{"id":1634,"date":"2021-11-10T17:13:55","date_gmt":"2021-11-10T20:13:55","guid":{"rendered":"https:\/\/www.serall.biz\/?p=1634"},"modified":"2021-11-24T20:05:17","modified_gmt":"2021-11-24T23:05:17","slug":"industria-4_0-e-sua-relacao-com-o_rings","status":"publish","type":"post","link":"https:\/\/www.serall.biz\/eng\/industry-4_0-and-its-connection-with-o_rings\/","title":{"rendered":"What is Industry 4.0 and how does it relate to O-ring seals?"},"content":{"rendered":"

Overview<\/span><\/h3>\n

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Today we are living a new revolution, the so-called fourth revolution or Industry 4.0, and we must be well informed about it, participating as a protagonist and not just as a follower.<\/span><\/p>\n

The term Industry 4.0 (i4.0) refers to the conjunction of technological changes in manufacturing, where operational priorities are established from a fully connected structure, aiming at the global competitiveness of industries.\u00a0<\/span><\/p>\n

The Industry 4.0 concept was established by the German government in 2011 and represents significant changes in many professions, directly impacting the training of people, who will have to learn new skills due to the use of high-tech devices that will become indispensable equipment for daily activities, and you are no exception.<\/span><\/p>\n

This article will explain the global definition of Industry 4.0 and the importance of using highly durable<\/strong>that will ensure the continuity of automated operations with minimal human input.<\/span><\/p>\n

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Industry 4.0 at a glance<\/span><\/h4>\n

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We will start by analyzing the main concepts surrounding the 4th industrial revolution, standardizing the language concepts. We will now go on to explain basic concepts that can be easily understood.<\/span><\/p>\n

Broadly speaking, the term Industry 4.0 means automation in data exchange across all manufacturing technologies, including Internet of Things (IoT), Big Data and analytics, cyber-physical systems, additive manufacturing, simulation and augmented reality (AR) for horizontal and vertical integration into machines, cloud computing and autonomous robots.<\/span><\/p>\n

Industry 4.0 plays a role in helping to integrate and combine intelligent machines, human actors (like you and me), physical objects, manufacturing lines, and organizational stage processes to build new kinds of technical data, systematic and highly agile value chains.<\/span><\/p>\n

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The term 4.0\u00a0<\/strong><\/span><\/h4>\n

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The name i4.0 is attributed to the chronological order of the previous industrial revolutions (Fig. 1), each of which brought about major changes in the field of manufacturing technologies. The first was the shift from hydropower and steam power to mechanical power, the second was to mass production, and the third was to automation through the use of information in automated systems.<\/span><\/p>\n

The first stage, Industry 1.0, started at the end of the 18th century using mechanical devices to transform water and steam energy into mechanical energy, mainly used in the agricultural sector. Later, Industry 2.0 began and was related to mass production, as the standardized form of production in general. It was not until the 20th century that Industry 3.0 came into action, along with advances in computer technologies, these advances were easy to use and were implemented in various stages of production, connecting many professions in a new language: programming<\/strong>. It was not until Industry 4.0 that all professions started to use computer programming systems to adapt to their local activities, but they are not required to know coding languages, but rather to learn and use software that connects user-computer-machine in their working life (Gorecky et al. 2014).<\/span><\/p>\n

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\"Industrial

Fig. 1. Diagram of industrial evolution<\/span><\/p><\/div>\n

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Intelligent Factories for Industry 4.0<\/strong><\/span><\/h4>\n

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The future of global manufacturing is based on smart factories, which consist of the widespread use of automation in digitalized factories and products, i.e., the four stages of the industrial revolution. However, to date there is no single definition that describes all aspects of Industry 4.0 in basic terms, making it difficult to distinguish all its components. The term and definition with most approaches distinguishes a minimum of 9 essential characteristics that make up Industry 4.0. As shown in Figure 2, these components are essential, but this does not mean that they are the only ones, each of these is explained below.<\/span><\/p>\n

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\"Industry

Fig. 2: Industry 4.0 Technologies<\/span><\/p><\/div>\n

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Cyber-Physical System (CPS), Big Data, Internet of Things (IoT) and Internet of Services (IoS)<\/strong><\/span><\/h4>\n

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CPS consists in the fact that each production station has sensors that communicate in real time all the physical situations represented in virtual models.<\/span><\/p>\n

Due to the large volume of information, the CPS is the foundation of the Internet of Things (IoT) combined with the Internet of Services (IoS). With both digital systems working in sync, it will be easier to connect and control the entire production chain, from production to machinery and even the warehouse (He 2016).<\/span><\/p>\n

The huge amount of data is processed in a big data analytics concept and consists of assessing all the information and is used to predict and manage all the information to evaluate and make complex decisions. Big data can manage four main dimensions: volume, variety, velocity and value (Witkowski 2017).<\/span><\/p>\n

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Autonomous Robots<\/strong><\/span><\/h4>\n

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Currently, robots used in factories only execute programmed instructions under certain conditions, but in Industry 4.0, robots will have the ability to interact with other robots, will be more compact, affordable and sophisticated than today's robots, resulting in robots with greater functionality and some degree of autonomy for manufacturing.<\/span><\/p>\n

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Augmented Reality (AR)<\/strong><\/span><\/h4>\n

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AR, is one of the most promising benefits of Industry 4.0, it can predict with high accuracy the frequency of total productive maintenance (TPM) of machines and enable a lower frequency of corrective maintenance, which means that components that need frequent replacement or maintenance should be replaced by other materials that guarantee a longer service life than the current ones and that can be scheduled in predictive maintenance. This represents a cost reduction compared to the continuous TPM currently performed (Masoni et al. 2017).<\/span><\/p>\n

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Additive Manufacturing (3D Printing)<\/strong><\/span><\/h4>\n

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The production of rapid and inexpensive prototypes using a 3D printer, allows rapid testing, decreasing project time and last minute changes in conjunction with the available processed data. This is one of the main advantages and one of the most relevant tools for Industry 4.0 adoption.<\/span><\/p>\n

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Cloud Computing\u00a0<\/strong><\/span><\/h4>\n

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It consists of entering and maintaining all the information of each station in a shared storage. As the available information is so extensive, it can be stored in a machine or service stations that are connected to the network (or to the cloud), and with this the functionality of each equipment and the data necessary for it, will be available in the system in the cloud, which allows managing large amounts of data without the need for local storage (large and expensive) and can be processed individually.<\/span><\/p>\n

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Simulation<\/strong><\/span><\/h4>\n

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Simulation means moving to advanced training. Simulations are performed in real time using multiple data in a virtual mode as close as possible to the real world, allowing to know or simulate the output of a system. This simulation includes the participation of people, robots, process stations and even warehouses. It is intended for operators who will optimize parameter settings in a virtual model before optimizing them in real activities. It is a high-level training with no waste of material.\u00a0<\/span><\/p>\n

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Simulation means moving to advanced training. Simulations are performed in real time using multiple data in a virtual mode as close as possible to the real world, allowing to know or simulate the output of a system. This simulation includes the participation of people, robots, process stations and even warehouses. It is intended for operators who will optimize parameter settings in a virtual model before optimizing them in real activities. It is a high-level training with no waste of material.<\/span><\/p>\n

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Importance of a TPM system in Industry 4.0<\/strong><\/span><\/h4>\n

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Let's start by defining what TPM is. Total Productive Maintenance or TPM is a management practice that takes into account all aspects of equipment maintenance, the behavior of people and the production process to achieve and maintain maximum efficiency of equipment and operations, in other words, it is the execution of preventive maintenance on all machines to prevent them from stopping due to a failure or malfunction that may cause them to show erratic behavior and have an impact on the quality of the final product.<\/span><\/p>\n

One of the key aspects to implement the principles of Industry 4.0, is the correct functioning of all equipment, from the simplest to the most complex parts, taking into account that due to natural causes, the equipment and its components tend to wear out and must be replaced.<\/strong><\/span><\/p>\n

We can distinguish eight steps to create a solid TPM for Industry 4.0, which covers different aspects, from defining the objectives to obtaining the appropriate technology and being able to measure the KPI's (Key Performance Indicator) that indicates the success of its implementation (figure 3), at first glance it looks very similar to the real TPM, but Predictive Maintenance 4.0 (PM) will be a key factor to ensure the continuity of the process without erratic data readings or downtime in the production line.<\/span><\/p>\n

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Fig. 3. 8 Key steps to adapt TPM for Industry 4.0<\/span><\/p><\/div>\n

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For TPM 4.0, it will be necessary to use reliable and long-lasting parts that show the least wear and tear in normal operation, paying special attention to the internal components of the equipment, which due to their location and function may result in machine stoppages that must be scheduled at increasingly longer intervals from each other.<\/span><\/strong><\/p>\n

The spare parts list should contemplate from the very beginning, the installation of parts that guarantee the greatest durability and that due to their working conditions wear out more commonly, such as filters, belts and seals, understanding that even the smallest parts are relevant in the process. An unscheduled machine stop due to a small part can cause the same or a greater inconvenience than a large part.<\/span><\/p>\n

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Creating a culture of reliability with small components in i4.0 processes<\/strong><\/span><\/h4>\n

FFKM O-Ring Seals<\/strong><\/span><\/h4>\n

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Os O-rings<\/a><\/span> are present in almost all stages of manufacturing, these products are widely used in mechanical systems<\/a><\/span> and in some electromechanical systems to seal different types of fluids, whether liquid or gaseous. Their operation is simple: they are mounted in the grooves or cavities of the system, where they deform slightly until they adopt the shape of the place where they are installed, thus preventing fluid leakage. (See figure 4)<\/span><\/p>\n

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Fig. 4: O-Rings mode of action <\/span><\/p><\/div>\n

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O-rings are distinguished by the following features<\/span><\/p>\n