COLLABORATION CRANKS IT UP

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 THINC® (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.

CAS generates the actual and exact shape of the materials after a cut to confirm that no interference takes place. Virtual Modeling requires exacting dimensions and definitions, and only the One Source design enables these parameters to ensure accurate cutting.

At the core of machine performance, THINC monitors the machine's vital thermal characteristics and compensates axis movement to the micrometer level, greatly reducing (if not completely eliminating) effects caused by thermal deviation over time.

This operation uses a LR-Mate 200iC six-axis robot integrated with the LT200-MY production cell and features a standard R-30iA Mate controller unit with teach pendant integrated on a fabricated base with slide-way mounting. The dual end-of-arm tooling has one set of part contact tooling for one part number (13 lb total end-of-arm capacity including parts and tooling).

Additional equipment in the cell configuration include two 4 in x 10 in belt type conveyors, Fanuc-integrated 2-D iRVision and required lighting (fixed mount), machine interface panel, perimeter guarding, interlocked door, and robot-side I/O interface to machine tool.

The Turbo Quick Load Servo 65 barfeeder automatically loads short bars up to 51 in length and up to 2-5/8 in diameter. This barfeeder is equipped with an automatic diameter changing system and servo motor technology that uses an electric motor for both the table elevation and pusher control. Its space-saving design takes up to 15 percent less floor space than the Quick Load Servo S3. Operators can maneuver around this machine in ease, with fewer footprints.

The TMAC7 tool monitoring adaptive control application monitors spindle horsepower in real time during the cutting cycle. It dynamically adjusts each axis feedrate to maintain an optimum torque curve for each cut that maximizes tool life and minimizes cycle time. Its interface also monitors coolant flow to insure steady tool load through each pass.

With the data collection features of the TMAC7, the cell can look back at historical data collected during the cutting process to calculate and adjust the relevant variable of the machine, the tools and coolant to increase overall efficiency and reduce tooling and operation costs. Because success depends on a shop's ability to meet the customers' requirements for repeatability, accuracy and speed, the solution becomes a win-win for everyone.

The cell uses the Matrix tool management system to control inventory, streamline purchasing and drive down costs by combining an innovative automated tool dispenser with powerful management software. Access to an item stored in the system's locked bins is electronically controlled by the management software according to pre-defined authorizations.

Drawer configurations can be swapped-in/out. Add-on cabinets connect with a click of a cable and multiple cabinets can be deployed in different locations and networked to run from one common database. This modular system can grow as application needs change through its patented locking system, large touchscreen, plug and play "smart" electronics, ergonomic design, and remote diagnostics. 

The THINC-ready ToolBoss® in the cell is an unmanned drawer-based crib/inventory management system for dispensing and replenishing metalcutting tools and supplies at point-of-use. This system can be configured with a virtually unlimited array of drawer sizes, cupboards, and lockers to accommodate various item and packaging dimensions. It helps establish secure 24-hour inventory control, streamline tooling and supply purchases, and build the foundation for seamless migration to an enterprise-wide tool management system.

This system combines in the cell with a Zoller pre-setter and a Captain L370 with the THINC-OSP control 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.

"Typically all the necessary tool attributes and information reside in three different places: On the machine tool, on the pre-setter and perhaps in the tool crib/inventory manager," explains Joe Alhafi, a senior engineer at Okuma.  "Without an interconnected system, an operator may have entered data such as part or inventory numbers twice – both at the pre-setter and the data inventory manager. Back at the machine tool, all this data would need to be entered into the machine again, probably from handwritten notes on a slip of paper. There had to be a better way to do this."

With this tool data management system everything gets tied together by a job, work, or unique ID number for that job. This information includes tool data, set up information, the part program, the part drawing, or any other information that the factory uses for managing a job.

The part number or the components that will make up a tool assembly can now be set up at either the pre-setter or the inventory manager. "Once it is set, it's set," remarks Alhafi. "The systems are interconnected or networked via wireless or cable, sharing the information no matter which machine you start with in the process."

For example, assume the first tool needs three pieces to make a tool assembly. With information already pre-set, a call over to the ToolBoss? through the THINC-OSP control cues up those exact three pieces from the specific tool requirement list previously set in the system. Simply remove the tool pieces from the ToolBoss?, assemble them and place the completed tool into the pre-setter.

After measurements are taken and stored, a new part number with attributes is now associated with that part number. Simply inventory that new part number into ToolBoss?, which then informs the machine that the transaction has taken place.

The operator then returns to the machine and inserts the tool(s). The computer prompts for insertion completion and/or other required functions. Stored tool data can now be retrieved by the pre-setter, including links, the radius and tool life information. No looking for that slip of paper or potentially keying incorrect data. All the communications happen over Ethernet.

In addition to a paperless process, the job ID number can be input with a bar code or other electronic method to eliminate the process of keying data into the system. With the control's ability to plug and play a USB barcode reader, the scanned barcode opens in an application window where the tool data management process can continue.

Inputting an incorrect tool, machine or offset number could cause a crash or the production or a bad part, but this system eliminates operator redundancy and potential mistakes to save time and money.

As tool life progresses, radiuses change and tool lengths shorten. If a tool is known to cut satisfactorily for five hours, but is only used for 2.5 hours, how does the operator remember this information when he needs it later?  What if several machines have the same tooling – how are the tools or information shared?

The Exact JobBOSS ERP manages data and shares it throughout the factory among standard, non-proprietary databases, accessible for sharing historical, current or planning information – even from a remote location. With all of this data stored, users can predict future tool use and supply chain needs. The system suppliers, Kennametal and Zoller, have their own utilities for tool management that link to supply chain systems capable of issuing purchase orders for upcoming tool needs.