#5 2012

CONTENTS №5

Discussing a Subject…

New computer numerical control solutions

Grigoriev S.N.  The development of domestic machine tool building - the backbone of engineering industry modernization

The paper analyzes the state of the art of domestic machine tool industry as a framework of the state's technological independence. Export and import of machine tools are examined, and the causes of import prevalence over export are identified. The paper presents the basic solutions in the field of industrial automation implemented in the innovative projects of STANKIN Moscow State Technical University within the program of Russian machine tool building development program.

Keywords: mechanical engineering, machine tool building, technological re-equipment, modernization, industrial automation, numerical control.

Martinov G.M., Lyubimov A.B., Bondarenko A.I., Sorokoumov A.E., Kovalev I.A.  An approach to building a multiprotocol CNC system

The paper examines the multiprotocol realization of computer numerical control system (CNC) for heterogeneous manufacturing equipment and substantiates the choice of the base set of industrial CNC protocols. The multiprotocol CNC system's kernel architecture is proposed; CNC applications for turning and milling-engraving machines are discussed.

Keywords: industrial protocol, servo drive, real-time system, numerical control kernel, motion control, CANbus, Memobus, SERCOS, EtherCAT.

Bretschneider J.  Machine tool solutions based on an innovative CNC automation system

The paper presents Sinumerik CNC solutions from Siemens ns such as Volumetric Compensation System for machine accuracy improvement, Advanced Position Control for increased performance, Sinumerik Ctrl-Energy for machine's energy conservation, and Sinumerik MDynamics for perfect milling.

Keywords: CNC, machine, virtual model, accuracy, cutting dynamics, efficiency, energy consumption.

Positioning accuracy at 5-axis cutting

Algorithms ensuring positioning accuracy of machine's driven element at 5-axis cutting are developed by all major CNC vendors worldwide. The paper discusses The approaches exemplified in Heidenhain's CNC systems. Key application areas of 5-axis cutting are overviewed.

Keywords: CNC, 5-axis cutting, accuracy, compensating moves, positioning, angular movement sensor, control loop.

Bruhl J., Nothnagel J.  IndraMotion MTX computer numerical control system

The paper presents the functionalities and features of the new release of IndraMotion MTX CNC system, such as multi-core processors, energy consumption monitoring, smart standby mode, optimized motion control. IndraWorks development environment from Rexroth offers fast and transparent access to all functions and system data of automation components. The new IndraMotion MTX micro trainer software simulates IndraMotion MTX CNC system on a PC.

Keywords: scalability, CNC, high-speed cutting, multi-core processor, energy consumption monitoring, motion control optimization, simulation.

Sandhofner M.  Integrated processing and movement control

The paper presents the capabilities of CNC software suite from B&R, which provides machine-tool builders with hardware drivers and visualization tools. The runtime environment enabling the simulation of machine's operation or a CNC's/PLC's code is a part of the standard CNC software.

Keywords: CNC, PLC, real-time, simulation, mechanical engineering.

Sandhofner M.  Integrated processing and movement control

The paper presents the capabilities of CNC software suite from B&R, which provides machine-tool builders with hardware drivers and visualization tools. The runtime environment enabling the simulation of machine's operation or a CNC's/PLC's code is a part of the standard CNC software.

Keywords: CNC, PLC, real-time, simulation, mechanical engineering.

Burkov A.P., Krasilnikiyants E.V., Smirnov A.A., Buldukyan G.A., Naumov R.Yu.  State-of-the-art induction motor drive for CNC machines

The paper presents the development results of an induction motor drive for CNC machines. A set of quality tests for the induction motor drive with feedforward connections subject to setup signal's derivatives is offered. Test results of the prototype drive meeting the requirements to such devices intended for CNC systems are included.

Keywords: machine, electric drive, CNC, requirements, prototype model, regulatory controller, response speed, accuracy, dynamic error.

Tikhonov A.O., Likhanov P.S.  High-speed cutting on CNC machines

The factors resulting in the trajectory error and the ways to mitigate their effect during high-speed CNC-aided cutting are discussed. The effects of exchange protocols, real-time characteristics of CNC systems, various control algorithms and drives on the quality of CNC-aided cutting are examined.

Keywords: CNC system, high-speed cutting, real time, motion generator's frequency, servo drive, servo cycle, asynchronous control, jittering.

Kovalenko A.V.  Automation of electronic beam parameters' control with a case study of a straight-channel electron-beam triode gun

The paper discusses the design of a servoloop for controlling an electronic beam with the help of a CNC system. The features of operating parameters' interrelations for the most popular electron-beam gun types (with direct and compulsory cathode heating) are analyzed. Control algorithms for power sources intended for such gun types are included.

Keywords: CNC, control system, welding, electron-beam gun.

Martinova L.I., Kozak N.V., Nezhmetdinov R.A., Pushkov R.L., Obukhov A.I.  Application aspects of the domestic AxiOMA Control multi-functional CNC system

The necessity of developing a domestic multi-functional high-end class CNC-system with performance meeting world standards is substantiated. The mechanism of CNC systems arrangement for specific technological tasks is shown. The practice of control system's customization to water jet complex, laser controls, lathe and milling machines is demonstrated.

Keywords: multifunctional CNC system, control system's kernel, control system's architecture, cycle logic machine control, master/slave control, laser processing control.

Vorobyov A.G., Kondakov L.A., Shchukin A.A.  The design of control systems for metal-cutting machine tools based on motion controllers

The paper classifies controllers according to motion control types. Key variants of cutting-machine's control system design using motion controllers are discussed. Applications of motion controllers in domestic machine tool building are overviewed.

Keywords: motion controllers, CNC systems, position controllers, mini and micro PLC.

Kholodny O.V.  KISS industrial rack servers from Kontron: less noise, more functionalities

In embedded system market and industrial automation, server solutions based on Wintel platform should ensure longer lifecycle along with all other traditional merits. KISS (Kontron Industrial Silent Server) in tended for standard 19-inch server racks comply with these requirements.

Keywords: embedded systems, service life, mean-time-between-failures, reliability, industrial servers, vibration stability, shock resistance, noise emission.

Kulaev A.N.  Field test of Ha-VIS Fast Track Switch

Ethernet-based network solutions are used in all industrial processes from office environment to process operation. However, Ethernet technologies are still limited in real-time applications. In this context, HARTING has developed a series of articles based on Ha-VIS Fast Track Switch technology featuring minimum response time and reducing the effects of Ethernet protocol's drawbacks.

Keywords: Ethernet technologies, response time, real time, priority.

Zolotarev S.V., Kudryavtseva M.E.  New development lines of ISaGRAF environment: towards the support of safety systems

The paper discusses some aspects of safety systems design with the help of ISaGRAF controller programming technology. Safety systems are understood according to IEC 61508 standard. The focus is made on the approach to PLC safety accepted in the specification of safe functional blocks of PLCOpen and implemented in ISaGRAF environment.

Keywords: safety, controller programming, functional blocks, PLC data type, certification.

Salikhov Z.G., Gazimov R.T., Demin A.V.  Automatic control system structure for roller cooling of hot metal

The paper discusses a design concept of an automatic control system for hot ingots, plates, and large flat bars cooling. The system's purpose is to improve the macrostructure of uninterruptedly-casted ingot, rolled plate or flat bar. The improvement is attained by applying a breakthrough heat pick-up technique realized by passing a turbulent cooling agent flow through hollow rollers contacting with the steel ingot, plate, or bar. The authors have examined the primary mechanisms of the cooling processes under cooling agent's flow changes. In view of the identified features, the paper offers a new self-tuning control system structure. It suggests to employ an observer-identifier with a simulation model that enables the continuous monitoring of the current macrostructure formation processes as well as significant extension of the control range of ingot or plate cooling.

Keywords: control, metal crystallization process, automatic control system, roller cooling of ingot, simulation model, identification.

Events

Modernization. Innovation. Advanced automation technologies

The paper offers an interview with Ms. O.V. Afanasieva, General Manager of Expotronika CJSC about the modernization and innovations of industrial automation, the state of the art in this field, and the preparations to PTA-2012 International Specialized Exhibition of advanced automation technologies, which will take place in autumn 2012 at the Moscow Expocenter premises.

Keywords: modernization, innovation, industrial automation, energy efficiency, energy conservation, investments.