Turning on the Digital Factory

The Sinumerik 828D mid-range CNC with version 4.8 software of the operating system from Siemens Industry, Inc. (Elk Grove, IL) offers an array of new hardware and software applications for integrated automation that can leverage the full productivity potential of the digital factory in a mid-range control. The Sinumerik 828D is a compact, panel-based CNC available in vertical and horizontal models for highly flexible machine design integration, with resident Advanced Surface and Top Surface technologies that ensure optimum surface finishes with 80-bit nano floating point accuracy. Also standard on the 828D is Shop-Mill and Shop-Turn graphical programming with interactive input help through animated elements. Up to ten axes of motion with two auxiliary axes are possible. Color displays, in sizes 10.4 in or 15.4 in, and the powerful Simatic S7 PLC are also standard.

For the builders of CNC milling, turning and grinding machines, the three steps in version 4.8 move 828D standard models into a highly competitive price point, depending upon the motion control needed. This software makes a range of new functions available to improve the speed, precision and safety of intermediate milling, turning and grinding machine tools, with simplified ISO code programming. Features include facility for compensating unwanted axis nodding movements and protection against machine, tool and workpiece collisions. Nodding compensation (NoCo) is used to compensate for dynamic position deviations in one or more linear machine axes caused by acceleration processes. These position deviations are caused by what is known as mechanical compliance within the machine. NoCo compensates for the dominant position deviation by initiating a corrective movement in the relevant machine axis, enabling improved machining quality simultaneously with higher jerk and acceleration values.

Nodding compensation can be used in conjunction with any technology, such as milling, multi-tasking, tapping, laser machining or water jet machining. NoCo is available in two variants: Eco and Advanced. The Eco variant is designed for dominant acceleration effects in which the compensation axis is combined with one influencing variable. Where there are several influencing variables which require several compensation axes, the Advanced variant is the option of choice. Version 4.8 also features a collision protection: Collision Avoidance Eco and Collision Avoidance Advanced. The Eco version enables machine protection by preventing collisions of the machine body with its own components within the work area. To achieve this effect in real-time, the assemblies that need protection are calculated as simple geometric bodies. This collision monitoring system is available in all three operating modes: JOG, MDA and Automatic. The protected areas can be engineered and visualized as a 3D image at the control interface.

The Advanced variant includes full machine, tool and workpiece protection. Software provided by Sinumerik product partner ModuleWorks GmbH (Aachen, Germany) runs via an interface integrated on an external PC and works together with the Sinumerik CNC in real-time to ensure that the machine, tool and workpiece can be continuously monitored and are dynamically protected during the stock removal process. The workpiece and tool data required is made available to the system during set-up. Collision Avoidance provides safety during operation.

Siemens Industry, Inc., 390 Kent Avenue, Elk Grove Village, IL 60007, 800-879-8079, www.industry.usa.siemens.com.