Digital Solutions

SMART TOOLING –A 360° VIEW OF
GEAR PRODUCTION

Today, it takes a lot of effort toanswer all of these key questions for gear production byacquiring data manually andanalyzing it subsequently.
In gear production, the requirements
for the volume of data needed andfor its analysis far exceed what can beachieved with conventional trackingsystems.

It Can All Be
So Easy …
SmartTooling delivers these answers
now – and it has never been easier,since data is collected and analyzed in acompletely automated process, tailoredto each customer’s specifications. To
ensure comprehensive data collection,
not only is the production equipment
integrated, so too are the machine tools
and measuring machines, as well as theworkflows on and off the machine. The
production equipment is described tothe desired level of detail by a digitaltwin and is kept in a central database,which is expanded during and after
the gear machining process. This data
enables identification, management,
tracking and analysis functionalities.
Particular emphasis is placed on analyzing productivity- and quality-relevant
aspects.

Which components has the tool machined? •How has concentricity and axial runout accuracy
impacted tool life and gear quality? • How havemodified process parameters influenced the toollife? • How do changes to the technological angles of the cutting edge affect the tool life? • Is
this the right tool for the next production order?
• What is the condition of the tool? • How many
more gears can I produce with this tool?

High Quality,
Reliable Processes
SmartTooling is an Industry 4.0 productwith its roots in the manufacturing ofbevel gears. Stringent requirements fortechnology and quality demand perfectcoordination between machining centers, measuring machines, production
equipment and workflows (see figure 1). As a way to resolve conflicting
challenges posed by ultra-high quality
standards, component variance andDigital Solutions

productivity, the digital integration of all
instances in a system such as SmartTooling enables three things: safety throughassistance, transparency through comprehensive data acquisition and new
optimization potential through data
analysis. As a technology leader andsystem supplier, Klingelnberg creates
unparalleled synergies in this regard.
How does this benefit customers? The
SmartTooling advantage yields improvements in planning on the one hand andefficiency in production on the other.
This is true for productivity-driven mass
production as well as variant-rich smalllot production.
As early as the machine setup stage,
the operator is vulnerable to various
potential causes of error due to manual
work steps. Installing the wrong tools
or clamping devices results in collisions,
ultimately damaging the machine andthe production equipment. The downtime resulting from these events thenusually prevents on-schedule completion of production orders.
SmartTooling delivers the key competitive advantage in such situations. As
soon as they are installed in an Oerlikon
Bevel Gear Cutting Machine, tools andclamping devices are scanned and automatically verified to determine theirsuitability for the current production
order. The machine will not accept anincorrect tool. In addition, geometries
such as actual heights are automaticallyreceived by the machine and imported
into the control unit. Manual input is
no longer required. This saves time andprevents errors. Instructional messages
assist the operator as needed to ensure
proper setup. Screw size, torque, documented anomalies and highly customer-specific information are displayed
immediately.

Fig. 1: SmartTooling components: In addition to production equipment, machine
tools and measuring machines are also integrated, as well as the workflows on
and off the machine.

Manual input is almost entirely
unnecessary – saving time andpreventing errors.

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Fig. 2: The digital twinof the configured cutter
head is enhanced on
the CS 200 with axial
runout and concentricity
information. Effects oncomponent quality andtool life are now visible
during the course ofproduction.

Significantly ReducedProduction Costs
Standardized, automated verificationof tool life quantity is also integrated,of course. This makes it possible tocompare the available tool life quantity against the number of components
to be machined. Selecting a tool with
sufficient residual tool life quantity prevents production breaks, since reworkduring an ongoing production order
is eliminated. If the tool must be used
despite an insufficient residual tool life
quantity, the standardized status indicator provides timely notice that a wear
test of the production equipment isdue – before concentricity errors in theclamping device or defects in the toolcompromise the quality of the components. Rejects and rework of the components are avoided in this way.
SmartTooling provides a wealth of datathat is automatically populated by theSmartTooling delivers the critical advantage: a 360° view of gear production
makes it possible to optimize and monitor processes at the next level.

machines. As the data inventory grows,
new information can be obtained about
factors impacting the tool life quantity, and tool life forecasts can be specified as a result. Tool use becomes increasingly more efficient, and costs arereduced. If the tool must be replacedprematurely, the cause can easily be
documented thanks to a selection of
precategorized reasons for replacementin the machine control unit. Based on
this information, the maintenance process can be initiated. The reasons forthe replacement can also be analyzed
and optimized in a targeted manner inthe case of a conspicuously high frequency of occurrence.

Complete Connectivity
Anyone who has ever wondered how
the setting accuracy of the cutter head
will affect the component quality andtool life can now look to SmartToolingfor answers, since the Oerlikon CS 200
type cutter head setting and checking
device is also integrated into the SmartTooling network. The unbeatable advantage: SmartTooling generates a digital twin of the cutter head / blade set
composition, which is enhanced during
the further course of production withproduction data in the form of specifically determined concentricity and axial
runout data (see figure 2).

Digital Solutions

Data – the Centerpieceof the System
Comprehensive data is the most valuable component of SmartTooling. The
system comprises master data suchas the digital image of the production
equipment on the one hand, and production data that is generated duringmachining on the other hand – for example, on an Oerlikon cutting machineor when setting concentricity and axial
runout on the Oerlikon CS 200 cutter
head setting and checking device. Thisdata is collected in a central database,namely GearEngine®. GearEngine® is aplug & play solution for integrating thecentral database into customers’ production networks quickly and withoutcomplications. All data converges in
GearEngine®. Individualized evaluations
and reports visualize correlations.
Each production equipment component
is given a certified DataMatrix markaccording to the internationally estab-lished GS1 standard in order to establish
an unambiguous link to the digital twin.
This gives marked equipment a unique
identity worldwide. Klingelnberg original equipment is ready for integrationin SmartTooling – it receives a certified
GS1 mark at the factory and is delivered
along with a digital twin. Using theSmartTooling app, users can immediately view and explore the digital twinsof their Klingelnberg tools.

Ready, Set, Integrate:
It’s That Easy

CompactMore on the Web
For more information about
SmartTooling, visit: www.
klingelnberg.com/smarttooling.
If you have any questions,e-mail us at:
i40@KLINGELNBERG.com

SmartTooling is readily integrated at anytime. New Oerlikon cutting machinescome already equipped with SmartTooling capability. Existing machines requirea software update and a handheld scanner to capture the production equipment during installation and removal.
The SmartTooling app is the software forworkstations, tablets, smartphones ormobile scanner terminals.
Once all of these components are integrated into the production line, thetask of collecting and analyzing datafrom all of the instances involved ingear production no longer seems at
all daunting. With a 360° view of gear
production, completely new methods
emerge for optimizing and monitoring
the processes at a new level.

Philipp Becher
Product Manager, Tool Sales,KLINGELNBERG GmbH

Copyright KLINGELNBERG GmbH

Away from the machine, there is also the(free) SmartTooling app for Windows
workstations and mobile Android devices. The app visualizes work-in-progress
for the production equipment. Thus avariety of information can be viewed:
tool status, anomalies reported on themachine, storage space and current application. In conjunction with a scanner,
the app can also be used to uniquely
identify production equipment. The app
also aids in initializing the production
equipment inventory in SmartTooling,that is, in generating the digital twin
to any desired level of accuracy. At thispoint, the geometries are also defined;
they are then automatically received by
the machine during setup. With regard
to the verification function on the machine, the app can be used to releaseproduction equipment in advance for
specific components and machines.