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TRANSCRIPT
06/07/2010
1
Advanced
Machining
Processes &
Systems Advanced Machining Processes & Systems
A Unified Manufacturing Resource Model for
CNC Machining SystemsPresented
by
Prof. S.T. Newman
S T Newman, A Nassehi & P VichareAdvanced Machining and Processes System
IdMRC
The University of Bath
Advanced
Machining
Processes &
SystemsContents
1. Current state of the art of machine tool representation and limitations
2. Research goal
3. Development of Unified Machine Tool Resource Model (UMRM)
4. UMRM applications
06/07/2010
2
Advanced
Machining
Processes &
SystemsCNC Machining system Resource Elements
CNC machining system resources
Machine tools Cutting tools Auxiliary devices
Accessories Tool and Material handling devices
Tool holding
elements Pallets Conveyers Fixtures Robots AGVs
Advanced
Machining
Processes &
SystemsEstablished Standards for Interoperability
Resource specific viewpoints
06/07/2010
3
Advanced
Machining
Processes &
SystemsCost of Non-Interoperability
Mori Seiki 3 axis VMC Mazak 3 axis VMC
Postprocessor 1 Postprocessor 2
CAM system
Machine specific postprocessors due to proprietary resource data model
Geometric data
Machine tool functionality
Machine tool configuration
?
?
Machine tool data transfer between various CAM system
Advanced
Machining
Processes &
SystemsMachine tool configurations
Z axis
Y axisX axis
Series Kinematic machine tool(SKMs)
Parallel Kinematic machine tool(PKMs)
Y axisX axis
B axis
A axis
Z axis
06/07/2010
4
Advanced
Machining
Processes &
SystemsSKMs v/s PKMs
• Conventional way of representing SKMs is not practical for
representing PKMs
Legend:
T: Tool1: Spindle2: Z axis slide3: Column4: X axis slideW: Workpiece6: Table7: Y axis slideF: Frame
F
7 6 W
4 3 2 1 T
Y axis
X axis Z axis
F
1
2
3
4 5 6 T
Legend F: Machine frame 1: Glide 1 2: Glide 2 3: Glide 3 4: End effector platform 5: A axis 6: B axis T: Tool
Advanced
Machining
Processes &
SystemsRepresentation of SKM structures
06/07/2010
5
Advanced
Machining
Processes &
SystemsRepresentation of PKM structures
Advanced
Machining
Processes &
SystemsResearch Goal and Related Benefits
Development of unified machine tool resource model which
canRepresent the functionality
of any machine tool available in the market
Machine tool functionality representation
Auxiliary devices and associated functionality
representation
Represent the functionality of various auxiliary devices attached
with the parent machine tool
+ Interoperability
Provide the neutral file format for exchanging machine tool functionality between various
CAM systems
+
A single data model to represent any machine tool resources
Unified Manufacturing Resource Model (UMRM)
06/07/2010
6
Advanced
Machining
Processes &
SystemsCNC machining system abstraction layers
Factory
Shop
Cell
Station
Advanced
Machining
Processes &
SystemsRepresentation of various manufacturing resource
CNC machining system resources
Machine tools Cutting tools Auxiliary devices
Accessories Material handling devices
Tool holding
elementsPallets Fixtures Conveyers Robots AGVs
06/07/2010
7
Advanced
Machining
Processes &
SystemsRepresentation of various manufacturing resource
Advanced
Machining
Processes &
SystemsRepresentation of Machine Tool Kinematics
06/07/2010
8
Advanced
Machining
Processes &
SystemsUnified Manufacturing Resource Model
Mac
hine
too
ls
Aux
iliar
y d
evic
es
Unified Manufacturing Resource Model (UMRM)
Cut
ting
too
ls
Mat
eria
l han
dlin
g d
evic
es
Fix
ture
s
Co
ntro
llers
Advanced
Machining
Processes &
SystemsUMRM Application Horizon
Resource specific
Toolpath generation
Interoperability
STEP-NC compliant controller and
bidirectional data flow between CAD to CNC
Multi-route processplan
Reconfigurability
Energy and cost optimisation
Digital factory simulation
UMRM
06/07/2010
9
Advanced
Machining
Processes &
Systems
STEP-NC Part programMachine data file
Machine tool resource specific process plan
UMRM for resource specific process plans
(STEP-NC Compliant)
INDEX C 65
STEP-NC compliant controller
Advanced
Machining
Processes &
SystemsUMRM applications: Intelligent Controller
Unified Machine Tool Resource Data Model
CNC machining system
06/07/2010
10
Advanced
Machining
Processes &
SystemsConclusions
• UMRM provides novel and versatile platform to represent
functionality of any CNC machining system.
• It is flexible enough to abstract CNC machining system
information depending upon desired level of detail.
• UMRM enables the basic model to investigate the various
attributes (process capability-nominal/actual, energy
usage, etc) of the CNC machining system.
• The proposed model is based on STEP-NC compliant
information modelling framework. Hence, it can be utilised
for developing an Intelligent STEP-NC controller.
Advanced
Machining
Processes &
Systems
Thank you
Prof. Stephen T. Newman
Department of Mechanical Engineering
University of Bath
BA2 7AY, Bath, UK
06/07/2010
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Advanced
Machining
Processes &
SystemsINDEX C65
Z
X
Y
Advanced
Machining
Processes &
SystemsDMU 50eV (5 axis BC type VMC) representation
06/07/2010
12
Advanced
Machining
Processes &
SystemsDMU 50eV representation (part-21 file)
ISO-10303-21;HEADER;FILE_DESCRIPTION(('DMU 50EV MANUFACTURING CELL','DMU 5 AXIS VMC'),'1');FILE_NAME('dmu1.STP','2008-03-20',('PARAG VICHARE','AYDIN NASSEHI','STHEPHEN NEWMAN'),('UNIVERSITY OF BATH'),$,'ISO14649',$);FILE_SCHEMA(('MACHINING_SCHEMA','TURNING_SCHEMA','MILLING_SCHEMA','MILLING_TOOL_SCHEMA','TURNING_MACHINE_TOOL_SCHEMA','MACHINE_TOOL_RESOURCE_SCHEMA'));ENDSEC;
DATA;#1=LOGICAL_MANUFACTURING_UNIT('DMU 50EV MANUFACTURING CELL',(),(#2),());#2=MACHINE_TOOL('DMU 50EV','DMG','MANUFACTURING LAB',#3,(#7),(#55));#3=AXIS2_PLACEMENT_3D('MACHINE TOOL PLACEMENT',#4,#5,#6);#4=CARTESIAN_POINT('MACHINE TOOL COORDINATES',(0.0,0.0,0.0));#5=DIRECTION('MACHINE TOOL AXIS',(0.0,0.0,1.0));#6=DIRECTION('MACHINE TOOL REF DIRECTION',(1.0,0.0,0.0));#7=MECHANICAL_MACHINE_ELEMENT('MACHINE FRAME',#8,(),(#12,#17),(),());#8=AXIS2_PLACEMENT_3D('MACHINE FRAME PLACEMENT',#9,#10,#11);#9=CARTESIAN_POINT('MACHINE FRAME COORDINATES',(0.0,0.0,0.0));#10=DIRECTION('MACHINE FRAME AXIS',(0.0,0.0,1.0));#11=DIRECTION('MACHINE FRAME REF DIRECTION',(1.0,0.0,0.0));#12=MECHANICAL_MACHINE_ELEMENT('SPINDLE HOLDER',#13,(#33,#35,#37),(#22),(),());#13=AXIS2_PLACEMENT_3D('SPINDLE HOLDER PLACEMENT',#14,#15,#16);#14=CARTESIAN_POINT('SPINDLE HOLDER COORDINATES',(0.0,466.0,1215.15));#15=DIRECTION('SPINDLE HOLDER AXIS',(0.0,0.0,1.0));#16=DIRECTION('SPINDLE HOLDER REF DIRECTION',(1.0,0.0,0.0));#17=MECHANICAL_MACHINE_ELEMENT('TABLE HOLDER',#18,(#44),(#39),(),());#18=AXIS2_PLACEMENT_3D('TABLE HOLDER PLACEMENT',#19,#20,#21);#19=CARTESIAN_POINT('TABLE HOLDER COORDINATES',(0.0,353.553,353.553));#20=DIRECTION('TABLE HOLDER AXIS',(0.0,-0.707,0.707));#21=DIRECTION('TABLE HOLDER REF DIRECTION',(1.0,0.0,0.0));#22=MACHINE_SPINDLE('MACHINE SPINDLE',#23,(#53),(#27),(),(),$,$);#23=AXIS2_PLACEMENT_3D('MACHINE SPINDLE PLACEMENT',#24,#25,#26);#24=CARTESIAN_POINT('MACHINE SPINDLE COORDINATES',(0.0,267.5,164.6));#25=DIRECTION('MACHINE SPINDLE AXIS',(0.0,0.0,1.0));#26=DIRECTION('MACHINE SPINDLE REF DIRECTION',(1.0,0.0,0.0));#27=TOOL_LOCATOR('TOOL LOCATOR',#28,(),(),(),(),$,$,#32,$);#28=AXIS2_PLACEMENT_3D('TOOL LOCATOR PLACEMENT',#29,#30,#31);#29=CARTESIAN_POINT('TOOL LOCATOR COORDINATES',(0.0,0.0,0.0));#30=DIRECTION('TOOL LOCATOR AXIS',(0.0,0.0,1.0));#31=DIRECTION('TOOL LOCATOR REF',(1.0,0.0,0.0));#32=TAPERED_SHANK_SOCKET('SK 40');
#33=LINEAR_AXIS('LINEAR X AXIS',#34,$,.T.,.T.,80.0,20.0,0.0010,250.0,250.0);#34=DIRECTION('LINEAR X AXIS DIRECTION',(1.0,0.0,0.0));#35=LINEAR_AXIS('LINEAR Y AXIS',#36,$,.T.,.T.,50.0,20.0,0.0010,420.0,0.0);#36=DIRECTION('LINEAR Y AXIS DIRECTION',(0.0,1.0,0.0));#37=LINEAR_AXIS('LINEAR Z AXIS',#38,$,.T.,.T.,50.0,20.0,0.0010,0.0,380.0);#38=DIRECTION('LINEAR Z AXIS DIRECTION',(0.0,0.0,1.0));#39=RECTANGULAR_TABLE('RECTANGULAR TABLE',#40,(#46),(#48),(),(),(),$,$,$,$);#40=AXIS2_PLACEMENT_3D('RECTANGULAR TABLE PLACEMENT',#41,#42,#43);#41=CARTESIAN_POINT('RECTANGULAR TABLE COORDINATES',(0.0,-310.0,105.0));#42=DIRECTION('RECTANGULAR TABLE AXIS',(0.0,0.707,-0.707));#43=DIRECTION('RECTANGULAR TABLE REF DIRECTION',(1.0,0.0,0.0));#44=ROTARY_SWING('ROTARY AXIS B',#45,$,108.0,0.0,0.0010);#45=DIRECTION('ROTARY AXIS B DIRECTION',(0.0,0.0,1.0));#46=ROTARY_FEED('ROTARY AXIS C',#47,$,33.0,$,0.0010);#47=DIRECTION('ROTARY AXIS C DIRECTION',(0.0,0.0,1.0));#48=CIRCULAR_TABLE('CIRCULAR TABLE',#49,(),(),(),(),(),200.0,$,50.0,30.0);#49=AXIS2_PLACEMENT_3D('CIRCULAR TABLE PLACEMENT',#50,#51,#52);#50=CARTESIAN_POINT('CIRCULAR TABLE COORDINATES',(0.0,0.0,50.0));#51=DIRECTION('CIRCULAR TABLE AXIS',(0.0,0.0,1.0));#52=DIRECTION('CIRCULAR TABLE REF',(1.0,0.0,0.0));#53=ROTARY_DRIVE('ROTARY SPINDLE DRIVE',#54,$,18000.0,$);#54=DIRECTION('ROTARY DRIVE Z DIRECTION',(0.0,0.0,1.0));#55=TOOL_MAGAZINE('TOOL MAGAZINE',#56,(),(),(),(),'NULL',80.0,250.0,32,$,(#60,#64),$);#56=AXIS2_PLACEMENT_3D('TOOL MAGAZINE PLACEMENT',#57,#58,#59);#57=CARTESIAN_POINT('TOOL MAGAZINE COORDINATES',(0.0,0.0,50.0));#58=DIRECTION('TOOL MAGAZINE AXIS',(0.0,0.0,1.0));#59=DIRECTION('TOOL MAGAZINE REF',(1.0,0.0,0.0));#60=AXIS2_PLACEMENT_3D('TOOL MAGAZINE - ACTIVE TOOL CHANGING POSITION 1',#61,#62,#63);#61=CARTESIAN_POINT('TOOL MAGAZINE - ACTIVE TOOL CHANGING POSITION 1',(-515.0,-2.447,922.0));#62=DIRECTION('TOOL MAGAZINE - ACTIVE TOOL CHANGING POSITION 1 DIRECTION',(0.0,0.0,1.0));#63=DIRECTION('TOOL MAGAZINE - ACTIVE TOOL CHANGING POSITION 1 REF',(1.0,0.0,0.0));#64=AXIS2_PLACEMENT_3D('TOOL MAGAZINE - ACTIVE TOOL CHANGING POSITION 2',#65,#66,#67);#65=CARTESIAN_POINT('TOOL MAGAZINE - ACTIVE TOOL CHANGING POSITION 2',(-515.0,-202.447,922.0));#66=DIRECTION('TOOL MAGAZINE - ACTIVE TOOL CHANGING POSITION 2 DIRECTION',(0.0,0.0,1.0));#67=DIRECTION('TOOL MAGAZINE - ACTIVE TOOL CHANGING POSITION 2 REF',(1.0,0.0,0.0));
Advanced
Machining
Processes &
SystemsRepresentation of SKM structures
06/07/2010
13
Advanced
Machining
Processes &
SystemsRepresentation of PKM structures
Advanced
Machining
Processes &
SystemsFixture specific information
Mod
ula
r Fix
ture
ele
men
ts
Cus
tom
ised
fixt
ure
elem
ent
s
Fixture setup
Machine setup
06/07/2010
14
Advanced
Machining
Processes &
SystemsCNC Machining System Representation
ISO-10303-21;HEADER;FILE_DESCRIPTION(('CNC MACHINING SYSTEM EXAMPLE 1','BRIDGEPORT 3 AXIS VMC '),'1');FILE_NAME('CNC_SYS1.STP','2008-01-09',('PARAG VICHARE','AYDIN NASSEHI','STEPHEN NEWMAN'),('UNIVERSITY OF BATH'),$,'ISO14649',$);FILE_SCHEMA(('MACHINING_SCHEMA','TURNING_SCHEMA','MILLING_SCHEMA','MILLING_TOOL_SCHEMA','TURNING_MACHINE_TOOL_SCHEMA','MACHINE_TOOL_RESOURCE_SCHEMA'));ENDSEC;
HEADER
#1=LOGICAL_MANUFACTURING_UNIT('BRIDGEPORT MACHINING CENTRE',(),(#10),(#20,#30));ENDSEC;END-ISO-10303-21;
LOGICAL MANUFACTURING UNIT
DATA;#10=MACHINE_TOOL('BRIDGEPORT 3 AXIS VMC','BRIDGEPORT','PRODUCTION LAB',#11,(#100),());#11=AXIS2_PLACEMENT_3D('MACHINE REFERENCE POINT',#12,#13,#14);#12=CARTESIAN_POINT('MACHINE REFERENCE POINT',(0.000,1000.000,0.000));#13=DIRECTION('AXIS',(0.000,0.000,1.000));#14=DIRECTION('REF_DIRECTION',(1.000,0.000,0.000));#100=GENERAL_MACHINE_ELEMENT('MACHINE FRAME',#11,(),(#200,#300),(),());#200=GENERAL_MACHINE_ELEMENT('SPINDLE HOLDER',#201,(#210),(#2000),(),());#201=AXIS2_PLACEMENT_3D('SPINDLE HOLDER REFERENCE POINT',#202,#203,#204);#202=CARTESIAN_POINT('SPINDLE HOLDER REFERENCE POINT',(1344.200,-1028.000,1744.940));#203=DIRECTION('AXIS',(0.000,0.000,1.000));#204=DIRECTION('REF_DIRECTION',(1.000,0.000,0.000));
MACHINE TOOL
#210=LINEAR_AXIS('LINEAR Z AXIS',#211,$,.T.,.T.,43.000,25.000,0,-610);#211=DIRECTION('Z AXIS',(0.000,0.000,1.000));#2000=MACHINE_SPINDLE('MACHINE SPINDLE',#2001,(#2010),(#2024),(),(),#2020);#2001=AXIS2_PLACEMENT_3D('MACHINE SPINDLE REFERENCE POINT',#2002,#2003,#2004);#2002=CARTESIAN_POINT('MACHINE SPINDLE REFERENCE POINT',(0.000,284.000,-140.940));#2003=DIRECTION('AXIS',(0.000,0.000,1.000));#2004=DIRECTION('REF_DIRECTION',(1.000,0.000,0.000));#2010=ROTARY_DRIVE('ROTARY Z AXIS',#2011,$,8000.000,$);#2011=DIRECTION('ROTARY Z AXIS',(0.000,0.000,1.000));
AXES
#2024=TAPERED_SHANK_SOCKET('MACHINE SPINDLE SOCKET',#2025,(),(),(),(),'BT 40');#2025=AXIS2_PLACEMENT_3D('SPINDLE SOCKET REFERENCE POINT',#2026,#2027,#2028);..#20=AUXILIARY_DEVICE('TOOL CHANGING ARM UNIT',#21,(),(#400),(),(),'BRIDGEPORT');#21=AXIS2_PLACEMENT_3D('MACHINE REFERENCE POINT',#22,#23,#24);.#4000=TOOL_CHANGING_ARM('TOOL CHANGING ARM',#4001,(#4010,#4060),(),(),(),'Bridgeport',(#4041),(#4051),0.500);#4001=AXIS2_PLACEMENT_3D('TOOL CHANGING ARM REFERENCE POINT',#4002,#4003,#4004);..#4020=TOOL_CLAMPING_FINGER('TOOL CLAMPING FINGER 1',#4021,(),(),(),(),'BT 40');#4021=AXIS2_PLACEMENT_3D('TOOL CLAMPING FINGER 1 REFERENCE POINT',#4022,#4023,#4024);
AUXILIARY DEVICES
Advanced
Machining
Processes &
Systems
CAD/CAM
N10G0 X80 Z15N15G1 X0 Z0 F0.3 S200 M03N20 X50N25 Z-15N30 X55 Z-20…..
Post-Processor
Unidirecional
Data Flow
Vendor specific
ISO6983 Code
Dialect
#31=WORKPLAN('MAIN WORKPLAN',(#32,#33,#34,#35),$,#36);#32=MACHINING_WORKINGSTEP('WS ROUGH CONE 1',#68,#11,#22);#33=MACHINING_WORKINGSTEP('WS FINISH CONE 1',#68,#11,#23);#34=MACHINING_WORKINGSTEP('WS ROUGH END FACE 1',#68,#10,#20);
STEP-NC(ISO 14649)
Bi-direcional
Data Flow
Use of Features
and Neutral
Formal language
ConventionalNC Controller
STEP–NC Compliant
Controller
Design/Planning Level
Shop-floor Level
CAD/CAM
N10G0 X80 Z15N15G1 X0 Z0 F0.3 S200 M03N20 X50N25 Z-15N30 X55 Z-20…..
N10G0 X80 Z15N15G1 X0 Z0 F0.3 S200 M03N20 X50N25 Z-15N30 X55 Z-20…..
Post-Processor
Unidirecional
Data Flow
Vendor specific
ISO6983 Code
Dialect
#31=WORKPLAN('MAIN WORKPLAN',(#32,#33,#34,#35),$,#36);#32=MACHINING_WORKINGSTEP('WS ROUGH CONE 1',#68,#11,#22);#33=MACHINING_WORKINGSTEP('WS FINISH CONE 1',#68,#11,#23);#34=MACHINING_WORKINGSTEP('WS ROUGH END FACE 1',#68,#10,#20);
STEP-NC(ISO 14649)
Bi-direcional
Data Flow
Use of Features
and Neutral
Formal language
ConventionalNC Controller
STEP–NC Compliant
Controller
Design/Planning Level
Shop-floor Level
Differences between the data flow using of ISO 6983 in NC programming and with the use of ISO 14649.
06/07/2010
15
Advanced
Machining
Processes &
Systems
tool_magazine
its_max_allowed_tool_diameter
its_max_allowed_tool_length
axis2_placement_
3d
active_tool_changing_position
bounding_geometryits_tool_conveyer_trajectory
length_measure
time_measuremin_tool_change_time
its_tool_capacity INTEGER
Unified Machine Tool Resource Model
Advanced
Machining
Processes &
SystemsUnified Machine Tool Resource Model
VDI live tooling
Shank type clamping
Clamping with threaded holes