Archive for the ‘CNC Control Software’ Category

GE Fanuc has developed a series of aftermarket services that the company said can deliver as much as 25 percent more machining capacity without buying new equipment.

GE Fanuc’s Engineered Solutions (www.gefanuc.com) business unit has developed a method to optimize machine tool processes that includes adjusting the functions on machine tools to ensure they operate accurately and that they deliver the correct information to the machine controller.

GE Fanuc Engineered Solutions aftermarket services tune-up such machine functions as feed-forward, look-ahead, contouring controls, NURBS interpolation, and feedrate and adaptive controls.

Tuning such functions on a machine tool can extend a machine’s capabilities, Gary Highley, manager of Engineered Solutions for GE Fanuc, said.

“Users often don’t understand the full capabilities of their CNC machines. There are literally hundreds of tools in the CNC that can be used to improve productivity of the machining process,” Highley said.

“Machine tool builders provide the best value CNC system to meet their machine specifications, but may not take advantage of some key advanced features unless specified by the end user. Awareness of this functionality can lead to huge improvements in manufacturing processes,” Highley added.

For example: A machine tool’s servo system may not be properly adjusted and optimized for manufacturing, he said. Servo motors are responsible for moving spindles and tables on machines, and parts will be made out of tolerance or nearly out of tolerance if they do not function properly.

To get the best performance from a machine tool, GE Fanuc tests and adjusts servo system parameters while monitoring the machine to ensure that the responses from the servo system match the mechanics of the machine.

In addition, current loops are adjusted to high settings to realize a high response rate, and velocity loop and position gain also are set high to get higher responses to commands and to suppress disturbance torque.

Highley has a long list of other adjustments, tests and checks that he does on a machine, but he said the current loops are the heart of the servo system.

“Faster current loops equal faster response to disturbances and reduced path error. A fast current loop allows for a fast velocity and position loop. Faster loops improve speed and accuracy,” he said. A high velocity loop improves a machine’s speed of response to commands, while position gain determines how fast the servo system reacts to position deviation. A high position gain helps to reduce errors as long as stability is maintained.

Highley said basic servo tuning on a machine run by an aerospace parts producer improved the cycle time and the part profile. Cycle time was reduced by tuning the velocity and position loops for higher speeds, and by reducing acceleration/deceleration times to 150 ms from 600 ms. Part accuracy was improved by reducing path errors and interpolation errors.

In a second example, Highley said another aerospace parts producer was able to save $150,000 in the production of one part as a result of servo tuning and machine optimization on a line of seven horizontal machining centers.

The shop could not hold tolerances on the part, even while machining at 72 ipm, and had to make significant edits to its part programs each time it ran the part. Also, a separate, edited program was needed for each part on each machine, and the edited programs were based on test cuts that were done each time a new batch of parts was run.

The machine optimization included correcting settings for pulses per revolution of the spindle, which is a feedback response to the CNC; adjusting gains on the machines and correcting high precision contour control parameters.

“The result is that the programmed path now is the path that they get,” Highley said, adding that the shop now uses one part program for all seven machines instead of individual programs for each machine, and it has reduced hand deburring operations by 98 percent.

With Manual Guide i, the current Fanuc GE CNC controllers can be directly programmed onsite in a simple manner – regardless of whether turning, milling or combining machining processes

Manual Guide i, a user-friendly workshop programming from Fanuc GE, is constantly being developed. In addition to the improvement of diverse machining and milling cycles, it has new functions for multi-channel turning as well as programming in the tilted working plane. With Manual Guide i, the current Fanuc GE CNC controllers can be directly programmed onsite in a simple manner – regardless of whether turning, milling or combined machining processes will be carried out.

Thanks to the basic module and the modules for turning and milling, a user can limit himself to the essentials.

Each module initialises all cycles, leaving the user to easily and quickly program the respective machining process.

* All machining functions on one screen – the ‘all-in-one-screen-design’ provides the user with an overview of all machine functions on one screen.

On this an operator can read all axis positions and rotating speeds, detect where the machine currently is in the program, and display the tool paths or the workpiece in 3D in the simulation window.

To constantly maintain an overview, a bar with soft-keys facilitates intuitive menu selection. This also applies for multichannel turning operations.

* Intelligent functions – for the Series 0i-TTC CNC controller, Manual Guide i makes intelligent functions available, which simplify two-channel turning.

A process table, for example, displays the relation between the spindle and the turret via a timeline.

Standby times and travel paths can also be included.

An additional screen mask serves for simulation: both tool paths can be simultaneously displayed in the 3D model, which primarily serves for NC program control.

Lastly, the all-in-one-screen-design provides an overview on co-ordinates, machine status and the executed programs for both channels.

Even for three-channel turning, which is possible with the Series 30i CNC controller, Manual Guide i makes the corresponding functions available.

* Tilted work plane – there are new functions for tilted working plane (TWP).

With Manual Guide i, the TWP can not only be determined via Eulerian angles but also via the roll, pitch and yaw command (RPY), three points in the space, two vectors, angle projection or the tool axis direction.

In order to be able to easily utilise these options, Fanuc GE has developed a guidance screen which graphically supports the operator while requesting the required data from him in a dialogue.

Also new is the realistic simulation of the generated NC program for the tilted working plane.

It can either be shown as tool paths or as a shaded display.

* About Fanuc GE CNC: – Fanuc GE CNC is a leading global supplier in factory automation.

These include products and solutions for the machine tool market based on a wide range of CNCs, motion control products, monitoring and control software products, CO2 lasers and services.

Fanuc GE CNC is a joint venture between GE and FANUC and the company’s European headquarters are at Fanuc GE CNC Europe in Luxembourg.

CNC platform has advanced scalability, an open user-programmable man-machine interface and software covering tool grinding, gear and high speed cutting and transfer and special machines

NUM (UK) is to launch a radical CNC platform for machine tool manufacturers at MACH 2008. Caled Flexium, it delivers ‘no-compromise’ control system solutions, said NUM (UK). Developed by NUM in France, the Flexium modular platform is claimed to offer unprecedented scalability that can be applied economically on a machine with a few axes, or as many as 200+.

This facility is combined with open programmability that gives users complete freedom to customise the man-machine interface (MMI) and add value, said NUM.

Flexium provides machine builders with a common platform for all system building activities, from standard machines to special-purpose equipment such as transfer machines and integrated production lines.

Supporting the CNC platform is the novel fidelity and accuracy of control that is made possible by NUM’s complete product line and proprietary communication interfaces – from controller to motor – and decades of intellectual property in designing machine tool control systems and software.

At the heart of the new platform is an advanced new CNC kernel.

The kernel is at least four times more powerful than the fastest version of NUM’s existing Axium controller, said NUM (UK) to manufacturingtalk.com.

NUM (UK) said it is a popular choice today in a number of machine tool applications including tool grinding, gear manufacturing, woodworking, high-speed cutting, and transfer and special-purpose machinery.

Two versions of the CNC kernel are available, Flexium 6 and Flexium 68.

* Flexium 6 is a compact solution that is cost-optimised for standalone machines with up to five axes of motion.

* The more powerful Flexium 68 will handle up to 32 interpolated axes, divided into as many as eight coordinated groups.

If more axes are required, to support very large equipment projects such as a multi-cell production line, then Flexium 68s may be interconnected using a real-time Ethernet link.

CANopen interfaces provide additional system expansion capability, including positioning drives, I/O and handwheels, and operator panels.

This allows the Flexium 68 system to be expanded to control over 200 interpolated axes, as well as further positioning axes and I/O.

The CNC kernels are rounded out by a complete range of system building blocks including an industrial PC front end with soft-PLC functionality, MMI panels, I/O modules, drives, and a broad choice of servo and spindle motors.

* Sotware flexibility – the Flexium platform gives machine tool OEMs complete control over the ‘look and feel’ of the machine.

The system’s PLC is programmed according to IEC 61131-3 standards, and offers a choice of development software, providing machine control programming environment in forms to suit individual programmers.

Flexium’s MMI is also completely adaptable, said NUM (UK) and can be easily programmed using standard tools such as HTML, Java Script, or one of the PC-based rapid software development environments such Visual Basic, Delphi, Visual C or C++.

This flexibility allows users to add their own unique ‘look and feel’ branding to each machine.

NUM (UK) said that it is in stark contrast with some competitive platforms, which have fixed user interfaces that may only be modified by the vendor.

* Motion control – NUM’s long-established range of drives and motors complement the Flexium platform with motion control capability that is highly optimised for machine tool applications.

Accuracy and fidelity of motion are central to the control loop, and are achieved by a number of novel measures including a high speed proprietary bus between the CNC kernel and drives, and fine interpolation of the movement profile by closing the positioning loop, at drive level, at 5kHz – an almost unprecedented speed in this application sector, said NUM (UK).

These features are combined with special motors with optimised torque ripple and high inertia characteristics to suit the requirements of the mechanics.

NUM’s control over the complete motion axis chain secures an unmatched performance where it matters most: at the direct mechanical interface to the machine.

Jan Koch of NUM said: ‘NUM’s CNC technology has been developed and refined over decades to the point where it is a leader in some machine tool segments.

We have always complemented this with strong engineering support, and a partnership ethos where we work alongside the machine tool company and take complete responsibility for the control system.’ He added: ‘Flexium greatly widens the applications potential, giving the machine tool industry a platform with almost unlimited applications scope.

We expect it to appeal to small and mid-sized OEMs, providing a common platform for any size of machine.

One that can be completely tailored to their needs, and which has great software flexibility for adding value and building a distinct brand’.

* NUM (UK) at MACH 2008, NEC, Birmingham, UK, April 21-25, hall 5, Stand 5687.

An ESPRIT CAM software add-in provides end users with direct access to the cutting-tool management capabilities of the WinTool Cutting Tool Management System

DP Technology, maker of ESPRIT computer-aided manufacturing (CAM) software, said that DATOS has released a WinTool add-in for ESPRIT 2008. This ESPRIT add-in provides end users with direct access to the cutting-tool management capabilities of the WinTool cutting tool Management System. The WinTool system allows users to centrally manage tooling libraries and cutting conditions, and makes these libraries available to a wide variety of users throughout the machine shop.

For ESPRIT, WinTool will automatically generate precise 3D representations of the cutting-tool assemblies for simulation within the CAM system.

The WinTool add-in for ESPRIT is designed to improve the ease of use in tool management and machine set-up.

Using the WinTool system, ESPRIT programmers now have full access to the tool crib, while machine operators receive professional instructions for tool setup generated by the WinTool system.

DP Technology told manufacturingtalk.com that because data can simultaneously be transferred to preset gauges, the occurrence of tooling problems and machining standstills are significantly reduced.

* About ESPRIT – ESPRIT is a high-performance cam system for a full range of machine tool applications.

ESPRIT delivers powerful full-spectrum programming for 2 – to 5-axis milling, 2 – to 22-axis turning, 2- to 5-axis wire EDM, multi-tasking mill-turn machining and B-axis machine tools, and high-speed 3- and 5-axis machining.

ESPRIT’s high-performance capabilities include machining any part geometry (solid, surface, or wireframe), universal post processing to format G-code for virtually any machine tool, and solid simulation and verification with dry runs rendered in dynamic solids for optimal part quality and consistency.

ESPRIT is 100% pure Windows, and provides a comfortable and familiar user interface for maximum productivity.

* About DP Technology – DP Technology is a cam software market leader with a mission to provide CNC programmers with the most powerful CAM software ever.

DP Technology’s flagship product, ESPRIT, captures the company’s vision of technology’s potential and its passion for excellence.

DP Technology maintains its worldwide headquarters in Camarillo, California, USA, and product development teams in California and Florence, Italy.

Sales and support operations are located in Europe, Asia, and North and South America. Request a free brochure from DP Technology….

Southfield, MICHIGAN, February 6, 2008: Planit announced today that it will demonstrate the latest releases of Edgecam and Radan in booth 3076 at the WESTEC Advanced Productivity Exposition, taking place on March 31 – April 3, 2008, at the Los Angeles Convention Center, Los Angeles, California. This premier event presents manufacturing & metalworking technologies used in the production of world-class products. WESTEC is expected to attract manufacturing professionals ranging from company executives to production engineers.

Edgecam will demonstrate Version 12 of its market-leading CAM system for solids based manufacturing, which expands on its 5-axis machining capabilities and delivers improved CAD data management, faster toolpath generation and new options for hole cycle optimization. Edgecam Version 12 extends the range of 5-axis machine tool support to include head/table configurations for both simultaneous and positional work. This is supported by full machine simulation to aid visualization of the machining process and verify work setup. The complete machine can be displayed, including all table/head and tool movements, helping to ensure safe operation and process optimization.

Radan will demonstrate the newly released version of its industry leading CAD/CAM software for sheet metal applications. Radan 08 delivers improved processing times, enhanced 3D import capabilities and significant nesting improvements. Radan will also demonstrate advancements to RadbendCNC, its off-line press brake programming package.

Education and training are critical to production and cost efficiency. The WESTEC conference includes SME-sponsored technical programming addressing advanced manufacturing technologies and processes. WESTEC is co-sponsored by the Society of Manufacturing Engineers (SME), the Association for Manufacturing Technology (AMT), and the American Machine Tool Distributors’ Association (AMTDA).

# # #

About Planit
Planit is the world’s largest supplier of design and manufacturing software for the engineering, woodworking and stone-cutting industries, with more than 85,000 industrial seats installed at thousands of customer sites around the globe. The company’s Alphacam, Cabinet Vision, Cabnetware, Edgecam, Jobshop and Radan solutions are best-in-class within their respective markets, providing customers with products and services to improve the productivity of their machine tools, shorten design and manufacturing time, optimize material usage, and deliver high quality goods and services to their customers. For additional information, visit www.planit.com.

About SME:
The Society of Manufacturing Engineers is the world’s leading professional society supporting manufacturing education. Through its member programs, publications, expositions and professional development resources, SME promotes an increased awareness of manufacturing engineering and helps keep manufacturing professionals up to date on leading trends and technologies. Headquartered in Michigan, SME influences more than half a million manufacturing practitioners and executives annually. The Society has members in more than 70 countries and is supported by a network of hundreds of technical communities and chapters worldwide.

Contact: Jane Briscoe
Telephone: 651-982-0100 ext. 5515
Emai: Email Contact        

Planit Solutions Inc.
25 North Lake Street
Forest Lake, MN 55025

In this video, we go over the CNC Control portion of the CNC Process.

Day 5 is all about CNC Control.  CNC Control is made up of three parts.  The CNC Control Computer, CNC Control Software and the actually CNC Controller.
The CNC Control Computer can be basic and inexpensive.  The computer will live in a harsh environment that includes dust and dirt.
The CNC Control Software is what processes the G-Code program we made in the last step.  You load it in and when you are ready, start the program.
The actual CNC Controller has drivers in it and translates the signals from the control program into motion.  It sends the signals on to stepper or servo motors that move the various axis.
All together these pieces can cost a lot or a little.  You can also cut down the cost if you build the cnc controller yourself.

Tomorrow we machine.  This is where the chips fly.

CNC platform is customizable and scalable

NUM is launching a new CNC platform for machine tool manufacturers. Called Flexium, the modular platform is claimed to have unprecedented scalability that can be applied economically on a machine with a few axes, or as many as 200 or more.

This is combined with open programmability that gives users complete freedom to customise the man-machine interface (MMI) and add value.

Flexium provides machine builders with a common platform for all system building activities, from standard machines to special-purpose equipment such as transfer machines and integrated production lines. Underpinning the platform is the exceptional fidelity and control accuracy that is made possible by NUM’s complete product line and proprietary communication interfaces – from controller to motor – and decades of intellectual property in designing machine tool control systems and software.

At the heart of the new platform is an advanced new CNC kernel. This is at least four times more powerful than the fastest version of NUM’s existing Axium controller, which is a popular choice today in a number of machine tool applications including tool grinding, gear manufacturing, woodworking, high-speed cutting, and transfer and special-purpose machinery.

Two versions of the CNC kernel are available. Flexium 6 is a compact system that is cost-optimised for standalone machines with up to five axes of motion. The more powerful Flexium 68 handles up to 32 interpolated axes, divided into as many as eight co-ordinated groups. If more axes are required, to support very large equipment projects such as a multi-cell production line, then Flexium 68s may be interconnected using a real-time Ethernet link. Canopen interfaces provide additional system expansion capability, including positioning drives, I/O and handwheels, and operator panels. This enables the Flexium 68 system to be expanded to control over 200 interpolated axes, as well as further positioning axes and I/O.

The CNC kernels are complemented by a range of system building blocks including an industrial PC front end with soft-PLC functionality, MMI panels, I/O modules, drives, and a broad choice of servo and spindle motors.

Software flexibility has been at the core of NUM’s development project. The resulting Flexium platform gives machine tool OEMs complete control over the look and feel of the machine. The system’s PLC is programmed according to IEC 61131-3 standards, and offers a choice of development software, providing machine control programming environment in forms to suit individual programmers. Flexium’s man-machine interface is also completely adaptable, and can be easily programmed using standard tools such as HTML, Java Script, or one of the PC-based rapid software development environments such Visual Basic, Delphi, Visual C or C++. This flexibility, which enables users to add their own ‘look and feel’ branding to each machine, is in stark contrast with some competitive platforms, which have fixed user interfaces that may only be modified by the vendor.

Jan Koch of NUM states: "NUM’s CNC technology has been developed and refined over decades to the point where it is a leader in some machine tool segments. We have always complemented this with strong engineering support, and a partnership ethos where we work alongside the machine tool company and take complete responsibility for the control system. Flexium greatly widens the applications potential, giving the machine tool industry a platform with almost unlimited applications scope. We expect it to appeal to small and mid-sized OEMs, providing a common platform for any size of machine. It can be completely tailored to their needs, and has great software flexibility for adding value and building a distinct brand."

Flexium CNC

Chatsworth, CA – Vertical machining center producer MAG Fadal announced that their FX series of machines will be available with the new Infimatic Freedom NC200(TM), a digital control designed specifically for metal-cutting machine tool applications, with three highly-intuitive navigation choices. The control is compatible with standard G Codes as well as part programs that have been created for Fadal CNC controls.

The operator pendant has been designed with the machinist in mind, offering a full keyboard, integrated mouse and easy-to-use LED-ringed pushbuttons. VeriCode(TM), the control system’s unique color-coded editor, has real-time syntax and semantic verification to simplify part programming, as well as the ability to facilitate background editing during machining. ServoScan(TM) technology automatically populates control parameters and other critical data when the machine is powered up, reducing errors and streamlining the start-up process.

Infimatic’s Freedom NC Portal(TM) is an interface for seamless integration of software from GibbsCAM, NextEngine, Renishaw or other sources whose technologies complement the core functionality of the CNC. Complete with advanced 3D graphics, the NC200(TM) comes loaded with integrated GibbsSFP®, the control-resident version of GibbsCAM that includes time-saving drilling, contouring and pocketing routines.

Engineered for maximum reliability in a contract shop or production floor environment, the Freedom NC200TM features fanless cooling, diskless data storage, advanced protection circuitry, all surface-mount circuit board construction, a water resistant panel, and a distributed architecture platform which enables electrical cabinet optimization.

Nationwide availability of the new FX series is planned for April 2008. Special editions of both the VMC 3016 FX and VMC 4020 FX are being offered on a limited basis earlier in the year. These machines will include a 10,000 RPM air/oil 40-taper spindle, the coolant-thru-spindle feature, and dual-arm tool changers, with 24-tool capacity on the 4020 FX and 20-tool capacity on the 3016 FX.

Since its introduction in 2006, the FX series has been embraced by manufacturers in applications ranging from die and mold machining to part production in the automotive, aerospace, medical and other industries. Its value-to-price ratio make it a natural choice for coupling with the economical yet powerful control platform developed by Infimatic.

On the 3016 FX and 4020 FX, rigid box-way construction with integral flame-hardened ways are complemented by Steinmeyer ETA+ dual-mounted ballscrews that optimize machine stiffness and virtually eliminate reversal error. Rapid traverse is 1,000 IPM (inches per minute), with a cutting feed rate up to 800 IPM.

X/Y/Z axes travel on the 3016 FX is 30" X 16" X 20" (762mm X 406mm X 508mm); the 4020 FX increases the working envelope with X/Y/Z axes travel of 40" X 20" X 20" (1016mm X 508mm X 508mm).

About MAG Fadal

Fadal Machining Centers (MAG Fadal), a division of MAG Industrial Automation Systems, offers a wide range of Vertical Machining Centers (VMCs) complemented by a full line of performance-enhancing rotary products. Close to 40,000 VMCs have been installed worldwide in applications for general machining, medical, mold/die, automotive, aerospace, woodworking and many other dynamic industries. With over 40 years of experience in the machine tool business, MAG Fadal continuously strives to apply innovative metal-cutting technology to its VMCs. Headquartered in its 280,000 sq. ft. manufacturing facility in Chatsworth, CA (Los Angeles area), MAG Fadal offers extensive training and support programs, including a global network of distributors trained to deliver world-class after-sales support. Also see www.fadal.com.

About Infimatic

Infimatic, headquartered in Hebron, Kentucky, is focused on the science and engineering of machine motion and automation control systems. As a division of MAG Industrial Automation Systems, the company brings a real-world depth of expertise in automation, CNC machining, robotics, process and motion control – with innovative solutions to common control issues. Infimatic systems are distinguished by their modularity, ease of configuration and integration, scalability and maintenance advantages, tough hardware architecture, dynamic productivity software platform, and first-caliber quality – all at a price point unmatched in the industry. Also see www.infimatic.com.

About MAG Industrial Automation Systems

MAG Industrial Automation Systems, Sterling Heights, Michigan, is a group of leading machine tool and systems companies serving the durable-goods industry, worldwide, with a large portfolio of highly-recognized and well-respected brands. With manufacturing operations on five continents, MAG ranks as a leader in the global metalworking capital equipment market. Also see www.mag-ias.com

Hello,

Today’s topic is controlling.  Since we are dealing with
machines that do work for us, we need to control those machines
somehow.  We need to control them for safety reasons as well.
If you give a machine improper commands it can easily get out of
control and cause harm to you or the part you are machining.  We want
to give appropriate commands to our machines, at appropriate
times so they are not "out of control". 

The language that these machines use is called G-code.  G-code
has been around since the early 60’s.  There are number
variations of G-code, but most are very similar to one another.
See the previous lesson for a sample of G-Code. 

We will need to use a computer to talk with our CNC machine.
Our computer will send signals to our CNC machine.  In-between
our computer and our CNC machine sits a controller.  A
controller converts commands into signals that are used to
control the motion of our machine.

As these signals are sent out of the controller, they go to
either stepper or servo motors.  This is how we create
motion.  These motors drive our various axis on our CNC machine.
While we are moving our axis, there is generally a cutting tool
of some sort removing material.  This is the machining process
coupled with CNC.

Here is a brief description of the two types of motors
generally used in CNC:
Stepper motors:
Simple design
Easy to use
Generate torque at low rpm
Do not know their position in relation to the program

Servo Motors:
Generate torque at high RPMs
Generally need gearing of some sort to be effective
More sophisticated
Can maintain their relative position, thus they can be more
accurate

Controllers generally stand alone near the CNC machine.  They
act as a translator between your computer and your CNC machine.
Generally they add quite a bit of cost to a CNC machine as well.
Controllers can cost anywhere from $1000-$20,000 or more depending
on their sophistication.

Now that we can control the machine, its time to machine with it.
That will be tomorrow, CNC Machining and everything that goes along
with it.

If you are interested in more information right now on Controlling,
you can go to my website.  Click this link now:
http://www.cncinformation.com/CNC_Controllers/CNC_Controller.html