Connected systems through connected companies

At a joint appearance at this year's Motek, the so-called Arena of Integration, a total of 13 predominantly medium-sized companies presented a range of modern production technologies that were coordinated and interconnected according to the idea of Industry 4.0, thereby forming a comprehensive solution. (Source: Nerling Systemräume)

A demo system was set up, based on a conveyor system from Schnaithmann Maschinenbau GmbH. Surrounding this, the individual companies connected with their solutions, resulting in a complete system. (Source: Nerling Systemräume)

The overall solution featured a central control system that ensured the workstations passing through this conveyor system only held positions relevant to processes or applications that were pertinent to the individual component. (Source: Nerling System Rooms)

Examples include a semi-automatic labeling and marking system from Design & Engineering, a solution from Elabo GmbH for robot-assisted removal of a product to a repair workstation, or a system from Tekon Prüftechnik GmbH for process-safe and sensitive inspection of electrical contacts for contact systems. (Source: Nerling Systemräume)

A cleanliness area was also established on the conveyor band, where, for example, a cleanliness-sensitive assembly can be carried out under a clean air curtain. The system room experts from Nerling were responsible for ensuring the necessary conditions for this. (Source: Nerling System Rooms)

The pilot project Arena of Integration was initiated by the State Network Mechatronics BW. (Source: Nerling Systemräume)

The joint booth with Ralf Nerling, General Authorized Signatory of the Nerling Group (center, foreground). (Source: Nerling Systemräume)

"The collaboration among the exhibitors was excellent, and the visitors showed great interest in the Arena of Integration," said Ralf Nerling, General Authorized Signatory of the Nerling Group. "We plan to participate again in this joint project in 2017." (Source: Nerling Systemräume)

To further increase production flexibility and continue to meet the challenges at the German site in the future, more and more companies are relying on optimized processes according to Industry 4.0 or on the use of networked systems. Especially many SMEs find this concept difficult to implement given a limited product portfolio, fewer processes, and a small machine park. However, a joint appearance at this year's Motek, the so-called Arena of Integration, proves the opposite: On a demo system, a total of 13 predominantly medium-sized companies presented a range of modern production technologies that were coordinated and interconnected according to the idea of Industry 4.0, forming a complete solution. The pilot project initiated by the Mechatronik BW regional network demonstrated how, through cooperation with market peers, interdisciplinary individual customer systems can be developed, whose complexity would exceed the resources of individual companies.

"In the Arena of Integration, the essential components of Industry 4.0 in mechatronics should be presented and simple ways shown how this concept can be implemented in one's own operations and how complex tasks can be solved together with other companies," explains Ralf Nerling, General Authorized Signatory of the Nerling Group, who presented a system room solution at the joint stand. A major challenge of the project was to form an integrative unit from various core competencies along the value chain. For this purpose, a demo system was set up in the arena, based on a conveyor system from Schnaithmann Maschinenbau GmbH. "Around it, the individual companies connect with their solutions to create a complete system," says the technical project coordinator Volker Sieber, Development Manager at Schnaithmann. The overall solution featured a central control system that ensured that the workpieces moving along the conveyor only stopped at positions relevant for processes or applications for the individual component.

Advantages not only for SMEs

Examples include a semi-automatic labeling system from Design & Engineering, a solution from Elabo GmbH for robot-assisted removal of a product to a repair workstation, or a system from Tekon Prüftechnik GmbH for process-safe and sensitive inspection of electrical contacts for contact systems. "Especially in times of digitalization, it is particularly difficult for SMEs to have all necessary components in-house," says Sieber. But large companies have also recognized the value of interdisciplinary partnerships. For the first time, Siemens' integrated multi-carrier system was used integratively on the conveyor belt. Phoenix Contact was also present: "With our control cabinet solution, we shed light on aspects of digitalization from the perspective of manufacturing, with its different automation requirements," explains Jörg Olsen from Phoenix Contact Deutschland GmbH.

Additionally, a cleanliness area was set up on the conveyor, where, for example, a cleanliness-sensitive assembly can be performed under a clean air curtain. The system room experts from Nerling were responsible for ensuring the necessary conditions: "We installed a climate tower above the conveyor to create a clean functional area. Such solutions are becoming increasingly important, as future recommendations from VDA 19.2 will require strict attention to technical cleanliness or component cleanliness in assembly," says Nerling. In the arena and beyond, the company cooperates especially with Phoenix Contact: "We incorporate their control elements into our PLC control system, as we also demonstrated on the circulating workpiece carrier," explains the authorized signatory.

Networking between companies

In the future, bundling the various strengths of market peers will increasingly become a decisive factor in achieving synergies and fulfilling complex tasks. The joint trade fair appearance was therefore intended to clearly demonstrate that Industry 4.0 is not only about the intelligent networking of machines but also about the networking of partners with each other. However, for such inter- and multidisciplinary projects, a holistic process view is essential, emphasizes Nerling: "Only when all components of a system work together will the customer's goal be achieved." Volker Schiek, Managing Director of the Mechatronik BW regional network, who initiated the joint trade fair appearance, also explains: "What is happening here is a pilot project, a completely new idea. We want to encourage more companies to engage with the topic of cooperation and show that networks can achieve much more."

Nerling is also convinced that collaboration with potential competitors mainly yields advantages and learning effects. "After all, every company's goal should be to outperform the majority of market peers. An exchange of ideas with similar competitors leads to them becoming better than all others in the industry. Therefore, everyone should focus on their particular strengths and develop a unique selling point."

Positive bilan

The system room builder sees the trade fair appearance with other companies from the Mechatronik BW regional network as a great success and plans to participate again in this joint project in 2017: "The interplay of the exhibitors was excellent, and visitors showed great interest in the Arena of Integration," says Nerling. "We managed to attract some interested parties – also through the mediation of our co-exhibitors. That’s what a functioning cooperation between partner companies looks like." Several other companies have already announced their intention to participate next year.

Dr. Wolfgang Baur, Chairman of the regional network, also gives a positive review: "The concept of the Arena of Integration is the practical implementation of the results from our study 'Industry 4.0 in the Göppingen region.' With the input from Motek 2016, we will develop the Arena into a platform in 2017 where integration and team capability across the entire value chain will be demonstrated with a classic network character."