend its service life. Based on the analysis of a number of indicators, the system foresees possible failures in the operation of the machine and, if necessary, stops it in order to prevent the breakdown of expensive key units. The Figure announced this on March 11, 2024.

source = Zyfra

The Predictive Service module, which has undergone pilot testing at the production site of the Il Branch of PJSC - Aviastar, is a functional part of the monitoring system for industrial equipment AIS Dispatcher from Zyfra Group of Companies, which was previously introduced at enterprises. Its testing takes place on the machine tools of the enterprise. The main goal of the module is to automatically monitor the operation and protect critical units and units of machines to prevent long-term downtime of equipment due to emergency repairs. Predictive Service monitors the technical condition of the spindle assembly and predicts the need for its repair in advance.

In particular, one of the main tasks that we want to solve with the help of predictive service is to provide a kind of "airbag" for the spindle of the machine. This is one of the most vulnerable and expensive elements, - explained Sergey Ionov, chief engineer of the branch of PJSC Il - Aviastar. Its breakdown entails significant financial and temporary losses for repairs with the shutdown of equipment. And some of the parts we produce require long-term processing - up to 30 days of almost round-the-clock operation of the machines. The introduced predictive service system allows you to track overloads, deviations from permissible vibration parameters and other disturbances affecting the operation of the spindle, as well as determine their causes and respond in a timely manner to prevent the failure of this critical node. We assess the first results of the pilot positively - the new module of the Dispatcher system copes with our task.

In addition to vibration indicators, the Predictive Service module is able to monitor and analyze the temperature, humidity, concentration of the lubricating fluid and other parameters that determine the performance of the machines. Results of comprehensive analysis of operation modes and condition of various equipment units are provided to technical specialists of enterprises on visual panels (dashboards). The complex of collected information on the operation of high-performance equipment allows you to conduct predictive analytics on the state of the equipment.

Based on this information, employees of the enterprise can adjust maintenance and repair plans, which are usually drawn up on the basis of data on the operating hours, as well as debug control programs to avoid overloads. In addition, the module has a built-in emergency protection function - it stops the operation of the machine if the system sees the prerequisites for damage to critical elements.

The Predictive Service module, as part of the Dispatcher complex, solves a task that is relevant for the Russian industry - import substitution, - said Sergey Emelchenkov, General Director of Zyfra Group of Companies. - In particular, it is a full-fledged replacement for the German system for protecting machines from accidents and damage Montronix. All Dispatcher modules are built exclusively on domestic components: the software is registered in the register of Russian software, and the hardware component is registered in the register of Russian electronic products. In addition, the Dispatcher has an FSTEC certificate confirming its compliance with information protection requirements. Thus, by introducing the Predictive Service module, industrial enterprises will be able not only to extend the life of equipment and reduce downtime, but also to increase the security of critical information infrastructure. This technology is of interest to a large circle of customers. In addition to the Branch of PJSC Il - Aviastar, a pilot implementation took place at Tekhpribor.

2020: Implementation of Digital Lifecycle Control of Metal Cutting Tools for Machine Tools

JSC Aviastar joint venture"," an enterprise Russia for the production of aviation equipment, is introducing digital life cycle control of metal-cutting tools for machine tools. The solution will act as a separate module monitoring system of the "Dispatcher" machine farm developed by the GC "," and in the Zyfra future will cover all the workshops of the enterprise.

This module, firstly, will allow you to track the location and movement of metal-cutting tools and take into account their condition. To do this, each tool is marked, identification barcode which is subsequently read by a special one. The scanner Information status of the tool, operations performed with it, service life and location will be stored in the "Dispatcher" with access for all interested specialists. Secondly, the system will monitor the tool during its use: monitor compliance with cutting technology, load and wear, inform about the critical condition. In the event of a tool failure, the program will inform the machine operator and "remember" under what circumstances the breakdown occurred. This will allow in the future, using analytical tools, to predict an abnormal situation and notify the operator in advance about the need to replace the tool or stop the machine.

In the future, the program will allow you to automatically create purchase requisitions for a new tool. Statistical analysis of data on the modes of operation of the tool will help to quickly conduct purchases and select more effective tools from those on the market.

The Manager system provides great opportunities for analytics and reporting. In particular, within the framework of this module, users can receive reports on the actual time and operating modes of the tool, its flow rate in section by part/batch/machine/area, compare tools from different manufacturers. The functionality of controlling the tool will be useful to a number of divisions: shop services and operators, technologists, economists, procurement specialists and top management, - said Mikhail Aronson, commercial director of Zyfra.

The implementation of the tool lifecycle control module will require changes to a number of established business processes in the enterprise. But we expect that the return on the project will be significant: we will gain transparency of tool turnover, we will be able to choose the most suitable tools for our tasks and use them effectively, reduce costs and improve procurement planning. This will ultimately contribute to improving the quality and reducing the cost of production, - commented Sergey Valerievich Semenov, Head of the Department of Information Technologies, Aviastar-SP JSC.

2018

On July 26, 2018, the Zyfra company announced that Aviastar-SP JSC had introduced a system for digitalizing the Dispatcher production at production. As a result, the company increased the efficiency of the machines by 34%. The Dispatcher system made it possible to connect production equipment to a single network of the industrial Internet of Things. With its help, machine operators can make the most of the equipment, and the company's management receives complete information about how the machine fleet works online.

Workshop of JSC Aviastar-SP

As of July 2018, more than 70 units of production equipment of Aviastar-SP JSC were connected to the Dispatcher system. The plans are to connect another 140 machines by the end of 2018.

The system performs a number of tasks:

• Details and analyzes the causes of equipment downtime;
• Allows you to automatically calculate the overall efficiency of the equipment;
• Collects accurate information about the operation of the machine and analyzes the time of each operation;
• Allows you to report on a form approved by your company.

"We have previously dealt with monitoring systems, so we knew exactly what requirements the system being implemented should meet. The main thing is versatility. Aviastar-SP uses machines from different manufacturers. "Dispatcher" combines all the various production equipment into a common network and ensures a stable process of informatsiyey̆ exchange and analysis. " ' Sergey Semenov, Head of Information Technology Department of Aviastar-SP JSC

Connecting to the Manager system made it easier to transfer control programs from the server to the machine. As a result, it is possible to save 1 hour of working time per shift per kazhdyy̆ machine.

In the "Dispatcher" at Aviastar-SP, notifications by e-mail and SMS were set up for those responsible for critical events, such as adjustment for more than 1 hour, unreasonable downtime for more than 20 minutes, work without load for more than 15 minutes, accident. This made it possible to achieve prompt decision-making and reduce organizational losses.