Executive Summary
The aerospace industry, with its stringent standards and complex manufacturing processes, demands unmatched precision, adaptability, and efficiency from its tools and systems. SixDigma, an aerospace manufacturing leader, faced limitations using traditional robotic setups, which could not meet the high precision and flexibility requirements of complex tasks. To address this, Think-PLC partnered with Siemens to implement a SINUMERIK Run MyRobot solution, transforming the automation process by enhancing precision, accessibility, and ease of integration. This white paper details the specific challenges faced, the solution provided by Think-PLC and Siemens, the technology and products used, and the transformational results achieved.
The Challenges in Aerospace Automation
SixDigma’s manufacturing operations required a level of flexibility that was difficult to achieve with standard machine tools and traditional robot controllers. They faced multiple challenges that limited efficiency and scalability:
- Precision Requirements: Aerospace manufacturing mandates exact tolerances and high repeatability, exceeding the capabilities of most standard robotic systems.
- Complex Part Accessibility: Aerospace components often require operations in constrained spaces, where traditional machine tools may not fit, and standard robotic arms cannot achieve the required precision.
- Operational Downtime and Setup Time: Each new part or process involved considerable setup and calibration time, leading to increased downtime and affecting the facility’s throughput.
- Seamless Integration with CNC and G-Code Compatibility: SixDigma’s production required the system to work seamlessly with traditional CNC machine control, allowing for smooth transitions between robotic operations and CNC-controlled machining processes.
Think-PLC saw the opportunity to redefine the manufacturing flexibility and precision by integrating a robot system with Siemens SINUMERIK Run MyRobot technology.
Siemens Run MyRobot Solution Overview
Think-PLC, leveraging its deep expertise in Siemens systems, proposed a solution combining the SINUMERIK Run MyRobot technology with a six-axis robotic arm. This setup transformed the robot into a fully machine-controllable device capable of handling precise and complex tasks. This unique approach allowed SixDigma to maintain their high manufacturing standards while providing flexibility across various applications.
Key Features of the Solution
Siemens SINUMERIK CNC Control Integration
The SINUMERIK control system allows the robot to function with the same precision as CNC machine tools, using G-code programming. This ensures the robot operates under CNC-level precision, meeting SixDigma’s demanding quality standards.
Real-time Simulation with Digital Twin
Utilizing digital twin technology from Siemens, SixDigma was able to simulate processes virtually before physical deployment — minimizing errors, shortening setup times, and improving overall accuracy.
Custom Control Systems for Versatility
Think-PLC designed a bespoke control system for the robot, capable of executing multiple high-precision applications such as laser welding, 3D printing, tool-changing, and more. This flexibility meant that SixDigma could expand its production capabilities without the need for additional machinery.
Enhanced Accessibility for Complex Aerospace Parts
Unlike enclosed machine tools, this robotic system can operate in open environments, accessing parts in tight spaces where conventional setups cannot reach. This feature is crucial for manufacturing aerospace components with intricate designs.
Technologies and Products Used
Think-PLC, leveraging its deep expertise in Siemens systems, proposed a solution combining the SINUMERIK Run MyRobot technology with a six-axis robotic arm. This setup transformed the robot into a fully machine-controllable device capable of handling precise and complex tasks. This unique approach allowed SixDigma to maintain their high manufacturing standards while providing flexibility across various applications.
Primary Components
Siemens SINUMERIK ONE CNC Control:
Known for high-speed precision and flexibility, the SINUMERIK ONE CNC supports complex manufacturing processes and G-code programming, crucial for aerospace applications.
This safety PLC ensures the robot operates within safe parameters, meeting the rigorous safety standards required in the aerospace industry.
Siemens Run MyVirtual Machine Software:
The digital twin technology provided by Siemens allowed SixDigma to simulate robotic operations, significantly reducing setup times and optimizing the process before any physical implementation.
Implementation Process with Siemens Run MyRobot
1. Initial Assessment and Customization
Think-PLC began by thoroughly assessing SixDigma’s existing operations, focusing on where traditional automation could be enhanced with robotic flexibility. After defining key pain points and objectives, the Think-PLC team customized the Run MyRobot system to fit the unique manufacturing requirements of SixDigma.
2. Digital Twin Modeling and Testing
Digital twin technology was integral to the deployment process. Using Siemens’ Create My Virtual Machine, Think-PLC enabled SixDigma to pre-test and validate the robotic setup in a virtual environment, making real-time adjustments that optimized both time and accuracy.
3. Deployment and On-Site Training
After testing, the Think-PLC team seamlessly deployed the system on SixDigma’s production floor. On-site training ensured SixDigma’s team could operate and maintain the system, supported by Think-PLC’s ongoing maintenance and optimization.
Results and Benefits
The integration of SINUMERIK Run MyRobot provided SixDigma with transformative benefits across several operational areas:
Enhanced Precision: The SINUMERIK control’s CNC-level accuracy allowed SixDigma to achieve the tolerances required in aerospace, leading to fewer errors and higher consistency across production.
Reduced Downtime: The pre-deployment simulations with the digital twin enabled SixDigma to drastically reduce setup times and allowed operators to resolve issues virtually, which decreased operational downtime.
Increased Flexibility: With the custom control design, SixDigma could expand its manufacturing capabilities to various tasks, from laser welding to 3D printing, which allowed them to take on diverse projects without investing in additional machines.
Accessibility for Complex Parts: The robot’s ability to work in open environments enabled SixDigma to handle parts with complex geometries, enhancing productivity and ensuring high standards of quality.
Future-proofing through Modular Design: The modular control system designed by Think-PLC makes future upgrades easy and cost-effective, aligning with SixDigma’s goals of maintaining cutting-edge technology.
Conclusion
The SixDigma case highlights Think-PLC’s advanced expertise in integrating Siemens technology into complex manufacturing environments. By delivering a solution that combines the flexibility of robotics with the precision of CNC systems, Think-PLC and Siemens’ Run MyRobot have empowered SixDigma to achieve a higher standard of operational excellence. This case underscores the impact of a robotics solution tailored to meet specific manufacturing needs, marking a new benchmark for automation in aerospace and beyond.
“And really, you guys provide this level of being able to think outside of the box a little bit with the design and that was really captured with the CATCH robot that you guys did for our CATCH facility. And really, from there it made us think internally, why wouldn’t we use Think-PLC a little bit more.”
“But for the most part, if it’s a random project out there I’m calling Bobby… I know that if Bobby works on the project, it’s going to be done and it will be done right.”
