Control processes with continuity

As a leading manufacturer of part cleaning systems for automobile production, Dürr Ecoclean GmbH in Monschau is a master of both the deburring, cleaning and drying processes and the processes that lead to the development of high-quality, tailor-made systems. In engineering, total data continuity is a must and the EPLAN Platform is used to design integratively across all disciplines. Dürr Ecoclean's customer have one thing in common: They need clean components. The Dürr Group's "Ecoclean" division specializes in the development and production of part cleaning machines and systems - and they are very successful: The company, with approximately 1,000 employees, is represented worldwide. The product line ranges from smaller standard devices for industrial cleaning to complex, partially robot-supported systems. In addition, Dürr Ecoclean also produces systems for recycling coolants and for linking metal machining production processes. In addition to Filderstadt and Monschau, there are also production facilities in France, the Czech Republic, China and the United States. In Monschau, the "CLA" division develops custom solutions for the automobile industry. Here, only watery media are used, and one of the tasks that the systems often have to take on is the deburring of parts. Dürr Ecoclean had a resounding success three years ago with the newly launched EcoCFlex system (Picture 1). Here, a six-axle robot at the center of the system takes over part handling and feeds the components to the different work stations, such as deburring, high-pressure water jets, spray cleaning, injection flood washing and drying. This provides a high degree of flexibility and fast adjustment to changes in workpiece geometry is assured. These systems are the trend, also because the automobile industry continually demands lower fuel consumption and fewer emissions. This requires higher cleanliness and smoothness requirements for components such as engine blocks and cylinder heads. Integrated development process
"Keep the whole process in view"; this motto also applies to engineering. Therefore, in 2008, Dürr Ecoclean replaced the systems it previously used for process and fluid engineering and migrated completely to the EPLAN Platform. Now, electrical design, fluid design and EI&C engineering work together in an integrated manner. The advantage of this solution is clear: All three disciplines work on one and the same data basis and see, metaphorically speaking, the same data from three different points of view. The consequence is that each change that a designer in one of the disciplines makes is also visible in the other disciplines. The previous common and error-prone task of comparing the data status and transferring changes is dispensed with completely. No matter what discipline the designer works in: He always uses up-to-date data, which is the basis for all colleagues in each engineering discipline, and the entire project is consistently displayed. More efficiency through integration
After taking a detailed look, the advantages that the EPLAN global data platform provided convinced the engineers in Monschau to quickly prepare for migration. The opportunity to considerably improve efficiency using this integrative engineering process was clearly seen. In order to achieve a smooth transition, also in the case of running processes, Dürr Ecoclean decided to proceed step by step. Therefore, in July 2008, the transition started with the migration from EPLAN 5 to EPLAN Electric P8. The second step followed closely on the heels of the first step: In Fall 2008, EPLAN Fluid (for pneumatics and lubricant engineering) and EPLAN PPE (for process engineering) were implemented. The latter is mainly used to display the flow diagram. In cooperation with the EPLAN company, the PPE module was adjusted so that the optics are the same as in the former system. Now, electrical engineers as well as process engineers can work with the PPE module. This provides more workflow flexibility - and changes that electrical engineers make are automatically located in the flow diagram. In EPLAN PPE, modules were defined for function assemblies such as filters and vacuum dryers. To a large extent, the EPLAN library is used for this - a good basis since the other EPLAN systems also access this library. Changes at the organizational level as well
At Dürr Ecoclean, the company was quite aware of the fact that the migration to a common CAx platform by itself would not fully utilize all the advantages of integration. Changes were also necessary at the personnel and organizational level. Therefore, process and fluid engineering design, which was previously part of mechanical engineering, was combined with electrical design. This also laid the foundation for more flexibility. That electrical designers were also trained in EPLAN PPE provided a great opportunity: A former design "bottleneck" could be removed, since previously only one colleague created the flow diagrams. Even at the organizational level, Dürr Ecoclean is now better off. First master project successful
Dürr Ecoclean was able to prove the advantages of integrated design from flow diagrams to pneumatics and lubricant engineering to electrical engineering when the first master project was developed using the EPLAN Platform. Several large systems were planned for an American tool machine manufacturer. One advantage was that within a single project you could change, for example, from the EI&C view to electrical or fluid engineering - without interfaces. This lets a component be continually processed. And since there is a consistent data basis, the time needed to manually import data is saved. The probability of making a mistake is substantially reduced because the system instantly recognizes and reports any inconsistencies. Time savings also plays a role, because, for example, a function text only has to be defined in one place. Diagrams in the appropriate standard and language
In addition, Dürr was able to create electrical diagrams directly in JIC format, which is the common and desired format in the USA - it's easy with EPLAN Electric P8's switch function. These diagrams are generated with cross-references and all functionality, i.e. without any loss of information. The translation function also proved to be useful: Since the translation come from a single system, all three disciplines work with the same uniform terms. Another advantage of cross-discipline engineering can be seen in the process representation for the customer. Dürr Ecoclean provides its customers, for example, with drawings from EPLAN PPE for agreement and approval. This demonstrates expertise and a high level of quality in the engineering process - and after approval, the data can be processed further right away. Seamless changing between disciplines
Not only customers, but also their own in-house engineers appreciate working with/on the EPLAN Platform. Day by day, colleagues see the major advantages of integration: For example, from EPLAN PPE, they can go directly to the schematics and change between systems and disciplines without changing mediums. This reduction in interfaces is a key advantage. And the fact that the user interface is identical makes it easier to work. Other locations to follow
In view of these advantages, it comes as no surprise that other Dürr Ecoclean locations will soon migrate to the EPLAN Platform. This also makes sense because the different design and production facilities use common plant modules. The French factory in Loué will be first. The goal is that not only the systems, but also the diagrams and documentation be created according to the same standards - regardless of the production location. Plans are in place to connect the CAD data platform to the ERP system in the near future. In the first step it will be possible to load the order part data from SAP into the CAx systems. In the second step, the trigger to order purchased parts should be sent to SAP directly from the EPLAN programs.