It‘s increasingly common to see Internet of Things (IoT) applications in the metal fabrication industry. They help users pursue fabrication automation and achieve other advancements that let them progress toward more agile workflows. Here are some exciting examples of how the IoT can help companies and operators.
Enabling Data-Driven Maintenance Decisions
Since IoT sensors collect real-time data, plenty of opportunities exist for metal fabricators to gather statistics that help them see which processes are going well and find room for improvement.
V. R. Vijay Anand is the head of digital machining at Sandvik Coromant, which supplies metal-cutting tools. He advocates for using data to solve the issues that challenge the fabrication sector.
The true challenge that we face as an industry is the concept of data and treating analytics as technology versus the true value that comes out of this data. When we start talking about analytics, data, IoT and all sources of data, we lose the aspect of how we can use all this data to create true value, he explained.
Coromant used the IoT and predictive analytics to move away from the scheduled approach to maintenance. That method should appeal to shop floor workers who want to get noticeable value from their IoT investments.
Machines that stay operational more often offer better agility because metal fabricators can plan workloads more accurately, meet client needs and scale up when required. Plus, since malfunctioning machines often cause unnecessary waste, staying on top of maintenance needs should reduce that problem.
Increase Capabilities and Support Your Reputation
Becoming more agile allows metal fabricators to show they’re well-equipped to meet customers’ needs now and in the future. It’s also vital to prove that quality levels will remain high, even if workloads rise.
For example, using the IoT to increase agility may involve collecting data from a CNC machine to verify that produced pieces meet quality standards. A connected sensor could pick up on tiny abnormalities that humans would miss. That increased level of visibility helps companies reassure customers that high quality is a top priority.
Keeping quality levels high is crucial when making pieces to meet customers’ exact specifications. For example, a plant with a 20-foot coil-fed CNC plasma cutter inside its 60,000-square-foot facility can use data from IoT sensors to verify production is happening as expected. That allows them to maintain high productivity levels and reduces the need for rework, showing more agility as a result.
Getting updated data is also critical as more companies invest in automated fabrication. High-tech machines typically have lower error rates than humans, partially because they don’t become tired or distracted. However, that doesn’t mean they’re perfect. The information provided by IoT sensors can reveal when an automated machine might need adjustments or other attention to meet quality minimums.
Identifying Instances of Tool Misuse
Achieving more agility as a metal fabrication operation also involves ensuring everyone has the necessary training to use tools correctly and safely. For example, businesses with a higher-than-average accident rate may lack the human resources to show flexibility when faced with marketplace changes.
Similarly, tools that are misused could have shortened lifespans and show gradually decreasing quality.
A real-world example of using the IoT to track how people use tools concerned a band saw in Georgia Tech‘s engineering lab. Although some saws can cut metal, this particular one was only meant for use with plastic. Even after hearing that rule, many students used it on metal and kept quiet about it.
Dr. Thomas Kurfess was working in the lab at the time. He wondered how the IoT could help identify instances when people used the saw on metal. The tool already had an accelerometer attached, which detected overall usage rates. Thus, it was only necessary to link the accelerometer data to a camera. Since cutting metal requires a particular level of force, the accelerometer could detect that activity. It also sent a picture of the user to Dr. Kurfess.
Although that example centers on using the IoT to confirm students don’t cut metal, it’s easy to envision how it applies to any fabrication tools. If a sensor shows abnormal statistics associated with metal-cutting work, it could indicate user errors or highlight the need for increased operator training.
Raising Workforce Productivity and Profits
Statistics indicate that automation could replace 35%-50% of human-filled positions by 2035 if the respective industries work well with automated technologies. For now, though, many use cases center on how smart machines could help people improve their work output.
One IoT pilot at a metal fabrication plant revealed the many benefits of partially automated fabrication. The plant specializes in a process called austempering, which hardens and strengthens metal-based alloys. First, the parts pass through a furnace that reaches 1,800 F. They are then doused in a salty liquid kept at a precise temperature. This approach makes the components more resilient against metal fatigue and shock.
The parts reach the furnace on nickel-titanium belts. However, conveyors that get out of alignment could damage the components and furnace, causing at least a day of downtime. IoT sensors give immediate feedback on belt alignment issues, letting the responsible parties address them quickly.
A later pilot stage involved adding an infrared sensor to the autoloader that deposits parts onto the belt. Quality issues could arise if a stack gets too high, so the sensor prevents that from happening. The operation expects a 10% reduction in job transition time, and representatives said progress toward that goal has already happened.
The fabrication shop closed its gap time, allowing more parts to pass through the furnace on a typical day. It increased its revenue after seeing that benefit. Plus, the sensors help the operators know when to place the parts on the belt, only doing so if the salt bath at the next stage is at the right temperature.
The IoT Supports Automated Fabrication
These examples show why people in the metal fabrication industry often choose the IoT to automate more processes, collect relevant data or both. Implementing smart sensors into the fabrication workflow is an excellent way to get reliable information that shapes actionable strategies.
