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Computers in Industry
journal homepage: www.elsevier.com/locate/compind
A R T I C L E I N F O A B S T R A C T
Article history: This paper attempts to propose a virtual operating system applied to operation training of
Received 15 July 2007 manufacturing facility and manufacturing process simulation. The system is based on VRML and
Received in revised form 21 March 2009 browser/server structure, so user only needs to install a free plug-in, and run the package normally via
Accepted 18 May 2009
Microsoft Internet Explorer. Initially this paper studies the system framework, structure models and
Available online 9 July 2009
concept models. Then, a communication approach based on VRML, Java and HTML, which is key to realize
the virtual operating of CNC machines, has been presented. The algorithm of material removed
Keywords:
simulation based on VRML Z-map is also presented in this paper. It has the advantages such as a lower
CNC machine tools
Virtual operating
memory requirement, and a faster computation speed. Finally, in order to validate the feasibility of the
VRML proposed approach, the CNC milling machine has been taken as an illustrative example for the prototype
Training development.
Machining simulation ß 2009 Elsevier B.V. All rights reserved.
* Corresponding author. In the era of the Internet, great changes have taken place in the
E-mail address: hwhe@gdut.edu.cn (H. Hanwu). research of virtual reality. The web, which is one of the most
0166-3615/$ – see front matter ß 2009 Elsevier B.V. All rights reserved.
doi:10.1016/j.compind.2009.05.009
H. Hanwu, W. Yueming / Computers in Industry 60 (2009) 686–697 687
popularly used Internet tools, aims to provide a light-weight, easily verification, machining process simulation and machining error
deployed and system-independent platform for users to search, evaluation, but ignored the virtual operating of CNC machine tools.
browse, retrieve, disseminate and share the information remotely Since virtual operation of CNC machine tools can mimic the
[10,11]. Based on the web, cooperative design, remote teaching, realistic operation of CNC machine, it is very helpful for the
remote training and remote meeting can be easily achieved. For operational training of the company’s staff. Ong and Mannan [26]
these reasons, more and more web-based virtual reality applica- presented a web-based teaching package that provided a dynamic
tions have been developed and they play a more and more and interactive environment for a module on automatic machine
important role in every walk of life. tools, but it still cannot provide a realistic virtual environment for
In the design and manufacturing area, there has been a lot of the student to practice how to operate a CNC machine tool.
research and development and a numbers of software tools have
been developed in this area. Li [12] developed an Internet-based 3. Virtual operation definition
integrated system which enabled designers to design products
collaboratively, supported product preview and evaluation of 3.1. Virtual machine model
design parts using web-based virtual reality technology. Kan et al.
[13] developed an Internet-based virtual reality collaborative A key factor for developing a virtual operating of CNC machine
environment (VRCE) using VNet, Java, and VRML. As it is a platform tools system is how to represent the CNC machine tools precisely
independent, VRCE can be run using inexpensive computer and effectively in the virtual environment. In this paper, we only
hardware and software and is composed of a set of comprehensive focused on the key motion components of CNC machine tools and
functionality with customizability which makes VRCE more ignore the physical status, such as the driving system of CNC
attractive than many existing VCS systems. Choi and Chan [14] machine. The main components of CNC machine are as shown in
presented a virtual prototype system (VP) for rapid product Fig. 1.
development. This VP system incorporates the dexel-based and the Based on the design method described in Ref. [4], those
layer-based fabrication approaches to simulate the powder-based components are defined as the follows (Node, SFVec3f, SFRotation,
and laminated sheet-based RP process, respectively. The virtual MFFloat are the types of data defined in VRML):
prototypes of this system can be transmitted, via the Internet to (1) Bed Definition
customers to facilitate global manufacturing. Object Bed
In the teaching and training area, enormous interest has been
Importing data types Node, SFVec3f
provoked by VR. Brodlie et al. [15] studied a cost-effective web-
based virtual reality system for surgery training using VRML. Wang Attributes
et al. [16] proposed a methodology that enabled people with (A1) Shape: Node
acquired brain injury (ABI) to receive rehabilitation training at (A2) Position: SFVec3f
home and in their own time to relearn activities of daily living
(A3) Color: SFVec3f
(ADL) at a low cost with the help of the Internet and desktop VR
applications. Waller and Foster [17] developed a web-based virtual End
training application in chemistry. Students can learn to operate the
virtual instrument using this application.
There also has been considerable interest in the medical area
employing Internet technology and VR technology. Liang and
O’Grady [18] proposed a methodology using VR technology to
realize the medical collaboration via the Internet. A virtual surgical
telesimulation application for micrographic dermatologic surgery
(MOHS) has been presented by Vélez et al. [19]. This application
can provide educational telesimulation in the dermatologic
surgery technique known as Mohs micrographic surgery.
In the Internet commerce, increasingly more e-commercial
applications are using virtual reality technology [20]. Lee and
Chung [21] developed an intelligent Internet shopping mall by
integrating virtual reality and avatar. This application can offer the
customer a far more interesting way to shop effectively.
Virtual machine tools and control panels model are placed in The specification for the CNC machine tools virtual operating
the two independence VRML windows, respectively. In order to prototype system’s hardware and software environment is
transfer the information between the control panel and the virtual described in the following sections.
machine tools, the communication among the two or more VRML
windows should be setup. 5.1. Environment
As there is no interface to allow a VRML window to communicate
with other VRML windows, we have to make a communication link 5.1.1. Hardware environment
between multi-VRML windows by using JavaApplet as a commu- The hardware runs the supporting system and creates the
nication bridge. computer–human interaction and determines the performance
692 H. Hanwu, W. Yueming / Computers in Industry 60 (2009) 686–697
of the virtual CNC machine (i.e. the precision degree of the Output device: 1700 CRT.
3D model, the calculation capacity of the computer and the Input device: keyboard and mouse.
realities of the computer–human interactive interface). The
hardware programming environment for the prototype system
5.1.2. Software environment
is as follows:
The prototype system is required to be network-oriented,
operating system independent with a high 3D render quality.
Personal computer: CPU, P4 2.0G; Memory, 512 M.
According to these requirements and the development
Graphic card: GeForce FX5200 128 M DDR Memory.
languages used, the software environment we chose is as
follows:
Fig. 12. Main interface of work piece set up or removal. Fig. 13. Main interface of cutting tool addition or removal.
694 H. Hanwu, W. Yueming / Computers in Industry 60 (2009) 686–697
Step 1: Determine how many points on the X, Y direction are (2) HZ1 is the Z axis value of the top plane of worktable in VRML
needed to describe the work piece which can calculate by Eq. (1) coordinates;
9 (3) Hj is the height of the fixture;
L >
>
X Dim ¼ = (4) TL is the length of the tool;
D (1)
W> (5) Hw is the height of work piece;
Y Dim ¼ >
;
D (6) H = HZ0 HZ1;
(7) clearance = H ToolLength Hw Hj, the space between cut-
XDim is the required number of points on the X direction, YDim is ting tool and work piece. The tool intersects the work piece
the required number of points on the Y direction, L is the length of when the value of space is a negative number.
the work piece, W is the width, D is the distance between the two
vertices. Set the current coordinates of cutting tool to be (x, y, z), the
From Eq. (1), the smaller the D is, the more accurate the work relative zero point coordinates on the XY plane to be (x0, y0), the
piece is and consequently more system memory is required. length of work piece to be L, the width of work piece to be W,
Step 2: Set the height of the dispersed points of the work piece discrete accuracy of work piece to be D, the length of cutting tool to
As shown in Fig. 18, set the height of the edge points (the points be LT, the radius of cutting tool to be R. XDim and YDim can be
in the dotted line frame) to 0, the other is the height of work piece, calculated using formula (1).
finishing the separation of the work piece.
(1) HZ0 is the Z value of the chuck jaw, changing when the tool is
move through the Z direction;
Fig. 18. Work piece entity. Fig. 19. Relative position between tool and work piece.
696 H. Hanwu, W. Yueming / Computers in Industry 60 (2009) 686–697
qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
The detailed steps of the algorithm for material removal are as
ði T X Þ2 þ ð j T Y Þ2 < R, the point (i, j) is considered to be the
the follows:
point on the XY plane of cutting tool. And the sequence number of
Step 1: Sequence operation of the center point coordinates of the point in work piece on the XY plane which corresponds to the
cutting tool on the XY plane by Eq. (2). point(i, j) can be calculated by Eq. (3):
9 N ¼ X Dim ðT Y þ jÞ þ T X þ i (3)
jx x0 j >
>
TX ¼ =
D (2) If N XDim YDim, then this point is on the work piece, namely
jy y0 j >
>
TY ¼ ; the projection point on the work piece’s XY plane of the tool; else
D means this point is not on the work piece, so abandon it.
Step 2: Find out the projection point on the work piece’s XY Step 3: Compare the height of the found out projection points.
plane of the tool. Name the array to store the height of the points as WHeight. If
Set all the points of the work piece to be one-dimensional array, WHeighti > (HZ0 LT), the height of the target point is considered
and the subscript of each point to be number. Set all the points of larger than the height of the tool, using Eq. (4) to refresh.
cutting tool on the XY plane to be two-dimensional array, and the WHeight i ¼ HZ0 LT (4)
subscript of X is i, the subscript of Y is j.
First traverse through all the values of i and j. The range of i is The workflow of the algorithm for material removed as shown
from TX to TX, the range of j is from TY to TY. If in Fig. 20.
6. Conclusion
(1) The design of the system’s control panel becomes more flexible.
(2) The reading/writing ability can be achieved by the JavaScript
imbedded in the HTML, overcoming the weakness that
JavaApplet needs to be complied with digital signature and
configure the complex system environment to allow it read/
write the local files.
Acknowledgements
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