Smart factory is a manufacturing model where digital technologies are heavily used in production processes. In this model, all devices, machines, sensors, and systems used in the production process are interconnected and create a data network. As a result, all data in the production process can be tracked, analyzed, and managed in real-time, which increases efficiency, minimizes errors, and reduces costs.

Smart factories are advanced technology production facilities that differ from automated machines aiming to minimize human labor and needs as they integrate artificial intelligence systems into the process. Instead of human labor used in production processes, fully automated systems are used, and any obstacles that may arise in the process are solved with artificial intelligence to maintain the system’s existence.

The competitive society of today has come to better understand the importance of such systems during the pandemic. Artificial intelligence, which has started to offer services in many fields using future technologies, has also begun to be used in many sectors. The integration of artificial intelligence and full automation into factory processes has given rise to the concept of smart factories.

The Smart Factory system emerges as a good method for achieving complete harmony among the manufacturer, supply chain, and customers, and for obtaining maximum benefit. Smart systems can adjust production lines according to customer demands and send the necessary products to the supply chain in real-time. This way, the dependence on labor will be reduced, and disruptions in production, especially during pandemic periods, will be kept to a minimum.

Transition to Smart Factories with Industry 4.0

Industry 4.0 can be defined as the integration of the current control and planning system applied on complex production tools in factories with today’s technologies and made compatible with software. Industry 4.0 is important in today’s world due to its dynamic nature. It is a system that includes the design of a fast, serial, and efficient production system and its implementation in the field, in a world where competition and production stand out.

Smart Factory is developed as a structure that is compatible with Industry 4.0 as a system. It appears as a technological reflection of the fourth industrial revolution in factories. The integration of computer systems with automation systems has been taken to an even higher level today, and artificial intelligence has also entered the game. The control of production lines is carried out in a fully automated system, and the management is carried out by artificial intelligence at certain points, which means that the system can develop further.management is carried out by artificial intelligence at certain points, which means that the system can be further developed.

With the integration of artificial intelligence into the system, self-monitoring of the production lines, instant intervention in case of malfunctions, automatic activation of different systems, and support for improvement efforts of the system have become prominent features. The system minimizes production disruptions caused by human errors in the harmony between humans and machines.

The Smart Factory is the key to achieving maximum efficiency in the production and logistics channels, while also facilitating the production of the most accurate and appropriate products at the right time according to the demands of society or consumers. With the transition to factories that employ smart production with Industry 4.0, it is possible to have a system that can:

• Ability to extract data from the sales system
• Analyze incoming orders , automatically plan production based on warehouse and inventory status
• It is a system that can transfer information to the logistics system,
•  Determine the destinations where products need to be shipped, and identify the required delivery timeframes for timely delivery.

Smart Machines Used in Production from Past to Present

The Smart Factory is the latest point reached in the manufacturing industry and is considered the first, second, third, and fourth industrial revolutions of the past. It is true that the systems used in manufacturing and production processes have undergone evolution from the past to the present. In the First Industrial Revolution, water and steam power were used for manufacturing and production processes, while the discovery of electricity in the Second Industrial Revolution led to the emergence of systematic production processes.

The third industrial era enabled the transition to automation systems by the use of information technologies, while the fourth industrial era opened the door to the era of smart factories.

The Future of Technology

The future impact of technology and the changes it will bring to human life is one of the most intriguing topics. Today’s technology aims to integrate the entire ecosystem using automation systems and artificial intelligence. The innovations brought by the information age and digital transformation and development are important agenda items of today. The increasing importance of artificial intelligence and robot technology indicates that the future will take a different direction.

Smart factories are managed through collaboration achieved by full automation and the use of artificial intelligence. This creates a new trend by designing a system that is compatible with the entire ecosystem. However, it is predicted that technology will reach future generations in a much more advanced way. Especially with the use of artificial intelligence in robots, it is already possible to perform many tasks through robots.

With the advancement of technology, robots can completely automate factory management and production processes, thus reducing the workload of humans. The widespread use of unmanned vehicles can make travel more efficient and comfortable. Moreover, as a result of these developments, shopping data can be collected to make the production process smarter and more organized.

The Smart Factory will become capable of making decisions for production planning, manufacturing stages, and even choosing logistics channels. Human beings will only have the task of controlling this entire system.

Development of Smart Factories in the Machinery Industry

The development of smart factories in the machinery industry has gained momentum in recent years, and it is expected that this trend will continue in the future. Smart factories are designed to make production processes more efficient, fast, and flexible, and to reduce production costs and improve product quality through the use of digital technologies.

In these smart factories, technologies such as the  Artificial Intelligence (AI), cloud computing, and big data are used to automatically control machines and equipment, detect maintenance and repair needs in advance, and increase efficiency in the production process.

With this development, manufacturers will have the capacity to produce higher quality products and make their production processes more flexible. Moreover, through smart factories, manufacturers will reduce production costs and increase their competitiveness.

As a result, the development of smart factories in the machinery sector is considered an important trend for the future of the industry and is expected to continue.

Durmazlar Makina is a leading company in the production of transportation vehicles such as buses, trams, metros, and high-speed trains. Like other manufacturers, Durmazlar Makina is investing in the development of smart factories and aims to create a more efficient, fast, and high-quality production process. Therefore, it is supporting its investments with smart factory production processes and digital technologies.

Digital Digital technologies such as robotic systems, artificial intelligence (AI), and big data are among the technologies used in Durmazlar Makina’s smart factory. With the help of these technologies, the production process has been automated, minimizing errors and increasing production efficiency

Will Smart Factories Open the Door to Unmanned Production?

As a result of the development of technology, the decrease in human workforce in the production system may lead to less use of human resources in the production area. This in turn creates concerns about unemployment. In this case, people will need to shift to different job areas. New doors will be opened in fields such as software, system usage, cybersecurity expertise, coding science, and technology management.

The Smart Factory system is a system that obtains some consumer trends and information by using databases during production. The production of machines is done in a modern way by using various data obtained. After data analyses, necessary instructions are given to all production lines in the system and the desired product definition is made. All of these processes are carried out automatically. The problems that arise can be solved by artificial intelligence.

Currently, factories that operate with very little human labor are starting to emerge. It is possible to develop systems in the future where fully unmanned production is possible, and production may become possible without the need for humans. However, there will be a need for humans in many areas such as supervising the system, addressing software-related issues, technological coding, system analysis and interpretation, and cybersecurity.

Smart Factory will reach a level where it can produce without human involvement, but new job opportunities in other areas will be created for humans within these systems.

The Machinery Industry is a sector that constantly develops with the historical development of humanity and creates the main lines of production by bringing innovations that can be considered revolutionary. Starting from ancient times, especially with the transition of humanity to collective life, human power has gradually left its place for industrial machines. The rapid growth and development in the field of industry from the past to the present have brought about mechanization and the development of machines.

Even though industrial and technological developments vary accordingly to the development levels of the countries of the world, the related development spread into the world’s industries rapidly from the first day they emerged. This movement, which was a historical turning point, emerged in England in the 18th century, especially during the time when the industrial revolution took place, is considered the beginning of the transition from production based on human and animal power to production with machines.

Sectoral Research and Development (R&D) organizations entered a rapid cycle with the industrial revolution. As a result of the industrial revolution led by England in the 1780s, 54 important inventions were made, and the first step of industrialization started with the invention of the steam engine in the 18th century.

Industrial Revolution and Mechanisation Process

The industrial revolution has gone through historical developments such as the first, second, third and fourth industrial revolutions. As the industrial revolution created the small industry movement, especially the production of iron, steel and textile accelerated with the introduction of machinery in this period. The popularization of the railway network also took place during this period.

The end of the 19th century and the beginning of the 20th century is known as the second industrial revolution. The prominent concept of this period is the concept of technology. As the sciences developed, machines also became more technologically advanced. The combine harvester in 1839, the sewing machine in 1844, and the canning and packaging machines in the mid-1880s are among the machines invented in this period.

This period, also known as the Third Industrial Revolution or the Modern Industrial Revolution, is the period between the 1970s and 1990s. The Lever Shears, which is one of the most important inventions of this period, was invented in 1978. A transformation to a period in which the importance of machines is increasing day by day and computers have become a part of life begins.

The development in technology has enabled the computerized and electronic production and use of machines. Labour rates were reduced and mechanization increased in order to reduce costs.

The Fourth Industrial Revolution is the period which has lasted until the period we are in and is known as Industry 4.0. During this period, concepts such as artificial intelligence and 3D printer technology have been introduced to our lives and everything that is being produced is produced with the help of fully-automated machines and computers, without the help of human power. The development of construction equipment started in the 1800s.

Historical Development of the Machines Used in the Industry

The machines used in the industry sector are used for manufacturing and production. Historically, the period of mechanization started with the industrial revolution and continued up to this day as the first, second, third, and fourth industrial revolutions. During this period, the concept of innovation also gained importance.

Some of the machines that were invented during the first industrial revolution are as follows;

• The seed planting machine was invented in 1701.
• In 1775, the steam engine, which was a great technological product of the time, began to be used.
• The automatic weaving machine was invented in 1785.
• The threshing machine was invented in 1793.
• The first sewing machine was invented in 1851.

At the beginning of the industrial revolution, the machines invented were first designed to be used in the agriculture and textile industries and they contributed to the development of these industries significantly.

Some of the machines that were invented during the second industrial revolution are as follows;

• Steam-operated machines were developed.
• Inventions were made in the field of yarn production and weaving. A few of them are flying shuttles and mechanical weaving.
• The machines used in electricity were also being used in the industry.

Development of the machines during the third industrial revolution is as follows;

• Computers, micro-electronic, and fiber optic lasers were invented in the field of technology.
• Developments were made in the fields of telecommunication, nuclear energy, biotechnology, and agricultural biotechnology.

As a result of the fourth industrial revolution, facilities and factories which can make products without the help of human power, via artificial intelligence originated.

Milestones of Mechanisation

There are some points in history which are considered milestones in the historical development process of mechanization. Historically, these milestones are as follows;

• The invention of the steam-operated machine in 1763 is the first milestone and also the beginning of the industrial revolution. Therefore, this period is also called Industry 1.0.
• The development in the machinery industry thanks to the production of iron and steel affected the period between the end of the 1800s and 1970, therefore the Industry 2.0 period emerged.
• The period between the years 1970 and 1990 is also known as Industry 3.0. During this period, analogue systems transformed into digital systems.
• The period starting from the year 1991 and last to the present is called Industry 4.0. During this period, machines such as the Laser Cutting Machine has been constructed to become computerized and artificial intelligence-aided. Thus, the importance of human power decreased significantly.

Historical Development of the Machines Used in the Production

Giving information about the historical development of some important machines used in production will clarify the subject and provide a better idea. The historical developments of the machines mentioned above are as follows:

The press brake is a type of press machine used to bend metal sheet plates. The first press brakes were used as a simple manual press in the 1800s.

Since the first presses were very difficult to use and required labour, the development of press brakes accelerated with the development of hydraulic systems in the 1920s.

Towards the end of the 1960s, computer-operated press brakes originated. These machines enabled the precision and speed of the process to increase. Today, press brakes are produced in many different sizes and features and they are used in the metal processing industry commonly.

Punch machines are used for cutting and shaping materials. Punch is indeed an original name. These machines appeared as simple technological products in the past. After the manual punching process was complete, motor-operated punching processes were carried out. Today, using computer technology, fully automated punchings can be performed.

Shears, also known as the guillotine shears, is a system that has been used since the 1700s. The shears, which were operated manually in the beginning, then started to be used with hydraulic systems. Later, it was transformed into a computerized system and today, it has been computerized and artificial intelligence-aided with CNC technology.

Generally used for industrial production, a laser cutting machine is a preferred technology for cutting iron, bimetal, aluminium, stainless, and similar metal materials. This machine, which was first produced and utilized by Durmazlar Makina in 2017, is one of the best examples to be given of advanced technology machines.

The laser power source is a resonator that has the capacity to cut materials such as stainless steel, aluminium, copper and brass up to 30 kW and is also produced by Durmazlar Makina for the first time in Turkey.

What the Future Has In Store for the Machinery Industry?

The concept of Industry 5.0, which has been used since 2017, has begun to shape life. In a sense, we started to experience this concept with the introduction of technologies, which do not contain the human factor, into our lives. We have started to get familiar with concepts such as full automation or production without touching. These technological developments have turned into a system in which all machines are integrated and managed by artificial intelligence.

With the development of technology, a system where employees will be robots and people can manage technology from their homes or places is not far away anymore.

You can visit our websites (https://www.durmaonline.com /  https://www.durmazlar.com.tr ) and read our other published blog articles.

Plasma cutting is a significantly important method of cutting any conductive products such as non-alloy steel, stainless steel, iron, and aluminium with minimum effort and expense. The basis of the working logic is to convert an ionized gas into plasma form and create an electrical channel towards the area to be cut. The plasma cutting process is performed by plasma cutting machines developed with the latest technology.

The gas type and pressure to be used during the cutting process inside the machine may vary depending on the material type and thickness to be cut. In addition, some of the compressed gasses such as oxygen and air are ionized by an electric arc. The ionized gas enables the desired cutting process to take place on the line formed between the cutting edge of the plasma machine and the material to be treated.

The most important criterion needed for plasma cutting is known as compressed gas. In addition to using different gases for this process, the most common plasma gas is compressed air. As it is available in many workshops and manufacturing shops, compressed air is very easy to supply. It can be used as an alternative to flammable and combustible due to its easy supply and accessibility.

Considering both in terms of health and the environment, performing cuttings with compressed gas is a much healthier and environmentally friendly process. As Durmazlar, we are going to discuss how plasma cutting works and the differences between plasma and laser cutting.

How Does Plasma Cutting Work?

During plasma cutting, hot and accelerated plasma is applied to the surface of the material with high electrical conductivity to be cut. Thanks to this cutting method, conductive materials such as aluminium, steel, sheet metal, and copper can be cut very fast and perfectly. Plasma-cutting machines are preferred by large industrial companies and many other areas with their high-speed precision cutting and low operating costs.

The main criterion of plasma cutting is that it creates an electrical channel through the material to be cut by a superheated and electrically ionized gas. This electrical circuit is grounded by the grounding busbar, thus ensuring the operation of the system. In accordance with the material to be cut by the operation of this system, compressed gasses such as oxygen and air are used. The electric arc is shaped between the hole (nozzle) in which the gas comes out and the material. An electric arc ionizes some of the gas and enables the creation of an electrical channel between the plasma and the material.

By using this electrical channel, electrons travel to the material through a cutting torch and create the heat needed to melt the material. During this process, high-velocity plasma and compressed gas spray the molten metals, preventing the formation of any roughness on the surface.

You can perform cuts on both fine and thick materials using plasma cutting. Steel sheets of 38 mm thickness can be cut using manual plasma cutting machines. Moreover, cuttings up to 150 mm in thickness can be performed with plasma cutting machines.

What Are The Advantages Of Plasma Cutting?

One of the most efficient ways to obtain products in desired sizes and shapes from metals such as steel, iron, and aluminium is plasma cutting. There are many advantages of using this method in manufacturing shops, workshops, and repair shops. One of these advantages is productivity.

It is possible to perform more cuts in a shorter time using this method. Cutting more products in a shorter time means producing more products in a shorter time for a manufacturing shop. This also means more production with less human power. Therefore a manufacturing shop or workshop can produce more with fewer workmanship costs.

Another productivity contribution of plasma cutting is that there is no need for a pre-annealing process before cutting. This means that the material to be cut is not exposed to any heating process before cutting. Heating and cutting the metal to be cut at a certain temperature increases both the time and effort spent on the work. Loss of material due to a possible error that may occur in the heating process can also be prevented.

As it is in the cutting process, plasma cutting offers great convenience after the process. The cutting torches of plasma cutting machines are performing much more precise and smoother works with the technology that has developed recently. Thus, no slag that needs to be cleaned after cutting is created. Since it performs the best cut with the least force on the material to be cut, post-cutting correction is not needed as there will be no adverse conditions such as warping, bending, or distortion on the surface post-cutting.

This cutting method offers advantages regarding health and the environment. Apart from these, the fact that the gas used in the machines is non-hazardous is also a great advantage in terms of occupational safety. The non-explosive and non-flammable gas used prevents an explosion or fire that may occur in the workplace.

What Is the Importance of Plasma Cutting?

Plasma cutting is preferred for cutting many metals thanks to its advantages. Almost all of these advantages also offer advantages for cutting stainless steel. In addition to these advantages, plasma cutting also prevents major workmanship errors in steel cutting.

Another importance of plasma cutting is that it produces accurate results after cutting. Since the measurements determined before the cutting are reflected in the work in the same way, there is no mistake or errors.

In this article, as Durmazlar, we will answer in detail about the advantages of plasma cutting and plasma cutting machines. By using Durmazlar machines, you can overcome all difficulties. We mainly aim to combine business processes by producing durable, flexible, and innovative machines. We aim for perfection in all our machines and attach importance to our communication with our customers in order to produce flawless machines. Please visit our website and contact us if you need further information about our products.

Customers prefer various cutting machines for different materials depending on the sector. The possibilities offered by the technology we have today make designs possible, which allow the completion of various processes depending on the material thickness and dimensions. In order to achieve this, the use of various cutting machines is required. One of these machines is the fiber laser cutting machine.

These are machines that assist in cutting or shaping materials through the use of a laser beam. Besides, they also allow the desired pattern or design to be applied to the material through the marking process. Laser-cutting machines have been used in a number of sectors for many years. In addition, these machines are able to process materials of different hardness and quality according to the relevant configuration. However, customers wonder about many issues such as what the fiber laser cutting machine does and what are the features of these machines. In this article, as Durmazlar, we will answer in detail your concerns about fiber laser cutting machines.

What Does Laser Cutting Refer To?

Generally used for industrial production, laser cutting is a preferred technology for cutting iron, aluminium, stainless, and similar metal materials. Laser cutting is mainly performed by directing the output of a high-power laser through optics.

The laser machine used for cutting materials also includes a motion control system that will follow the CNC or G code of the pattern to be cut into the material. Also, the focused laser beam is directed at the material and then melted, burned, vaporized, or ejected by a jet of auxiliary gas. At the end of the process, customers achieve a high-quality edge surface. Industrial laser cutting machines are preferred for cutting profile and pipe materials as well as flat sheet materials. 

What Are the Functions of the Fiber Laser Cutting Machine?

Fiber laser cutting machines have become increasingly popular for businesses in recent years. It can be said that fiber laser cutting machines are an advantageous option due to the wide variety of surfaces that can be cut, the economical maintenance materials, and achieving higher quality products in sensitive processes.

Functioning with the principle of intensive processing, the fiber laser cutting machine’s main criterion is that the output is flawless. The factors affecting the margin of error, which is close to zero, may include the cut surface, detail, and amount of processing.

Areas of Use of Fiber Laser Cutting Machines   

Fiber laser cutting machines are used in many areas since they meet expectations in terms of both quality and cost. The general areas of use are as follows:

1. Since punches of all shapes and sizes can be prepared through laser cutting, The mold industry is among the areas where laser cutting is used the most.
2. Manufacture of machinery and spare parts for machines.
3. Fields of architecture and engineering.
4. Ship and yacht industry.
5. Production of cranes, steel construction, heavy construction machinery, and sub-industry products.
6. Manufacture of construction materials, lifts, and sub-industry products.
7. Manufacture of laboratory and medical instruments.
8. Heating, ventilation, and air conditioning industries.
9. Manufacture of exhibition stands, display stands, and shelves.
10. Manufacture of electrical and lighting products.
11. Production of advertising signs used for visual communication.

Various designs in interior architectural projects. A large number of engravings on furniture, wall decorations, or various objects in the houses. Fiber laser cutting machines offer many advantages. These are as follows:

1. Energy-saving

Fiber laser cutting machines save energy. The advanced technology and design it has are ideal for energy saving.

2. Reliable

These state-of-the-art laser-cutting machines are designed to offer precise results. In addition, they are durable, reliable, and long-lasting.

3. Exclusive

Fiber laser cutting machines in the industrial laser processing market enable precise and serial cutting processes.

Features of Durmazlar Laser Cutting Machines

The types and features of Durmazlar laser cutting machines are as follows:

1. Fiber Laser Cutting Power Supply System: BRILASE

Durmazlar designed and developed the first domestic fiber laser power supply system of Türkiye, BRILASE. The superior beam quality they have allows fiber lasers to be the first choice for precision cutting and marking applications.

2. HD-TC Laser Pipe and Profile Cutting Machine

Durmazlar HD-TC Laser and Pipe Profile Cutting Machine offer the opportunity of cutting pipe and profile materials with a thickness of 0.8 mm to 10 mm by use of laser cutting power up to 4 kW. The Fully Automatic Loading and Unloading feature requires less operator effort and saves time.

3. HD-FO Laser Cutting Machine

Durmazlar HD-FO Laser Cutting Machine stands out with its high-quality materials and industrial designs as well as its production efficiency. The ease of use, low operating costs, fast opening top cover, easy access to the cutting area, compact bridge design, and ease of transportation offered by HD-FO Laser Cutting Machines increase efficiency in all areas.

4. HD-FS Laser Cutting Machine

The HD-FS Laser Cutting Machine is designed similarly to the HD-F series using the same components. As Durmazlar, we recommend you use HD-FS Laser Cutting Machine in order to add value to your business by achieving further quality, performance, and efficiency.

5. HD-F Laser Cutting Machine

Durmazlar HD-F Laser Cutting Machine stands out with its fast and precise cutting technology. The servo motor-driven rack and pinion mechanism allows HD-F Laser Cutting Machine to reach high acceleration.

6. HD-FL Laser Cutting Machine

Durmazlar HD-FL Laser Cutting Machines are able to reach high accelerations and speeds by use of the linear motor system. They guarantee quality, performance, and effectiveness.

7. HD-FA 5 Axis Laser Cutting Machine

HD-FA 5 Axis Laser Cutting Machines are laser cutting machines that can cut three-dimensional parts. Durmazlar HD-FA 5 Axis Laser Cutting Machines are also ideal for automotive and various high precision and 3D complex part production. They also offer several advantages thanks to the cutting system with the feature of “Simple Fixture Usage”.

In this article, as Durmazlar, we have answered in detail your concerns about fiber laser cutting machines. By using Durmazlar machines, you can overcome all difficulties. We mainly aim to combine business processes by producing durable, flexible, and innovative machines. We aim for perfection in all our machines and attach importance to our communication with our customers in order to produce flawless machines. Please visit our website and contact us if you need further information about our products.