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Cellular Collaboration: You want industry leverage? A dozen high-profile suppliers have worked together to create an advanced turning cell for the automated production of aluminum crankshafts for engines. But wait . . . it does aerospace, medical, automotive and construction operations, too. Check this out.
The LT-200MY turning center is an opposed twin-spindle turning center in the 6 in chuck class, which does just that. Its multi-function twin spindle integrates equal mill/drill functions on both turrets. 24 tool stations are available for either mill or lathe functions. Any tool from either turret working on either spindle (milling or lathe) combines with automatic part transfer between spindles to greatly diminish part cycle time.
The turning cell uses THINCŪ (THe Intelligent Numeric Control), a control that evolves with technology and is not frozen in time like other machine controls once they hit the factory floor. All aspects of the machine (motion, PLC, and Windows applications) are completely controlled by the motherboard, allowing the software to be a fluid platform since the off-the-shelf industrially-hardened motherboard can be upgraded by swapping a single board.
In the cell, ADMAC Parts software combines feature-driven CAM and conversational part programming, virtual system checks and project management functions for the generation of 100 percent error-free design code and the production of accurate parts the first time, every time. Operators can program a machine from the cell on the shop floor or from their computer in an office. The 3D Virtual Monitor Function offers advanced program verification and crash detection through empirical confirmation of the entire manufacturing process as it will occur on the machine. With 3D Virtual Monitor, the programmer can optimize tooling paths, qualify tool lengths and holder types, check and confirm synchronization codes during simultaneous processes, and catch any errors before they create scrap on the machine.
This LR-Mate 200iC six-axis robot is integrated with the production cell and features a standard R-30iA Mate controller unit with teach pendant integrated on a fabricated base with slide-way mounting. Its dual end-of-arm tooling uses one set of part contact tooling for one part number (13 lb total end-of-arm capacity including parts and tooling).
The ToolBossŪ in the cell is an unmanned drawer-based crib/inventory management system for dispensing and replenishing metalcutting tools and supplies at point-of-use.
A Zoller pre-setter and a Captain L370 with the THINC-OSP control combine in the cell to create a tool data management center that eliminates the redundancy of what an operator or engineer needs to manage tool data as it moves through the system along with the tools.
The Partners in THINC have created a crank shaft production cell that uses an LT-200MY turning center with THINC-OSP control from Okuma America Corporation and Abso scales for the automated production of aluminum crank shafts.
The system components provided by collaboration partners working in this cell include a Fanuc LR-Mate 200iC robot integrated by Gosiger Automation, a Turbo Quick Load Servo 65 barfeeder from LNS America Inc., a Marposs Quick SPC touchsetter, a Zoller toolsetter, tooling from Sandvik Coromant, TMAC-7 tool monitoring and AutoComp (for quick SPC) software from Caron Engineering, Schunk Chucks, Kennametal ToolBoss and ISCAR Matrix interfaces/tool management systems, and Renishaw inspection probes.
In true lean manufacturing tradition, this multi-function cell decreases lead times by combining machining operations. Its application opens up possibilities for aerospace,medical, automotive and construction.
The turning center used here is all about process flexibility, high feature utility, and completing the greatest amount of primary and secondary machining possible in one compact platform. The LT-200MY is an opposed twin-spindle turning center in the 6 in chuck class, which does just that.
Its multi-function twin spindle integrates equal mill/drill functions on both turrets. 24 tool stations are available for either mill or lathe functions. Any tool from either turret working on either spindle (milling or lathe) combines with automatic part transfer between spindles to greatly diminish part cycle time.
The left and right spindles run at 4,500 rpm, while the milling spindle (for the U and L axes) runs at 6,000 rpm. The M and S through C axes have .001 positioning capability. The work envelope uses a shower coolant format.
Turret indexing accuracy is maintained by a large crown gear in the turret coupling with roughly 6,000 lb of clamping force. A robust spindle design allows the flexibility of feeds and speeds needed to cut work pieces of a variety of materials and yields excellent surface finish and impressive metal removal rates. The 480 mm span across large ways provides optimum support for the cross-slide and headstock carriages. Off-center milling capabilities now become possible with 3.62 in of Y-axis stroke. Simple direct program commands and fixed cycles make it easy.
HOW DOES YOUR CONTROL AND SOFTWARE STACK UP?
Against This Control?
This turning cell uses THINCŪ (THe Intelligent Numeric Control), a control that evolves with technology and is not frozen in time like other machine controls once they hit the factory floor. All aspects of the machine (motion, PLC, and Windows applications) are completely controlled by the motherboard, allowing the software to be a fluid platform since the off-the-shelf industrially-hardened motherboard can be upgraded by swapping a single board.
This machine control remains current over time, easily accepting new innovations to continually become more intelligent, more effective and more invaluable to your business.
This machine control essentially removes the barrier between the business office and the cell on the factory floor. Ethernet capability makes this control compatible with a wide variety of standard computing technology, expanding the reality of the paperless environment.
Connections involve dual USB ports that can readily incorporate both computer and industrial peripherals to take advantage of the control's PC roots. One USB facilitates internal communication with the machine. The other is open to infinite possibilities - cameras, printers, scanners and more.
There is power in numbers. With up to one GB of RAM, this control is loaded with the memory needed to handle sophisticated machining operations . . . even those that haven't been imagined yet.
Against This Software?
This turning cell also uses ADMAC Parts software and 3D Virtual Monitor for code development and validation. Combined with the 40 GB PC-based THINC-OSP control, the cell operators and programmers have a host of options and capabilities at their fingertips.
ADMAC Parts software combines feature-driven CAM and conversational part programming, virtual system checks and project management functions for the generation of 100 percent error-free design code and the production of accurate parts the first time, every time.
Operators can program a machine from the cell on the shop floor or from their computer in an office through the One-Touch IGF program function. This software covers all of the specific NC language requirements and areas of G- and M-code program language for the THINC-OSP control. An associative application called Program Check Function is a standard feature, allowing any OSP based program - whether generated by a longhand programming source, custom variable-based, or after market CAD/CAM system - to be simulated offline.
One Touch IGF-XL lets the programmer create an optimum machining application that makes the best use of his machine capabilities. One Touch IGF-XL allows programmers to describe part geometry using simple commands such as Face/Long/Groove/Thread, from which the system draws the defined shape. Using this shape description, the system develops the complete part program. One Touch IGF-XL offers an automatic decision function and a list editing function.
Adding the 3D Virtual Monitor Function offers advanced program verification and crash detection through empirical confirmation of the entire manufacturing process as it will occur on the machine. With 3D Virtual Monitor, the programmer can optimize tooling paths, qualify tool lengths and holder types, check and confirm synchronization codes during simultaneous processes, and catch any errors before they create scrap on the machine.
Debugging for errors offline increases productivity, improves cycle time evaluation and decreases machine downtime. Regardless of the shop size or level, programming expertise, or CAD/CAM product loyalty, operators and programmers can run error-free part programs.
Collecting records and operating data about the machine in real time allows the evaluation of performance parameters. MACMAN NET does this and connects up to 99 machines while monitoring machine operating conditions and collecting maintenance information on demand.
MACMAN REMOTE assesses the status of the machines, even when no one is on the shop floor. By using remote control software, all functions can be selected and changed from a remote location, allowing diagnosis of problems off site - even from a Blackberry.
Think It Through
As machines become more complex, involving additional axes, automation and set-up changing, there will be more room for human error to occur. Many applications and development tools concentrate on the cutting portion of a program and forget about additional peripherals and internal components that can collide with a spindle or tool.
There is an Collision Avoidance Software (CAS) system available that incorporates 3D modeling of machines, blanks and tooling, along with the power of the THINC-OSP Control to create a virtual machine. By running the real-time virtual application seconds ahead of the actual cutting, interference can be detected early and the machine safely stopped before a costly collision occurs.