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 and has a wealth of experience and enviable know-how in boring machines and milling centers. It operates globally: its main markets are Asia, the Americas and Europe, all of which are extensively backed by a network of sales and support structures.

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.

In the rapidly evolving landscape of industrial manufacturing, the push towards Industry 5.0 aims to harmonize advanced technology with human ingenuity and environmental sustainability. Artificial Intelligence (AI) is a breakthrough technology playing a crucial role in the Industry 5.0 transition, as exemplified by the AIDEAS project.

PAMA, a leader in the design and production of large machine tools for metal cutting, is integrating AIDEAS solutions to optimize the lifecycle of its products across four main stages: design, manufacturing, use, repair-reuse-recycle. This article focuses on the end-of-life 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 Smart Retrofitter solution.

The Smart Retrofitter involves upgrading existing machinery with modern sensors, processors, and connectivity features to enhance their performance, efficiency, and adaptability thanks to new functionalities. This approach is particularly cost-effective and exploits circular economy principles, as 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. By understanding the relationship between machine operations, configuration settings, and energy consumption, the AI algorithm can estimate the expected energy consumption.

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, enables to adapt the operations according to the actual load at plant level, or adapting to the actual availability of green energy. This would not only reduces operational costs but also contributes to environmental sustainability.
• Predictive Maintenance: the data collected and analyzed by the AI algorithm may also supports predictive maintenance. by comparing the actual and the estimated energy consumption, it would be possible to identify process inefficiencies or potential issues before they lead to machine failure. It means that PAMA could schedule maintenance proactively, reducing downtime and maintenance costs
• Increased Competitiveness: by adopting Smart Retrofitter and integrating advanced AI technologies, PAMA could enhance its competitiveness in the global market. The ability to upgrade and offer more efficient and reliable machine tools provides a significant advantage.

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

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