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The JUNKER Group drives forward with digitalization

Process-optimized production with the digital twin

Combining real and virtual machines results in an intelligent system able to predict characteristics and operating behavior from the production planning stage and throughout the product lifecycle. The digital twin for JUNKER grinding machines is a virtual representation of the real system, enabling comprehensive digital exchange between the virtual and real world.

The digital twin represents the grinding machine in the digital world. A series of algorithms connects it to the real world via sensors and control systems. It serves as a basis for Industry 4.0 and simulates the behavior and properties of the real-world grinding machine early in the development process. Thanks to the connection to real data, such as machine positions and environmental conditions, the digital twin runs complex simulations. These simulations allow for the planning and optimization of subsequent processes.

During the design phase, the digital twin enables not only implementation of complex product requirements, but also testing without the need for time-consuming, costly prototypes. The digital twin allows risk-free software testing and grinding program optimization. This system also facilitates machine acceptance performance long before completion of the real machine. It considerably simplifies information exchange with suppliers and customers about the complex processes in the production grinding machines. The interfaces to automation, software environments and entire production lines are checked in advance in order to identify potential obstacles.

System optimization and process design prior to machine production reduces the length of the development and production phase. The smooth commissioning process on JUNKER grinding machines resulting from the advance simulations, optimizations, straightforward training also speeds up the production process. Thanks to the digital twin, the operating and grinding processes within the machine are error-free and optimized right from the very start. The virtual machine makes it possible to plan and implement efficient and optimized conversion measures and changeovers at a later point.

The advantages at a glance:

  • Earlier definition and implementation of upstream processes
  • Meaningful predictions about machine characteristics, performance and operating behavior
  • Shorter development and delivery times as well as cost savings for new products and machine conversions
  • Risk-free software tests and simulation of modifications
  • Optimization and acceleration of the entire engineering process
  • Digital preliminary acceptance and easier training for the customer
  • Easier and quicker coordination with suppliers
  • Optimization of customer communication thanks to visualization of automated concepts and operating processes