Autonomous Digital Twin
In cooperation with Salvagnini, LCM developed that company’s new generation of lean panel benders to meet the requirements of Industry 4.0. LCM has made the design and production processes entirely virtual while ensuring that all the relevant physical parameters are automatically taken into account. The digital twin developed by LCM includes the MAC 2.0 automatic material identification (material attitude correction) system. In numerous computer simulations and physical measurements of bending processes with a variety of different metal sheets, the Smart Automation Team at LCM established constants of their mechanical properties. These were then mapped in a complex simulation model and incorporated in efficient software that controls the bending process in such a way that optimum product quality is guaranteed every time, irrespective of the number of workpieces, sheet thickness or material quality. Sensors on the motors of the automated panel benders measure the process parameters in a matter of milliseconds, thereby determining the material’s properties. In this way, a stopping point is calculated for the tool path right at the start of the bending process which is calibrated to the material. This means that the new automated panel benders can process batch size 1 as well as large batches with no waste – and with the highest production quality and maximum energy and resource efficiency combined with minimal set-up and cycle times.