JANUS Engineering AG and GROB-WERKE GmbH & Co. KG Set New Standards in NC Manufacturing with Custom Digital Twins
In a collaborative effort between GROB-WERKE GmbH and JANUS Engineering AG, a new postprocessor and realistic machine simulation (RMVM) were developed for the G900 machine series. Tailored specifically to the demands of e-mobility this partnership demonstrates how digital twins and innovative development processes can shorten development cycles and optimize production workflows. Companies benefit from customized solutions that enhance efficiency and provide a decisive competitive edge in the market.
Challenges and Innovative Solutions in Development
The G900 series was initiated to handle giga-castings, which were not feasible with previous machines due to their size. The development of an appropriate postprocessor was essential for the new G920X, G920F4, and G920F5 models. Given the series' critical importance to the automotive sector and existing sales commitments, there was considerable time pressure to finalize the postprocessor and validate programming and simulation within the digital twin.
The most significant challenge was that the machines were still under mechanical construction, preventing tests on physical units. Despite this, the development of the Siemens NX postprocessor and corresponding simulation had to progress to deliver functional NC programs for testing as soon as the machines were ready. Being a completely new series, neither simulations nor postprocessors previously existed.
Image Source GROB-WERKE: The New Machine Models G920F4 and G920F5
Developing the Software Framework and Digital Twin
JANUS Engineering created an initial software framework based on existing postprocessors, delivering quick results with functional postprocessors and simulations. The dual-channel programming was developed from scratch. Simultaneously, a digital twin was built using Siemens RMVM (Run MyVirtual Machine), a virtual simulation tool for production processes. RMVM is primarily used in CNC programming, process planning, and optimization, enabling offline programming and optimization without machine access. It improves planning accuracy, productivity, and offers a safe environment that replicates real machine behavior.
Image Sources JANUS Engineering: GROB Exhibition Component in Siemens NX
The objective was to develop a machine simulation integrating HMI and PLC to achieve 100% machine behavior replication. In operations like underbody manufacturing, the two spindles do not synchronize but independently execute their NC programs, moving autonomously across X, Y, Z, and A, C axes. This unique combination of high dynamics and an intelligent kinematic concept makes the G920F a standout compared to competitor machines.
The collaboration accelerated postprocessor development, with functions directly tested in RMVM, reducing costly machine testing time. The customized postprocessor meets GROB's specific requirements and offers tailored solutions. Digital testing and shortened development cycles reduced commissioning times, prevented collisions, and significantly boosted efficiency.
The initial version of the base postprocessor and existing PLC were integrated and tested in RMVM. Multiple development iterations, including postprocessor refinements, PLC optimizations, and the incorporation of machine data, continuously enhanced the RMVM.
"The product is continuously being developed in close cooperation
with GROB and end customers in order to meet the changing
requirements of the market.
This includes the growing variety of parts and new technologies
that enable a flexible and future-proof production process."
Martin Marquardt, Member of the Executive Board at JANUS Engineering AG
Market Launch and Future-Proofing Through Continuous Development
Market Launch and Future-Proofing Through Continuous Development
JANUS Engineering has delivered a fully tested MachineKit extensively validated in RMVM and on the physical machines. Challenges such as the utilization of angled heads and multi-clamping have been resolved, ensuring the machines are operational from the start. Companies benefit from a continuously updated MachineKit, tailored to the latest technological advancements and specific customer needs. This includes a fully programmed CAM project with fixtures and tools, alongside a MachineKit containing 3D machine models and a digital twin of the control system.
The product was first showcased in early 2023, though without available postprocessors or RMVM. Initial simulations were conducted using VISUAL COMPONENTS. The final product, now equipped with a fully functional postprocessor and RMVM, debuted at AMB 2024. By this point, over 50 machines had already been sold in less than a year.
Future development will continue to address the growing diversity of components and emerging technologies, facilitated by close collaboration between GROB and end-users, ensuring flexible and future-proof machines. This approach enables companies to adapt swiftly to market changes.
About GROB-WERKE:
For nearly a century, GROB has been a global leader in the development and production of systems and machine tools for major automotive manufacturers, suppliers, and other industries. With production facilities in Germany, the USA, Brazil, China, Italy, and India, and a global sales and service network, GROB is an internationally recognized name. The company employs 9,000 people and generates €1.8 billion in revenue (FY 23/24). Its product range includes universal machining centers, complex manufacturing systems with automation, assembly lines, and production solutions for electric motors, batteries, and fuel cells.
Website: https://www.grobgroup.com/
GROB-WERKE GmbH & Co. KG
Industriestraße 4
87719 Mindelheim
Germany
Phone: +49 (8261) 996-0
Fax: +49 (8261) 996-268
Email: info@de.grobgroup.com