WAFIOS, whose bending machines produce hairpins, axial flux coils, stator connection assemblies and busbars for e-mobility, has detailed three operator-assistance systems: myWAFIOS.ai, an AI assistant reached by scanning a QR code on the machine; the WAFIOS Assistant, which guides setup across two connected displays; and the Smart Pay-Off Interface (SPI), which lets a machine configure its own pay-off unit.
“A small number of experienced operators are often responsible for keeping production running, while training new employees becomes more difficult. At the same time, valuable expertise is lost if it is not systematically passed on. That’s why we need AI-powered systems that support machine operators and serve as a digital memory of our experienced operators,” said Uwe-Peter Weigmann, WAFIOS’s CEO and Spokesman of the Executive Board.
myWAFIOS.ai handles questions about machine setup, troubleshooting and tool changes. It searches technical documentation, manuals and validated knowledge from experienced WAFIOS specialists, and an operator needs only a smartphone to reach it. If the answer isn’t there, the system links to the WAFIOS Service team. The assistant runs on any mobile device and answers in multiple languages via German servers.
Underneath it is connectavo, the cloud-based maintenance platform WAFIOS has offered since 2020, which carries its own AI assistant called Conny. Communication runs through an optical QR code carrying an offline link, and the machine itself stays offline at all times, which WAFIOS says protects the machine against cyberattacks.
Two connected displays take the operator through setup on the WAFIOS Assistant. According to the company, setting up new parts previously required classroom training, and operators can complete both the setup procedure and the training through the system itself, which standardizes procedures and preserves know-how for the next generation of operators. All data remains within the customer’s own company, and the Assistant runs on all High-Performance Machines equipped with WPS 3.2 EasyWay.
SPI works further upstream, joining the pay-off and the machine into one system before production starts. The connected machine configures the pay-off unit itself, presetting the basic rotation speed and other relevant parameters from available production data. Pay-off speed, the force settings of the pay-off arm and the current operating status are among the information displayed at all times. The new generation of pay-offs carrying SPI is available for various WAFIOS wire bending, straightening and spring machines.
“With myWAFIOS.ai and the WAFIOS Assistant, we make the knowledge of our experienced employees available to everyone, anytime and directly at the machine. This shortens training times, reduces setup times, and ensures that answers to important questions are available exactly when they are needed,” said Jörg Eisele, a Member of WAFIOS’s Executive Board responsible for sales.
Source: WAFIOS
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