Universal Manufacturing Platform (UMP) for Global CNC Machining

Professor Stephen Newman & Dr Aydin Nassehi

Advanced Machining Processes & Systems Research Group (AMPS) Id MRC University of Bath, UK

International Workshop Hanyang University, Sunchon University

Contents

1. The Drivers for Interoperability 2. Current Status of CNC Interoperability 3. Universal Manufacturing Platform (UMP) for CNC
3.1. New Data Models 3.2. Abstraction of Resources 3.3. Integrated Data Communications

4. Challenges in the Implementation of the UMP

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Drivers for Interoperability : Global Manufacturing

Boeing 787 part and sub-assembly manufacturers (Source: Adapted from the Seattle Times)

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Drivers for Interoperability : Global Manufacturing

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Drivers for Interoperability : Legacy Parts

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Drivers for Interoperability : Metalworking SME

Adaptable Manufacturing :
the flexibility and agility of a manufacturing enterprise in handling changes in resources, jobs and strategies

Resource fluidity :
the ability to use different available resources interchangeably with minimum effort

Interoperability :
the ability to seamlessly transfer information from one computer system to another while maintaining the integrity of the information

Metalworking SME Shopfloor

International Workshop Hanyang University, Sunchon University

Contents

1. The Drivers for Interoperability 2. Current Status of CNC Interoperability 3. Universal Manufacturing Platform (UMP) for CNC
3.1. New Data Models 3.2. Abstraction of Resources 3.3. Integrated Data Communications

4. Challenges in the Implementation of the UMP

International Workshop Hanyang University, Sunchon University

Current Method of NC Part Programming

Vendor-specific extensions

ISO 6983, G code

Low level of data: language describes simple movements and switching instructions
% N05 N10 N15 N20 N30 N35 N40 N45 N50 N55 N60 N65 N70 N75 N80 ... G54 G00 Z10.000 G91 G0 Z200 T5 D1 WW G90 M5 G00 X0.000 G00 Z5.000 M08 S3183.000 M03 F1477.000 G00 X60.000 G00 Z5.000 G00 X60.000 G01 Z-0.500

CAD/CAM

Machine-specific part programme generated by postprocessor

Post-Processor ISO 6983 One-way: No feedback of data to planning department

Standard does not support complex geometries (e.g. spline interpolation)

No possibility to change complex NC programmes at shopfloor level NC Machine Tool

No idea of geometry being machined or tolerances !

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Current Status of CNC Interoperability Lack of Interoperability in Conventional CAx Process Chain

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Introducing STEP-NC (ISO 14649) Its a new data model for Intelligent CNCs Part geometry and the process plan is defined Entities are based on STEP AP224 machining features It is a hierarchical data model that is interpreted by the controller, not a linear programming language like ISO 6983 Well structured hierarchy based on a Workplan with Workingsteps Tool paths and tool functions (speeds and feeds etc) do not need to be defined.

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STEP-NC (ISO14649) Physical File Structure

Intelligent Controller
Pocket 1 -plunge -roughing -finishing

Bi-directional Data flow

CAD/CAM HEADER;

DATA; HEADER: FILE_DESCRIPTION ((EXAMPLE OF NC PROGRAMME FOR MILLING: SLOT, #1=WORKPIECE('PART2',#2,0.1,$,$,$,(#200,#201,#202,#203,#204)); ISO 14649 #41=BOTTOM_AND_SIDE_FINISH_MILLING($,$,'FINISH_POCKET1',#51,15.0,$,#97,#61,#70,$, #71=SETUP(SETUP1,#72,#85,(#83,)); #19=PROJECT(''EXECUTE EXAMPLE2''),#20,(#1,) POCKET, HOLE.'),'1'); #2=MATERIAL('LM25','ALUMINIUM',($)); #72=AXIS2_PLACEMENT_3D('SETUP1',#164,#165,#166); $,2.0,1$); #20=WORKPLAN('EXAMPLE2',(#21,#22,#23,#24,#25,#26,#27,#28,#29,#30,),$,#71); FILE_NAME ('tape.STP',$,('ISO14649'),(''),A. Nassehi','University of Bath', 'UK'); #42=DRILLING($,$,'DRILL_HOLE1',#52,1$,$,#98,#62,#70,$,$) #83=WORKPIECE_POSITIONS(#1,#84,$); . #21=MACHINING_WORKINGSTEP('ROUGH_POCKET1',#86,#9,#40); #43=REAMING($,$,'REAM_HOLE1',#53,1$,$,#99,#63,#70,$,$,.F.,$,$) #96=MILLING_CUTTING_TOOL('TAPERED_ENDMILL_20MM',#126,(#106,),(5$),8$,#91,$); FILE_SCHEMA (('MACHINING_SCHEMA','MILLING_SCHEMA')); #9=CLOSED_POCKET('pocket1',#1,(#40,#41,),#74,$,$,$,$,$,(),$,#17,#160) #22=MACHINING_WORKINGSTEP('FINISH_POCKET1',#86,#9,#41); ENDSEC; #10=ROUND_HOLE('hole1',#1,(#42,#43,),#76,#146,$,$,$,$,$,$,#147,$,#18,$,$) #23=MACHINING_WORKINGSTEP('DRILL_HOLE1',#87,#10,#42); #50=CONTOUR_BIDIRECTIONAL(0,0,.F.,0,0,0,0); #125=MATERIAL('EM05C05','HSS/CO',($)); #51=CONTOUR_PARALLEL(4.0,5.0,.T.,CW,$,CONVENTIONAL); #126=TAPERED_ENDMILL(#136,4,null,.F.,$,$); #24=MACHINING_WORKINGSTEP( 'REAM_HOLE1',#87,#10,#43); #52=DRILLING_TYPE_STRATEGY($,$,$,$,$,2.0,2.0,20$); #136=TOOL_DIMENSION(2$,$,$,$,1.5,$,$); #25=MACHINING_WORKINGSTEP('ROUGH_SLOT1',#88,#11,#44); #53=DRILLING_TYPE_STRATEGY(75.0,5$,2.0,5$,8.0,1$,$,20$); #159=TOLERANCED_LENGTH_MEASURE($,null,$,$); #26=MACHINING_WORKINGSTEP('FINISH_SLOT1',#88,#11,#45); Hole1 #160=POLYLINE('pocket1',(#205,#206,#207,#208,#209,#210,#211,)); -pre-drilling #60=MILLING_TECHNOLOGY($,TCP,$,2.0,$,0.3,.F.,.F.,.F.); #200=CARTESIAN_POINT('CLAMPING_POSITION1',($,2$,25.0)); -drilling #217=CARTESIAN_POINT('SLOT3_2',(1$,2$,$)); ENDSEC;

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A Comparison of STEP-NC and G&M Codes

Geometry Operation Op Sequence Geometry Workingsteps Workplan

NC Functions Tool Path Post Processor

CAD/CAM

NC Functions Tool Path (Optional) STEP NC

Uni-Directional Information Flow

G & M code ISO 6983

Tool Path Data

Part Geometry & Manufacturing Data

STEPSTEP-NC ISO 14649

Bi-Directional Information Flow

Geometry NC Functions Functions Workingsteps Workplan

Low Level G & M Data

Tool Path Path

CNC Controller

NC Functions Tool Path STEP STEP-NC -

High Level CAD/CAPP & CAM Data

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STEP-NC View for CNC Interoperability The vision of STEP-NC replacing the postprocessors
CAM Software CNC Machines

1 UNIGRAPHICS STEP, STEP-NC file 2

Bridgeport Machine STEP-NC Controller

Mazak Machine STEP-NC Controller

MasterCAM 3

Key
1

Unigraphics STEP-NC interface MasterCAM STEP-NC interface PowerMill STEP-NC interface Bi-Directional data transfer

DMG Machine STEP-NC Controller

DelCAM PowerMill

Wadkin Machine STEP-NC Controller

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Total Interoperability in a CAx Network From the CAx chain to Interoperable CNC Manufacture

International Workshop Hanyang University, Sunchon University

Contents

1. The Drivers for Interoperability 2. Current Status of CNC Interoperability 3. Universal Manufacturing Platform (UMP) for CNC
3.1. New Data Models 3.2. Abstraction of Resources 3.3. Integrated Data Communications

4. Challenges in the Implementation of the UMP

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A Universal Manufacturing Platform

Information loss in the State of the Art CAx chain

Manufacturing information Retention utilising UMP

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UMP Vision
CNC CAD

CNC CAM

Multiple views of information

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UMP Vision
CNC CAD CAM CNC

An Integrated Datawarehouse
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UMP : Encoding Manufacturing Information

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UMP : Resource Abstraction

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UMP: Connection
CNC with PC based controller Agent Directory System
Abstraction Agent Abstraction Agent Abstraction Agent Abstraction Agent Director Abstraction Agent Agent Carrier Agent

CAM System

Monitor Agent

Monitor Agent

Manufacturing Network

Carrier Agent

Monitor Agent Monitor Agent

Monitor Agent

RS232

STEP-NC compliant CNC

CAD System

Interface PC

Legacy CNC

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Overview of Universal Manufacturing Platform

ENCODING: Manufacturing Datawarehouse a repository for product, resource and process models ABSTRACTION: Manufacturing Knowledgebase and Interfaces maintains integrity of the data in the data warehouse and performs information transformations CONNECTION: Communication Hub allows various interfaces to CAx systems to pass information to the lower layers International Workshop Hanyang University, Sunchon University

CAx interfaces of the Universal Manufacturing Platform

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An example of CNC Interoperability

Siemens 840D CNC & Legacy Fanuc CNC

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UMP CNC Interoperable Demonstration

International Workshop Hanyang University, Sunchon University

Contents

1. The Drivers for Interoperability 2. Current Status of CNC Interoperability 3. Universal Manufacturing Platform (UMP) for CNC
3.1. New Data Models 3.2. Abstraction of Resources 3.3. Integrated Data Communications

4. Challenges in the Implementation of the UMP

International Workshop Hanyang University, Sunchon University

Challenges in the Implementation of UMP

User Advantage but No advantage to Vendors with Interoperability?? Knowledge and information standards Product modelling for manufacturing applications Manufacturing resource modelling Machine specific manufacturing processes simulation Interoperable CNC controllers

Getting NC Operators to TRUST the Platform thus Creating a Culture Shift to enable Interoperable CNC Manufacture
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Conclusions UMP represents a paradigm shift to horizontal platforms in CNC manufacturing (DEC, IBM => Web based) UMP enables the realisation of plug and produce interoperable CNC manufacturing UMP has numerous advantages to users, who generate a market pull for vendors to adopt a new interoperable manufacturing vision UMP will support global interoperable manufacturing network where products are designed anywhere and manufactured anywhere Ubiquitous Manufacturing

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Any Questions ???

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