Case Study: Real-world Applications of the AIDEAS Technology suites in PAMA

PAMA S.p.A. has been in the machine tool market for more than 90 years. It has a wealth of experience and enviable know-how in boring machines and milling centers. PAMA operates globally: its main markets are Asia, the Americas and Europe, and all of these markets are extensively backed by a network of sales and support structures. This article will explore the real-world applications of the AIDEAS Technology suites in PAMA machines

PAMA has established itself on a worldwide level resulting from the tradition and technological excellence of its products that, as of today, comprise a wide range of machine tools and related services: horizontal and vertical milling and boring machine, machining centres, head attachments, automation and technology services.

Figure 1. PAMA headquarters

In today’s rapidly evolving industrial landscape, Industry 5.0 emerges as a vision that harmonizes advanced technology with human ingenuity and environmental sustainability. AI stands as a pivotal technology in this transition, such as developed by the AIDEAS project.

The Smart Retrofitter solution

PAMA is integrating AIDEAS solutions to optimise its products’ lifecycle across 4 main stages: design, manufacturing, use, repair-reuse-recycle. This article focuses on the latter stage.

A central tenet of Industry 5.0 is enhancing existing machinery through Smart Retrofitter, which bridges the gap between traditional manufacturing equipment and cutting-edge technologies. In the AIDEAS project, this is achieved through its Smart Retrofitter solution.

The Smart Retrofitter involves upgrading existing machinery with modern sensors, processors, and connectivity features in order to enhance their performance, efficiency, and adaptability due to its functionalities. This approach is particularly cost-effective and relies on circular economy principles, since it leverages the existing capital equipment while injecting new life through technological advancements.

In the AIDEAS project case, the Smart Retrofitter solution involves an innovative combination of hardware and software designed to improve manufacturing processes. The key components of this suite used in PAMA’s pilot include:

• Industrial PC, which acts as the central processing unit for data collection, preprocessing and analysis.
• Programmable Logic Controller, which manages the data acquisition from sensors and the machine tool.
• Acquisition Board, which gathers data from various sensors installed on the machine tools, focusing on energy consumption metrics.

This setup is pivotal in monitoring and managing energy consumption, a crucial factor in modern industrial operations. A significant aspect of this Smart Retrofitter solution is its ability to monitor energy consumption in real-time.

The acquisition board collects data from multiple sensors placed on the machine tools, providing detailed insights into the energy usage patterns. This data is then processed by the IPC, which runs sophisticated AI algorithms. The AI algorithm can estimate the expected energy consumption by understanding the relationship between machine operations, configuration settings, and energy consumption.

The Benefits of AIDEAS technology suites

The integration of the AIDEAS technology suite in PAMA’s machine tools is expected to result in several practical benefits:

• Energy Savings: The ability to estimate the effect of process parameters on the energy consumption. This enables the operations to adapt according to the actual load or adapt to the actual availability of green energy. This not only reduces operational costs but also contributes to sustainability.
• Predictive Maintenance: The data collected and analyzed by the AI algorithm also supports predictive maintenance. By comparing actual and estimated energy consumption, it is possible to identify process inefficiencies or potential issues before they lead to machine failure. This means that PAMA can schedule maintenance proactively, which means reducing downtime and costs.
• Increased Competitiveness: By adopting Smart Retrofitter and integrating advanced AI technologies, PAMA also enhances its competitiveness in the global market. This gives PAMA the ability to upgrade and offer more efficient and reliable machine tools.

The case study of PAMA’s adoption of the AIDEAS technology suite exemplifies the transformative potential of Smart Retrofitter, in the context of Industry 5.0.

PAMA not only improved its operational efficiency but also sets a benchmark for sustainable and intelligent manufacturing practices, through seamlessly integrating an IPC, PLC, and acquisition board to monitor and optimise energy consumption.

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Figure 2. PAMA machines