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2022 華南展招展書
HMI

倍福應用案例 | 云端連接的工業 PC 助力實現單件流義齒制作

  2022年04月01日  

  美國口腔修復體制造商 Glidewell Dental 自 21 世紀初興起的口腔 CAD 技術革命之后得到迅猛發展,并于日前成功實現了高度自動化生產。倍福靈活的自動化解決方案幫助該公司旗下的一家義齒加工廠實現了現代化改造。在這里,C6015 超緊湊型工業 PC 用作物聯網網關,通過云端提供患者專用的 NC 程序,并且每 2 秒就從總共 40 臺銑床傳輸一次生產數據,以便進行分析。

基于 EtherCAT 和 PC 的控制技術

在義齒精密銑削加工中的應用

  公司于 1970 年成立于 Jim Glidewell 位于加利福尼亞州歐文市的公寓中,目前在全球擁有 4300 多名員工,主要生產各種口腔修復體和醫療設備產品。在口腔修復領域,例如在供應牙冠、牙橋或義齒等口腔修復體時,每個產品都需要單件流生產。對于 Glidewell Dental 來說,每周生產數以萬計的患者專用設備需要耗費大量的工程工作?!拔覀兠磕甓紩c大約 60,000 名牙醫有業務合作,占美國修復市場上所有執業醫師人數的近五成?!盙lidewell 公司工程部副總裁 David Leeson 說道。

  牙醫可以將患者口腔解剖結構的“印?!编]寄給 Glidewell,或者掃描并上傳 3D 數字印模圖像到該公司在 Amazon Web Services(AWS)云上建立的專有數字平臺中。然后使用專有的人工智能技術生成與印模相匹配的修復體定制設計,并將每個患者專用的修復體的 CAD 文件變成一個唯一的 NC 項目。最新的 Glidewell BruxZir? 工廠根據牙齒大小、顏色和厚度等特點進行分配,并選擇合適大小、形狀和顏色的未加工過的氧化鋯瓷塊。一個機器人將銑削坯料搬到銑削塔上進行詳細的解剖塑形,然后給修復體上釉,使其表面看上去更加自然。條形碼掃描器和視覺應用程序負責在整個加工過程中跟蹤檢測箱子。

  “光學掃描儀會生成成品的三維幾何形狀,并通過一個算法將其與設計文件進行比較,從而形成一個閉環過程。牙種植體的尺寸必須小于 50 微米才能通過質檢,而大多數情況下,它的尺寸都小于 20 微米?!盙lidewell 公司自動化經理 Kunal Patil 說道?!岸绻褂檬止みM行上釉,就會產生高達 150 微米的方差?;?PC 的自動化可以幫助我們提高精度?!?/FONT>

Glidewell 已經在其工廠實施了兩條完整的口腔修復體生產線,用于生產 BruxZir? 氧化鋯修復體,每條生產線有 20 臺銑床,共計 40 臺銑床。公司目前正在實施第三條完整的生產線,共計 60 臺銑床

生產線擴展需要更高的控制性能

  在 BruxZir 工廠建設初期,Glidewell 工程團隊就知道,所有的自動化技術都必須具有高靈活性、高可擴展性,并具有工業級強度。另外,Glidewell 需要從一個由四臺銑床組成的單一銑床塔擴展到一個由五臺銑床塔構成的系統,最后擴展到第二個由 5 臺銑床塔構成的完整系統,共計 40 臺銑床。最后,這些組件需要長期承受大量的氧化鋯陶瓷磨料粉塵。

  自 Glidewell 于 2018 年開始實施第一個銑削塔起,工程團隊很快意識到,傳統的機床控制技術已經無法滿足任務需求?!拔覀兣鉀Q很多涉及機器人和多臺控制器之間的同步、調試和實時通信等問題,同時使用熟悉的控制器?!盞unal Patil 說道?!拔覀冊趯Χ嗉易詣踊脚_進行評估后,選擇了倍福?!?/FONT>

倍福的多點觸控控制面板用于提高銑削過程的可視化程度

性能強大并具有物聯網功能的工業 PC

  BruxZir 工廠配備了倍福的多款工業 PC 和 TwinCAT 3 自動化軟件解決方案。一臺經過 AWS 認證的 C6015 超緊湊型工業 PC 用作物聯網網關,從云端傳輸 NC 程序。一臺性能強大的 C6930 控制柜式工業 PC 用作主系統控制器,與多個機器人、視覺系統、現場設備和銑床塔的機床控制器進行通信。每個銑床塔都配備一臺 CX5140 嵌入式控制器,它通過使用 TwinCAT NC I 控制四臺銑床上的 4 軸運動,即每臺控制器控制 16 根軸?;?PC 的控制器具有良好的連接性、處理能力和可擴展性,可以在同一個標準系統中實現 20 臺銑床、80 根運動軸的自動化。Kunal Patil 認為,這些控制器還符合成本效益和耐久性要求。

  BruxZir 工廠需要滿足 2020 年生效的《加利福尼亞州物聯網安全法》中的規定和要求,David Leeson 解釋說道:“倍福工業 PC 讓我們可以在 Windows 環境中運行經過認證的防病毒軟件。這個解決方案可以在不影響性能的情況下滿足所有網絡安全要求,這一點給我們留下了深刻印象?!睋?Kunal Patil 說,他的團隊能夠在同一個軟件平臺上使用 C# 和.NET 編程標準機床控制邏輯、高級數控程序和 API。

  TwinCAT IoT 和 C6015 工業 PC(與提供開源邊緣運行時和云服務的 AWS IoT Greengrass 連接)每 2 秒發送一次有價值的生產數據供分析。除了便于進行故障排除和預測性維護之外,這樣還能夠更容易發現數據挖掘,以提高機床性能和產品品質。

 

(左起)倍福團隊成員應用開發工程師 John Helfrich、區域銷售工程師 Charles Usher 和應用工程師 Lauren de Rosset 與 Glidewell 公司的自動化部經理 Kunal Patil 以及工程副總 David Leeson 密切合作

通過 TwinSAFE 和伺服技術提高精度和效率

  EtherCAT 可以確保車間的實時通信速率,實現高性能生產。此外,TwinSAFE 將安全功能集成到控制系統中?!坝捎谟泻芏嗉庸ち鞒掏瑫r進行,我們不希望在按下某臺設備的急停按鈕時,每臺設備都會停止運轉。TwinSAFE 讓我們能夠停止特定的銑床和安全區域,而且我們還可以在同一個項目中創建這種邏輯?!盞unal Patil 說道。

  倍福的 AX5000 伺服驅動器和采用單電纜技術(OCT)的 AM8000 伺服電機為取放機器人提供動力,將新的箱子送入銑床塔。銑床中使用了配備有 OCT 單電纜技術的節省空間的緊湊型驅動組件,即 AM8100 系列伺服電機和 EL7211 伺服電機端子模塊。在這個應用中,AM8100 伺服電機已經證明了其具有高精度、高可靠性以及堅固耐用性,而方向的不斷變化給組件帶來了巨大壓力?!叭绻姍C稍有偏差,我們的最終產品就會與設計文件不一致,即便只是輕微的振動,也會讓材料出現破損和缺陷?!盞unal Patil 在描述修復體制作工藝的高要求時說道。

基于 PC 的控制技術

有效減少了組件的使用數量和成本

  自從過渡到使用倍?;?PC 的控制技術后,BruxZir 工廠同時實現了高精度的制造和數據采集。每臺銑床每 10 分鐘即可完成一箱,并保持 24 小時不間斷生產。公司目前正在實施第三條完整的生產線,共計 60 臺銑床?;?PC 的自動化系統顯著減少了所需的組件數量,David Leeson 說道:“我們以前的控制器每臺只能控制一臺銑床,而倍福的控制器每臺可以控制四臺銑床。此外,對于實現相同的數據采集和云連接,以前的控制器還需要單獨配備一臺 PC?!盞unal Patil 還補充了一點,即 Glidewell 所考察的其它控制解決方案的成本幾乎是倍??刂品桨傅膬杀?。

  Glidewell 還在繼續評估倍福的新技術,包括通過 EtherCAT G 實現千兆通信,以及 TwinCAT HMI 可視化軟件,以進一步提升其解決方案的性能?!癎lidewell 和倍福有著相似的歷史,都是從公司只有一個人開始,憑借著對創新的熱情,實現了快速增長?!?Kunal Patil 說道?!八?,我們認為倍福不僅是我們的供應商,更是能夠與我們同舟共濟的合作伙伴?!?/FONT>

(文章來源:倍福)

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