DE.CA.: bidirectional data for 4.0 metalwork

The context

Specialising in rolling and light-to-medium metalwork, DE.CA. produces flanges, plates and rings for the water, extraction and wind sectors. Its 4.0 machine fleet lets it work a wide range of materials to specification, from carbon and stainless steels to aluminium and copper alloys.

Within a fleet that also includes fully robotised machines, designed and customised in house, the company introduced two devices using advanced technology: a numerically controlled CNC lathe and a wire saw. Unlocking their full potential and making them compliant with 4.0 regulations, particularly on bidirectional data exchange with control and management systems, called for an enabling IoT solution.

The project

IDA delivered that bidirectional exchange by reading and translating data encoded in the various protocols devices use to transmit information externally. In the metalworking sector, access to and control of machine tools runs through the FOCAS software libraries (Fanuc Open CNC API Specification), which IDA integrates: the application interfaced with the lathe and its protocols, completing every step the 4.0 regulations require, namely data reception, verification, analysis and storage in the Data Space.

The results

With bidirectional exchange active, DE.CA. not only sees lathe performance in real time but can send the machine instructions to carry out tasks, read progress, monitor job completion and know the time spent on each individual operation. IDA also ensures secure, uniform data transmission and a clear display that every operator in the company can read.

What comes next

The next step is an operator panel on the various machines, to track production and monitor consumption for individual orders in detail, based on the characteristics of the part, size and material, and of the cut, speed and depth. It will improve planning, surface potential waste and costs, and raise both production efficiency and product quality.