#5 2015

CONTENTS №5

Discussing a Topic…

Industrial automation - a framework for digital manufacturing in machine-building

Introduction

Grogoriev S.N., Martinov G.M.  Methods and tools for multilevel specialist training in the field of digital machine-building

The state of the art in machine-building is analyzed with the focus on integrated informational model development. Key technologies needed for successful implementation of digital manufacturing are identified. The need in integrated approach to specialist training for digital manufacturing is substantiated. Methods and tools for multilevel specialist training in the field of digital machine-building are presented.

Keywords: digital manufacturing, industrial information systems, advanced technologies, specialist training.

Dil'man A.M., Medvedev V.I.  Application of novel Industry 4.0 technologies in machine-building

The paper discusses the application of Industry 4.0 concept in machine-building. Industry 4.0 comprises the elements industrial automation, informatization and simulation.

Keywords: automation, informatization, integration of industry, mathematical modeling, digital model.

Novel hi-tech solutions for Russian metal-working

By presenting novel products and services for a variety of industrial tasks at Metal-Working'15 exhibition DMG MORI has confirmed its innovative capacity.

Martinov G.M., Nikishechkin P.A., Grogoriev A.S., Chervonnova N.Yu.  Organization of interaction between key components of AksiOMA Kontrol NC system for integrating new technologies and solutions

The paper substantiates the need in improving the openness of present-day NC systems to facilitate the integration of new technologies and solutions. It offers an additional compound channel between the system's kernel and terminals enabling the integration and the interaction between additional hardware and software. The ideas are exemplified in two hard-/software solutions integrated in AksiOMA Kontrol NC system.

Keywords: numerical control, openness, components interaction, compound channel, non specific data packet.

Sladkov D.V.  Dynamic Efficiency - a reliable and efficient cutting process

The paper offers HEIDENHAIN's Dynamic Efficiency solution for improving the performance and quality of heavy and rough cutting at NC workstations. It discusses the features, advantages, and operation principles of Dynamic Efficiency functions: active ripple control, adaptive part presentation and trochoidal milling.

Keywords: heavy and rough part cutting, numerical control, active ripple control, adaptive part presentation and trochoidal milling.

Sonnykh M.V., Chernikov G.V.  MTXmicro from Bosch Rexroth: the functionality for automating standard metal-cutting machines

The requirements to NC systems for automating light and medium turning and milling machines are formulated. With the case study of Rexroth MTXmicro NC the paper demonstrates the capabilities of flexible and low-cost topology based on single-block architecture. It discusses some system programming options as well as open tools for integrating custom user functions.

Keywords: NC systems, open architecture, Sercos protocol, low-cost topology, single-block architecture.

Nezhmetdinov R.A., Pushkov R.L., Lyubimov A.B., Martinova L.I., Evstafieva S.V.  Numerical control of milling machining centers with high-speed communication protocols

Quaser 184P vertical turning machining center is analyzed, an import replacement strategy for some of its hi-tech modules and control system is offered. The kinematic diagram of the machining center is examined, key requirements to NC system are formulated, and a network control architecture is offered. An application example of NC system operation in a multiprotocol data exchange mode is offered. Data reading from linear encoders by means of passive I/O modules with memory sharing is illustrated.

Keywords: vertical turning machining center, NC system, network NC architecture, SoftPLC, EtherCAT, SERCOS.

Modernization of gear machinery: machine tools with decoupled kinematics

The paper describes a gear machinery modernization solution based on Mitsubishi Electric's L Series motion controller aimed at building a machine tool with decoupled kinematics. The modernization included the replacement of many mechanical elements with virtual drive connections that resulted in the improvement of machine's performance and the quality of tooth gear cutting up to the quality class 4…6. Operator requirements slackened significantly because specially developed windows on the operator panel enable easy programming of workcenter's operating cycles by simple parameterization of operating modes and dimensions input directly from the blueprint.

Keywords: gear machinery, decoupled kinematics, tooth gear, parameterization.

Martinov G.M., Kozak N.V., Abdullaev R.A., Bogdanov S.V.  Implementing electrics control for planing-and-milling workcenter with the help of AksiOMA Kontrol software controller's tools

The development of an electrics control subsystem for a planing-and-milling workcenter is discussed. The paper examines the implementation features of a data exchange channel between the NC and PLC as well as the control and diagnosis of electrics actuators.

Keywords: machine tool's electrics, NC system, control system structure, software controller, SoftPLC interface, M-commands, diagnosis.

Kovalev I.A., Sokolov S.V., Martinova L.I., Rybnikov S.V.  NC system design for thread-grinding machines

The paper discusses the design of a specialized control system for thread-grinding machines. It offers an original control structure allowing for thread grinding specificity and tougher requirements to equipment precision. An example of software electrics controller programming for processing operator panel's keys is included.

Keywords: NC system, thread grinding, Soft PLC, NC system structure.

HG-92-2000-B6 innovative horizontal grinding machine for turbine compressor's rotor grinding

Features and capabilities of DANOBATGROUP's innovative HG-92-2000-B6 horizontal grinding machine for turbine compressor's rotor grinding are presented.

Keywords: rotors of marine turbines, horizontal grinding machine, grinding disk, precision.

Kovalenko A.V., Oreshkin O.M.  NC application features in electron-beam and laser machining

The processes of electron-beam and laser machining with NC control and their key parameters are discussed. Control features are analyzed, their resemblances and differences are outlined from control viewpoint. A control scheme for the parameters of these processes using a NC system is offered.

Keywords: NC, control system, electron-beam machining, laser machining, actuator, energy carrier.

Metal processing automation with FAGOR NC systems

Preset-day machine-tool building and metal working are tightly related with NC, motion control systems, electric drives, sensors and measuring systems, data communication protocols, manufacturing processes and robot system. The paper presents Fagor's new 8065/60 NC systems and discusses their application in metal working industry.

Keywords: NC systems, programming, integration, speed, processing accuracy.

Davidovich S.B., Poluektov A.L., Chibranov K.A.  Novel approach to robot-building: ready-made FAST software modules reduce engineering time

The variety of products manufactured at automated manufacturing lines is demonstrating steady growth coupled with batch size shrinkage. Flexibility and customization capability are becoming increasingly important. The advantage of robots is that they are not tied to any rigid operation algorithm and can be tuned to address a specific task. Therefore their role in certain industries such as packing is increasing. This poses new challenges in machine-building: robotic centers comprising control systems or kinematic algorithms should allow the integration with existing automation systems. This entails considerable efforts to be spent on coding and/or user interface development.
By enhancing the functionality of its proven FAST system Lenze offers commercial robotic solutions based on ready-made software modules enabling fast application development. This approach reduces significantly the time for interface development, user training, programming, testing and commissioning and therefore the total engineering time.

Keywords: the robotized complexes, ready program modules, reduction of time expenditure.

Ivanov V.P., Lin'kov V.S., Chernetsky R.I.  Task automation for robotic welding centers

The development and implementation of specialized automatic devices for robotic welding centers are considered. The advantages against conventional PLC-based solutions are discussed.

Keywords: import replacement, robotic welding center, distributed microprocessor system, task automation.

Kohnyuk R.V., Leonidov P.V., Oliveira A.R.  Application of advanced robot equipment in stamping manufacturing

The paper presents an advanced solution for stamping production based on ABB's manipulating robots. The application of robot systems enables considerable improvement of production efficiency.

Keywords: manipulating robots, efficiency, stamping production, press, machine vision system.

The experience of nanoCAD platform application in SibVAMI JSC

Pavlov S.A.  T-FLEX NC. Capabilities and advantages

The paper presents standard capabilities and innovative functions of the recent releases of T-FLEX NC system and T-FLEX NC Tracer software included in the T-FLEX software suite.

Keywords: NC, machining simulation, piston milling, high-speed machining, 2D and 3D machining.

Shaverin A.V.  Selecting inductive sensors for machine tool applications

With examples from Omron product the paper discusses the characteristics and features if inductive sensors to be allowed for in machine-tool building. Selection recommendations are included.

Keywords: inductive sensors, machine-tool building, diameter, noise immunity, oil resistance, shock resistance.