Machine Tool CNC: Motion Control and Monitoring

 

The most important part of the machine is the control part, because the control system determines whether the machine is economical, whether it can be operated ergonomically, and whether it is possible to eliminate possible misoperations. “Machine manufacturers and machine users are increasingly focusing on the long-term economics of automation solutions,” says Uwe Haeberer, head of machine tools at Siemens Automation and Drives (A&D) in Nuremberg. In addition, the eyes of machine manufacturers are mainly focused on low engineering costs, short development time, and no restrictions on their creativity; while machine users pay more attention to operating costs as low as possible, or more generally, value TCO (total cost of ownership) ) Be as low as possible. “In order to meet the growing customer demand for the entire life cycle of a machine, machine builders and their automation partners have developed innovative platform solutions that are modular and many can be scaled. And it's versatile, and then offers the widest possible flexible and Internet-based solution at a customer-acceptable cost," said the Siemens machine tool expert.

The development trend of machine tools is obviously more and more complicated. In Germany, simple machines are used less and less, and five-axis machines are being used more and more. For example, when milling, five-axis machining can complete a complete machining of a part after one clamping. The same is true for lathes, such as the increasing number of milling functions performed by lathes. Even when machining certain parts, the lathe is only milled.

Norbert Armbruster, head of sales for the electronic drive and control business unit at Bosch Rexroth, believes that the computer interface to the standard IT system becomes the standard for machine control. He emphasizes: "Traditional CNC control and computer technology are increasingly integrated. Processing production data with standard office software will also be possible.” Leopold Schenk, General Manager of GE Fanuc Deutschland, also saw another trend: “Control devices will become smaller and smaller, functions will become stronger and stronger, and product cycle times will It is getting shorter and shorter, and the accuracy is getting higher. The main reason is that highly integrated electronic components are used in the control device.” Another general trend is that all components are purchased from a single control, control device, drive device, and possibly Automation devices, such as robots. In this regard, Fanuc and GE Fanuc cover the entire range of automation. In the field of automobile manufacturing, a trend that can be clearly perceived is that there is no need for a PC, and in particular, a hard disk is not used as a large-capacity memory because the hard disk is easily broken as a mechanical device.

Mechanically mechanized integration

The trend of turning electronically from electronics, or the best combination, will inevitably lead to mechatronic solutions. The advantage is obvious: reducing the machine also reduces wear and thus increases reliability. Using a central axis through a separate axis, electronic synchronization and coordination will result in a modular combination. The mechatronics solution provides the best coordination of mechanical and electronic units as an integrated component, such as linear drives or spindles, and provides OEMs with a coordinated system that improves performance and efficiency.

Trends in machine tools also include increasing automation. For example, more and more pallet changers are installed now, so that more workpieces can be automatically processed in sequential order. This highly automated machine can replace two or three simpler machines, so the number of machines required will be reduced. Another trend is that the protection of the equipment will be replaced by a correspondingly stable mechanical structure by the intelligent monitoring and correction mechanism of the electronic control unit.

The modularity of electronic components and software today allows for fully self-contained machine modules by means of decentralized smart devices following the trend of modularization of mechanical parts, which can be designed, programmed and commissioned independently of each other. In this way, even with innovation, there will be no reaction to other modules. For example, the smart device (adjustment component) and the functional components are separated on the frequency converter, so that the power can be divided according to the adjustment situation, and at the same time, it provides a new possibility for intelligent integration. With the new drive series Sinamics, Siemens Automation and Drives assembles its drive units to be the best smart device for the user. In a future-oriented system, the design of the structure must enable the smart device to be arranged where it is needed, that is to say in the central solution of the control device and the decentralized solution of the drive. At the same time, there is no need to make software changes.


The first field experience shows that Indro Motion MTX has considerable potential for shortening production cycles

For many equipment manufacturers, increasing productivity is their highest goal, which is to increase speed and reduce life cycle costs, such as through simulation, preventive maintenance, and integrated integration. The pocket controller solution for the CNC has tapped new potential for the use of standardized hardware. For example, when purchasing a control device, the OEM can be provided with all necessary software packages with engineering tools. With this software package, all types of software from the pocket control device to the PC solution can be uniformly operated. Uwe Haeberer, head of machine tools at Siemens Automation and Drives (A&D) in Nuremberg, believes that there are more opportunities to support users and accompany users throughout the life of the device. He said: "We use our service projects around machine tools to provide support to our customers, from initial conception to development, from equipment operation to machine retrofit. Our support for mechatronics solutions is greatly reduced. The time it takes to get the machine to market, because the machine can be virtualized, simulated and optimized before the first prototype is produced.” With virtual production, you can simulate and optimize the production plan of the part without actually having to produce a bit of chipping. “Using our Motion Control Information System (MCIS) software tool, customers can monitor and optimize their entire process. Internet-based electronic production services (EPS) can monitor and maintain machines, enabling experts to Call important data related to the machine directly from all over the world when asking a question or when you are in trouble.” Haeberer said this when describing the new Siemens product line. First of all, thanks to the worldwide network service, Siemens can provide consulting, spare parts and components to the after-sales service personnel 24 hours a day, in order to quickly troubleshoot in an emergency.

Everything for customer satisfaction

Customer satisfaction is the first priority, and the customer's desire is that their problems can be solved first. To meet this desire, GE Fanuc maintains close contact with its customers and works with customers to find solutions. GE Fanuc offers a wide range of products and tools for this catalog: from simple CNC solutions to high-tech CNC solutions, including electric motors and robotics, the entire automation technology. Provide an extremely reliable system based on the user's budget and automation needs. For example, control devices are provided, which can be operated by an operation panel or not. In order to implement a variety of customized solutions, it is also possible to provide a suitable application power supply.

According to Gardner publications and VDW, sales of machine tools worldwide in 2004 were 36.4 billion euros, of which the total value of machine tools produced in Germany was 7.5 billion euros. As for machine control devices, according to Bosch Rexroth, the world’s total value is 40. About 100 million euros, Europe accounts for 50%, Asia accounts for 35%, and America accounts for 15%. In the next five years, the global growth of the machine tool market is about 3% on average.