#5 2017

CONTENTS №5

Discussing a Topic…

Digital machine-building

Grigoriev S.N., Martinov G.M., Chadeev V.M., Aristova N.I.  Digital machine-building: development trends and prospects

The development of Industry 4.0 is an evolutionary process stemming from such sources as Internet technologies, virtual manufacturers, intelligent devices, self-replicating finite-state machines, etc. The authors overview the papers of this Journal’s issue, which mainly address the implementation of digital manufacturing concept.

Keywords: Internet, virtual manufacturers, intelligent devices, self-replication, digital manufacturing.

Nezhmetdinov R.A., Nikishechkin P.A., Kovalyov I.A., Chervonnova N.Yu.  An approach to the design of logical control systems for process equipment meeting the Industry 4.0 concept

The paper examines up-to-date development trends of modern industrial plants and analyzes the correspondence of existing design concepts of logical control systems to Industry 4.0 philosophy. It describes the design concepts of a logical control system and offers a model of its architecture enabling the integration with machine-building factories. A case study of machinery’s and robotic equipment’s operation synchronization based on the approach proposed is included. The capabilities of diagnostic data communication to upper control levels are discussed.

Keywords: logical control, controller, numerical control, PLC, process, Industry 4.0, smart manufacturing.

Koriath H.-J., Hoffmann M., Blau P.  Industry 4.0 digital technologies for machine-tools and industrial equipment

The fourth industrial revolution Industry 4.0 is based on the application of digital processing technologies for large data volumes. With examples of European research projects the paper discusses innovative approaches to industrial equipment maintenance and condition monitoring as well as automated product quality inspection.

Keywords: industrial equipment, sensors, digital technologies, automated quality inspection.

Local production and advanced technologies for Russia

On the Metal Processing 2017 exhibition, DMG MORI manufacturing company has demonstrated the operation of the most popular equipment types such as machine-tool models of DMU 50 ecoline, DMC 635 V ecoline, CTX 310 ecoline integrated with YASKAWA robot, and DMU 50 for 5-axis machining, all manufactured at the factory in Ulyanovsk, Russia.

Keywords: metal processing, digital manufacturing, localization, Industry 4.0.

Chadeev V.M., Aristova N.I.  An invariant algorithm for automation efficiency evaluation

The influence of the automation of robot’s components manufacturing on the robot’s work hour cost is investigated. The relationship between robot’s price decrease and the automation of its components manufacturing is analyzed. A case where robots are used to improve the automation level is discussed.

Keywords: automation in industry, robot, automaton, robot's cost, robot’s life, production step, invariant automation theory.

Martinov G.M., Obukhov A.I., Pushkov R.L., Evastafieva S.V.  Implementation and application of multi-axis machining functions in AxiOMA Control NC system

The paper reviews the solutions of AxiOMA Control NC system enabling the development of effective kinematically independent control programs for multi-axis machining. It describes the tuning features of popular five-axis kinematics and discusses the specificity of path selection algorithm during the implementation of the motion preset in the NC system.

Keywords: NC system, multi-axis machining, interpolation, kinematics, feed control.

Kovalenko A.V., Oreshkin O.M.  Estimating the orthotropy of surface roughness during laser glazing

The application of a system making it possible to measure surface roughness during laser glazing is discussed. The opportunity of estimating the roughness in two orthogonally related directions is demonstrated based on the analysis of system operation data.

Keywords: laser glazing, roughness, non-contact roughness assessment, scatterometry, orthotropy.

Dimitryuk S.O.  High-speed surface treatment trajectories in NC systems

High-speed surface treatment is a promising development line in mechanical engineering. NC systems featuring high-speed data processing and large memory content are needed to implement this technology. Therefore, the application of high-speed treatment on the obsolete equipment can be limited. To eliminate this obstacle, the paper offers an approach allowing to “unload” the cutting tool.

Keywords: high-speed treatment, NC systems, trajectory, tool loading.

Grigoriev S.N., Martinov G.M., Sokolov S.V., Kozak N.V.  Development and application of a custom toolkit for diagnostics and tuning of servo drives in heterogeneous equipment control systems

The paper presents an approach to the development of a toolkit for servo drive diagnosis and tuning. The toolkit enables the acquisition and analysis of data from heterogeneous equipment with various communication protocols. With the example of a milling machine with the drives controlled by SERCOS III and EtherCAT protocols, the paper discusses the toolkit’s application features. The results of a test part machining are included.

Keywords: drive diagnostics, motion parameters measurement, NC system tuning, data image model, multiprotocol system, control in heterogeneous environment.

Martinova L.I., Stas' A.V., Grigoriev A.S., Babin M.S.  Automation of operational inspection on numerically controlled milling machines

The objectives of automated inspection on numerically controlled machine tools are determined. The structure of dimensional couplings formation during the transition from machine tool’s coordinate system to the part's one is revealed. Mathematical models and cycle algorithms for automatic checking of billet position on the machine tool are presented. The application of measuring cycle results in a control program is demonstrated.

Keywords: NC system, operational inspection, measuring cycle, billet position checking, part geometrics.

Sladkov D.V.  Safe control technologies for machine tools

Safety issues in machine tools and commercial plants gain increasing importance. Most of innovations address human operator’s safety but the protection of material assets and environment should be also considered. The aim of functional safety is the minimization and elimination of risks associated either with plant’s design operation or with its failure conditions. Functional safety can be implemented through redundant hard-/software tools. To sensors mounted on an axis is just an example. It often happens, however, that a solution with a single position sensor is desirable from economic reasons. HEIDENHAIN offers such solution in the form of a position sensor with functional safety and a serial digital interface.

Keywords: functional safety, redundancy, position sensor, serial digital interface, NC system.

Inductive sensors: the sensors working with full stretch

The paper describes the features and performance attributes of IMC/IQC Series smart sensors equipped with IO-link 1.1 industrial communication interface.

Keywords: inductive sensors, smart sensors, communication interface.

Yuriev A.I.  AksIM^TM encoders help Universal Robots in intellectualization of operations

Using collaborative robots is a noticeable trend in present-day industrial automation. The paper describes the robots with embedded AksIM^TM rotary absolute encoders from Universal Robots.

Keywords: industrial automation, collaborative robots, rotary absolute encoders.

Baryshnikov A.V., Svetlov D.O., Sonnykh M.V.  System solutions from Bosch Rexroth for the automation of complete-cycle bearing pin preprocessing line

The paper shows how Bosch Rexroth’s fine mechanics solutions, drive technologies, and digital NC systems enable cost-effective integrated automation of hi-tech complex machining process for precision components of internal-combustion engines.

Keywords: automated processing line, NC system, automation of vehicle components manufacturing, part cutting, internal-combustion engine.

Chernyakov D.Yu.  Mapp Motion: fast and easy implementation of motion control function

The paper presents mapp Motion software toolkit from B&R, which can be used in motion control programming. B&R mapp technology is a part of Industry 4.0 concept.

Keywords: motion control, programming, drive systems, Industry 4.0.

Rodygin N.D., Lezhnin D.V.  Application of GE Proficy Scheduler in the development of flexible industrial solutions

With a case study of a machine-building cell, the paper discusses the key functions of Proficy Scheduler system for automatic generation of flexible production schedules.

Keywords: flexible production schedules, machine-building, design, effectiveness, bottlenecks.

Shilov V.A.  Implementation of flexible production module based on FEELER turning lathes and TOPTEК gantry robot

The paper reviews the structure of a flexible production module comprised of NC-controlled FEELER turning lathe, TOPTEК gantry robot with a controller, and workpiece and part storage. It describes its operation algorithm in large-batch manufacturing of sleeve-type parts. Solution’s merits and drawbacks are discussed.

Keywords: flexible production module, turning lathe, NC, gantry robot, algorithm, large-batch part manufacturing.

Tyurin D.N., Chekavinskaya Ya.S.  The experience of Ivanovo engineering plant in part machining cost saving

The paper offers a solution enabling milling machines modernization and their equipping with a real-time control system alternative to NC. The control system’s capabilities and components are described. Its application reduces significantly the machining cost.

Keywords: real-time control system, NC, lean production, production cost.

Chistyakova T.B., Romanov N.V., Fedin A.K.  Hard-/software system for electrochemical machining of metal and alloy articles

A lifecycle support system for electrochemical machining is offered. Relationships for calculating key output values of EDM machining process are presented.

Keywords: lifecycle support systems, electrochemical machining, mathematical model.

Bakhaev D.V.  Standardized integration of robots with NC systems

The paper discusses Easy Connect, RMR Handling, and RMR Machining technologies enabling robots connection with SINUMERIK NC system. It analyzes solutions’ merits and drawbacks and lists the challenges to be surmounted in each case.

Keywords: NC system, robot, PLC, integration, safety system, programming.

Nikolaev O.A., Tretyakov I.V., Shmelyov D.V., Shobanov L.N.  Machine time losses and rational monitoring of NC machines

Machine time losses at production planning and organization, tools and equipment selection, and preproduction phases at the engineering plant are identified as well as their causes related with personnel activities. Practical cases are discussed. Time losses can be eliminated owing to a machine tool monitoring system along with the integrated site automation.

Keywords: machine time losses, monitoring system, NC machines.