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The Sinumerik Success Story

50 Years of Experience and Innovation

1960

1984

2010

Special

mot ionworld

Volume 9, July 2010

The Magazine for CNC Automation

C o n t e n t s m o t i o n w o r l d | J u l y 2 0 1 0

p CNC History

3 Revolution in manufacturingSinumerik milestones

p Interview

6 Market Potential Identifi ed EarlyDevelopments in NC technology

p What Users Say

9 Reliability Is KeyStatements of contented Sinumerik users

p Feature

10 Journey Through Time to SinumerikMuseum Industriekultur, Nuremberg

p Sinumerik Yesterday – and It Still Works Today

11 Reliability for DecadesMetallbaubetrieb Liebing, Germany

13 35 Years and Still RollingStalkwas SC, Poland

14 Oldie with Youthful ÉlanCNC-Technik Leidig, Germany

p Sinumerik Today – and the Story Continues

16 Pioneer in Metal ProcessingGrob-Werke GmbH & Co., Germany

18 Dream Team for Perfect MoldsSinumerik innovations

Dear Readers:

Half a century of Sinumerik technology – that is a milestone well worth celebrating. And we are pleased to be celebrating the event with you. This special edition of motion world traces the 50 years that have passed since Sinumerik emerged as a tech-nology and recounts the generations it has evolved through, starting with the fi rst industry-standard NC and continuing all the way to the very latest member of the family – the Sinumerik 828D. Examples of industry applications let you see for yourself that some of our so-called antiques are by no means “retired” inventory. In addition, we will also be taking you on a short visit to the Industrie kultur Museum in Nuremberg, which has an exhibit documenting past decades of Sinumerik history, as well as presenting our very latest innovations and new features too.

We hope you will enjoy reading this special anniversary edition.

Cordially,

Uwe Häberer

Global Head of Machine Tools at Siemens AG

2 motion world special | July 2010

p CNC History

3 Revolution in manufacturing

motion world special | July 2010 3

Sinumerik milestones p

Revolution in Manufacturing

Half a century ago, Siemens heralded a new era

for manufacturing companies with the world’s

fi rst industrial-standard NC.

1960

World’s fi rst industrial-standard NCThe most important European electrical outfi tter in the fi eld of mechanical engi-neering in the 1950s launches the fi rst industrial-standard NC (numerical control) onto the market with Sinumerik. Sinumerik soon provides impressive proof of its practi-cal aptitude in the form of a turret lathe. Over the course of several generations of systems, the fi rst genuine path PLC (pro-grammable logic controller) is developed based on discrete electronic components. Special versions of the PLC follow for machining technologies such as turning, milling, grinding, and nibbling.

1976

First CNC with microprocessorIn 1973 the Sinumerik 500C, which for the fi rst time is based on a process computer, takes a major step toward CNC (computerized numerical control). The Sinumerik System 7 introduced in 1976 is the fi rst CNC equipped with a microprocessor, and enables DNC (distributed numerical control) networking. The improved version, Sinumerik “System 7 Sprint,”

enables contours to be pro-grammed.

C N C H i s t o r y

machining technologies such as turning, milling, grinding, and nibbling.


1984

Openness of the user interfaceThe System 800 subscribes to the principle of “openness,” which also defi nes all other CNC generations. The fi rst CNCs in this family to come onto the market are the Sinumerik 810T/M and 820T/M with an open human-machine interface (HMI) for adapted user interfaces; they are positioned in the medium performance range. In subsequent years, the modular Sinumerik 850 and 880 (with a varying number of axes) for the upper performance range are added. This family of PLCs is completed for the lower performance range with the compact Sinumerik 805.

1996

World’s fi rst CNC with “Safety Integrated”Under international guidelines and laws, people working with machinery must be protected against dangerous move-ment. To this end, various functions are used to monitor, for example, speed. The use of electronics and software in place of contact-based hardware were the key to this groundbreaking innovation. Through the pioneering work of Siemens, integrated safety technology has now become established as standard practice in mechanical and system engineering.

1979

Openness in the NC coreSiemens launches the Sinumerik 840D in 1994 for the upper performance range as a system standard and equips this PLC with digital drive coupling and an open NC core. This enables the integration of software components into the CNC, which makes the technological expertise of tool manufacturers part of the automation process. Digital coupling of the CNC to the drives fi nally enables further development at various levels. The family of PLCs is extended once again: the Sinumerik 810D is provided for midlevel requirements, while the company covers the lower application area with the 802D.

1994

Multichannel capability of CNCSinumerik System 8 is a multichannel CNC with an integrated PLC that is equally suited to turning and milling as it is to drills and nibbling machines. A CNC distinguished by its compact “shoe box size” design is devel-oped in parallel with the Sinumerik Primo. The launch onto the market of the IBM 5150 (the fi rst IBM PC) in 1981 is followed by Sinumerik System 3, a CNC that is posi-tioned between the System 8 and Primo.

Openness of the user interfaceThe System 800 subscribes to the principle of “openness,” which also defi nes all other CNC generations. The fi rst CNCs in this family to come onto the market are the Sinumerik 810T/M

1996

World’s fi rst CNC with “Safety Integrated”

C N C H i s t o r y


Machine simulation and virtual prototypingIn order to further increase the productiv-ity of machine manufacturers and users, Siemens opens the era of “machine simulation” and “virtual prototyping” at the start of the new millennium. “Mecha-tronics support” assists machine manu-facturers in the development phase. Newly developed simulators enable machining procedures and entire produc-tion processes to be analyzed in virtual mode, while a virtual CNC control allows integration into commercial simulation systems. Other tools for end users include Web-based condition monitoring and cross-manufacturer platforms for online diagnostics, online maintenance, and online service.

Integrated solutionsIn order to optimize the product develop-ment process, CAD/CAM and CNC systems must increasingly merge with one another. Medical technology companies use this integration, for example, in the manufactur-ing of implants. Following initial data cap-ture, the image data created are used for the modeling, design, and programming of the implants. With the CAM software NX, the tools and functions can be tested virtu-ally under production conditions. The CAM language can be translated into NC code for the machine through the use of optimized postprocessors and transferred to Sinumerik via DNC.

2005New PLC generationThe new Sinumerik generation of PLCs, based on the Sinamics S120 drive system, also ensures communication via Industrial Ethernet/Profi net. As a high-end PLC of this generation, the Sinumerik 840D sl for high technology is the fi rst product to come onto the market. It is characterized by extreme openness and fl exibility. It is followed by the Sinumerik 802D sl, a simple and cost-effective variant that is primarily of interest to companies in emerging countries. The family of products is completed by the

Sinumerik 828D, which is positioned between the two and is an ideal PLC for job-shop businesses.

2010

Innovative motion control and operationThe Sinumerik MDynamics technological package for the Sinumerik 840D sl and the Sinumerik 828D integrates the new Advanced Surface motion guidance. It ensures that fi ner surface fi nishes are achieved in an even shorter machining time than was previously possible. The graphical representations for the new standard Sinumerik user interface, Sinumerik Operate, have been enhanced, and an explorer structure has been developed that contains practical functions taken from day-to-day PC use, such as copy and paste. This enables machine operators to make more intuitive use of the new user interface. The basic structure is based on ShopMill/ShopTurn and is particularly user-friendly and offers innovative functions.

2001 2008

New PLC generationThe new Sinumerik generation of PLCs, based on the Sinamics S120 drive system, also ensures communication via Industrial Ethernet/Profi net. As a high-end PLC of this generation, the Sinumerik 840D sl for high technology is the fi rst product to come onto the market. It is characterized by extreme openness and fl exibility. It is followed by


Developments in NC technology p

Market Potential Identifi ed Early

We spoke to Hans B. Kief, pioneer of

NC technology, co-founder of the European

NC-Gesellschaft (NCG), and author of the

CNC Manual, about 50 years of Sinumerik.

I n t e r v i e w


How did you get the idea of publishing the CNC Manual?

Hans B. Kief: In 1974, I and seven other com-pany representatives founded the Deutsche NC- Gesellschaft to promote and distribute NC technol-ogy. At the request of the founder members, I published the NC Manual with the aim of providing a reference work for general consumption. It was self-published at fi rst, before the distribution rights were bought by Hanser-Verlag in 1991. Over 335,000 copies of the CNC Manual have been sold to date. The 27th edition appeared in 2009.

The aim of the book was to provide a general under-standing of the basic knowledge of the subject that was missing in the early days of NC technology. Sellers of machines no longer had to explain the NC principle, and in particular the programming, to every potential customer: they simply gave them the book. A few years later it became a reference work.

When you look back over the last 50 years, where does NC technology stand today, particularly with regard to its beginnings?

Hans B. Kief: The task of NC technology is preci-sion control and position regulation of all axes of NC and CNC machines. That hasn’t changed up to the present day. On the other hand, the technical possibilities provided by today’s CNC machines have increased considerably. The reliability of the sys-tems has also increased enormously, despite an extended range of functions, greater complexity, and reduced size. However, the more favorable price and outstanding programming and simulation systems are decisive factors for the increasing acceptance of CNC machines.

» Compared with other NC/CNC manufacturers, Siemens

recognized at an early stage the potential to achieve

a technological advantage through intensive

development. Within a few years, CNC technology

became the standard for manufacturing companies.«

Mr. Kief, your nickname in the CNC arena is “NC Pope.” Is this title due to the fact that you are the author of the bestseller CNC Manual?

Hans B. Kief: It was important in terms of my tech-nical lectures to constantly keep abreast of progress in the entire NC fi eld in order to put forward a per-suasive argument to both users and manufacturers. As a result of my numerous lectures at specialist events both at home and abroad, I was initially dubbed the “NC itinerant preacher.” The term “NC Pope” – which I still use today as a user name in the CNC arena – was not coined until later.

How did you fi rst get into CNC technology?

Hans B. Kief: At the time I was working for BBC in Mannheim as a test bay engineer when the fi rst numeric PLC arrived one day for testing. Apart from the analog measuring system, nothing worked at fi rst, which meant I was forced to redesign every-thing. Between 1958 and 1964, our team developed three NC generations with relay, transistor, and IC technology, one after another. That’s why I’m still regarded today as one of the “pioneers” of NC tech-nology.

When the company ceased NC development in 1964, I took up a position as head of the sales department for numeric PLCs at Masing & Co., which was taken over shortly afterward by Bosch. Before my retire-ment, I worked all over the world as a specialist in CNC and FFS systems and as a representative for automation issues. In collaboration with the German aircraft and automotive industries we designed the fi rst function blocks for CNCs in order to increase the level of automation and functional safety of CNC machine tools and keep waste to a minimum.

Hans B. Kief


With its CNC control, Sinumerik was one of the first suppliers in this segment. When did you first come into contact with Sinumerik?

Hans B. Kief: It was during a machine tool fair in the early 1970s when I was presenting the CNC of a competitor for whom I was working as sales man-ager. The early CNCs were a long way from today’s technology and very expensive by comparison. The computers worked very slowly and had RAM with very low capacities. Manual entry of the operating software was also a long process. This didn’t change until the introduction of microelectronics with fast processors and adequate memory capacities.

Mr. Kief, what do you consider to be the greatest achievements since Siemens presented its first industrial-standard NC on the European market in 1960?

Hans B. Kief: Compared with other NC/CNC manu-facturers, Siemens recognized at an early stage the potential to achieve a technological advantage through intensive development. This is true not only of the CNC, but also of all peripherals such as drives, programming, simulation environment, safety functions, technical support, and market presence. Within a few years, CNC technology became the standard for manufacturing companies. Close collaboration between machine and PLC manufacturers contributed to this situation in no small measure.

CNC-controlled machines are now mass products and have become established in the medium-sized business sector. How do you see CNC controls and machine tools developing?

Hans B. Kief: We have now reached a high level on the market with sophisticated technology. Yet despite everything, we can expect technologies in the future that will offer completely new possibili-ties. That was the case with laser technology, gener-ative production methods, high-speed cutting, and water-jet cutting. And this trend is also set to con-tinue in automation systems. The only question is which companies will be able to make commercial use of these new possibilities.

Germany is generally regarded as the cradle of the machine tool industry. In recent years, Asia, and China in particular, has become increasingly important in this sector. How do you see this trend?

Hans B. Kief: Not very positively when customers are just sought for available products rather than new markets being gained and completely new solutions developed. A few years ago, German machine tool manufacturers made the same mis-

takes as formerly leading American companies. Japanese customers were the first to snap up orders, and now a similar situation is under way with China and India. Manufacturers still fear competitors at home more than they fear those in Asia. However, it is advisable to counter the threat from overseas competitors by adopting a joint strategy.

CNC controls have developed in recent years at the same breakneck speed as computer technology. Are you satisfied with the results, or are there areas where the manufacturers of control and automation technology should improve?

Hans B. Kief: There are a number of factors that impact whether a company enjoys market success. First of all, sales staff should be very familiar with the market and the competition. Likewise, they should be up to speed with the latest technology. They should also listen to their customers and deter-mine their exact requirements. After all, customer orientation is just as important as product quality. Armed with this knowledge and working in teams alongside motivated developers, it is possible to create accurate solutions with which future chal-lenges can readily be overcome.

For years, the tool making sector has suffered from concerns about the development of new blood. There are ever fewer young people who are inspired by machine tools and CNC technology. What can you draw on from your own wealth of experience to motivate young people to enter this sector?

Hans B. Kief: I think for a person to learn and then practice a technical trade, he or she needs to have both the interest and the right makeup; these factors are just as important as good school qualifi-cations. So as well as passing their final secondary school examinations, those coming into the trade may need an interim educational qualification or a high school qualification. Yet graduates often lack the aptitude and skills that are required for a tech-nical trade. Those who leave school without a qualification can first do an apprenticeship as a skilled tradesman, which then opens up various opportunities for study or advanced training. Unfor-tunately, despite good prospects, many trainees do not complete their apprenticeship. This is where training supervisors at the companies where apprentices are trained have a special responsibility to motivate young people and point out to them their future prospects. You’ve heard the saying “better to get on than get out.” Generally speaking, everybody involved must pull together to resolve the problem of a shortage of new blood in the technical trades!

Mr. Kief, thank you very much for talking to us.

I n t e r v i e w

motion world special | July 2010 9motion world special | July 2010 9

Reliability Is KeyMany customers are using an older generation

of Sinumerik and don’t want to give it up.

Company Schlosserei Ernst Liebing,Germany

Machine Machine type

Trumatic TC20A Nibbling and punching machine

Year of manufacture 1970

PLC Sinumerik 381 C

Company Stalkwas, Polandwww.stalkwas.com.pl


HEID type DFRV6 NCC250 Hydraulic turning machine


PLC Sinumerik 520 K

Company U.C.M. ReŞiţa S.A., Romaniawww.ucmr.ro


Dörries 4000 Vertical boring and turning mill


PLC Sinumerik 520 K

Company CNC-Technik Rolf Leidig, [email protected]


Steinel BZ30 Milling machine for four-sided machining


PLC Sinumerik 550C with punched-tape reader

Company Federal Mogul GmbH, Germanywww.federalmogul.com/en


Weisser Heilbronn Turning machine


PLC Sinumerik 5T

Company Rothe Erde GmbH, Germanywww.rotheerde.com

MachineMachine type

Carnaghi Vertical turning machine


PLC Sinumerik System 7

Machine type

manufacture

» Is service-friendly and just keeps going«

Machine type

manufacture

» It’s been working

accurately and reliably for

40 years. Minor problems

are resolved by Siemens

service engineers in no

time at all «

Machine type» Very stable and reliable, no

problems with the PLC, no system errors «

» Very few problems

over the years, good

service «

Machine type

manufacture

» Reliable and immune to interference during the entire operating time«

» Very few problems

» Robust, service-friendly, few failures – even under extreme temperature conditions. May it continue«


Museum Industriekultur, Nuremberg p

Journey Through Time to Sinumerik

A walk along Museumsstraße in the Museum of

Industrial Culture in Nuremberg ends at a spectacular

exhibition of structural change and automation.

Along the 100-meter stretch of road, replicas of old workshops and machine demonstra-tions, together with historical stores and a

cinema, bring to life 200 years of industry and tech-nology. Throughout this exciting journey through time, a light curtain is always visible that is in front of a very modern presentation resembling a trade fair. This presentation is the arrival point of the jour-ney: today.

Since November 2008, Museumsstraße has ended with today’s times that are characterized by struc-tural change and automation: “Essential to round off the subject,” says museum curator Matthias Murko. A film explains the change in industrial working

processes toward greater flexibility, quality, and speed, which only became possible through auto-mation engineering and data processing. Siemens motors, drives, and PLCs are at the heart of the exhibition. “The world’s undisputed market leader in automation technology finally has its head office in the Franconian metropolis,” explains Murko. Simatic and Sinumerik are delivered to the whole world from Nuremberg-Moorenbrunn.

The oldest exhibit is currently a head-high Sinumerik 270 dating back to 1970, which numerically con-trolled a 5-axis milling machine for training purposes at the Vienna University of Technology. The type-writer with an integrated paper-tape punch on which the CNC program was created is also on display. Other items in the exhibition recall modular automation solutions of the 1990s, including the Simodrive 611 drive system with an integrated Sinumerik 840D for turning and milling machines. Bringing us closer to the present day is a Sinumerik 840D sl with a Sinamics S120 from 2005 – a solution in which components established in the IT world have been transferred to the automation of machine tools. p

Address: Museum Industriekultur Äußere Sulzbacher Straße 60 bis 62 90491 Nuremberg, Germany

info www.siemens.com/sinumerik

Fürs

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ger

/Pu

blic

is

F e a t u r e


S i n u m e r i k Y e s t e r d a y – a n d I t S t i l l W o r k s T o d a y

Lieb

ing

Metallbaubetrieb Liebing, Germany p

Reliability for Decades

A 40-year-old Sinumerik 381C controls an equally old Trumpf

printing machine virtually without any errors over the years.

Four decades ago, Trumpf built the Trumatic TC20A nibbling and punching machine. It was automated with one of the first contour-

controlled NCs. The Sinumerik 381C was part of the then innovative System 300, which was based on discrete electronic structural components (transis-tors, resistors, etc.) and adapted for Trumpf for nibbling and punching. Electrohydraulic stepper motors served as the drives.

Using transistor technology and four 71-bit wire cir-culating stores, the old Sinumerik control was able

to carry out extensive circular contour calculations. Up to 71 signals could be sent one after another to the wire of each circulating store. The signals were then received in the same sequence at the end of the wire after 200 microseconds. This made it possi-ble to process large programs using the punched-tape reader.

PLC use unchangedErnst Liebing can prove just how reliably the ma-chine and PLC have worked over the years. Working together with daughter Christine and son Andreas,

On an external computer, Christine Liebing writes the punched-tape programs, prints them out, inserts them in the punching machine, and then upgrades this with the necessary tools



worked for the company since 1996 and is very familiar with the machine and the PLC. Using an external computer, she writes the punched-tape programs, prints them out, inserts them in the punching machine, and then upgrades this with the necessary tools.

Programming – a real challengeCompared with modern CNCs, most of which have logical and graphical user interfaces such as ShopMill or ShopTurn, writing programs with the Sinumerik 381C is still a real challenge. Feed num-bers need to be input for all movements and hole spacing. Christine Liebing finds these on an external table attached right next to the programming area. The amount of time she needs varies according to the size and complexity of the task. “If the holes are arranged symmetrically, it can be done relatively quickly. In that case, the values for 500 punched holes can be input in half an hour. It takes a lot longer when circles or other shapes need to be nibbled out,” explains the junior director.

Where there are questions concerning the NC, the master metal engineer consults former Siemens service engineer Wolfgang Frieser, who officially retired in 1993. He was involved in the development of the first Siemens NC PLCs and knows the Sinumerik 381C inside out. If one of his “old” cus-tomers needs help he can still be called on today. It is a great help to Ernst and Christine Liebing, as they are both keen to stress: “The machine and PLC almost always operate without any problems, but when a problem does arise, we are very pleased that Wolfgang Frieser is able to help us out.”

The machine operates just as smoothly and with the same high level of quality as it did 40 years ago. According to Liebing, the minimal precision losses can be accounted for by mechanical wear. The punching machine is still accurate to within a tenth of a millimeter. The sheet metal workers are very familiar with their machine and therefore know how to handle the PLC. Because of condensation in the structural components, they fitted a fan heater in the PLC housing some years ago. This keeps the PLC dry so that it can operate without any problems. p

The 1970 Sinumerik 381C is based on discrete electronic assembly parts and was modified for a nibbling/punching application

infocontact

www.siemens.com/[email protected]

as well as six other colleagues, he is head of a small metal construction company in Dentlein am Forst, a district in Middle Franconia. He still uses the Sinumerik 381C-controlled Trumatic TC20A in his workshop even today. Specializing in simple steel designs and sheet metal processing, the company supplies private customers, public institutions, and industry. For example, the company manufactures automatic grippers and small parts for the mainte-

nance department of a Feuchtwangen automotive supplier. There is also a lot of demand for various types of perforated metal plates used for steel gratings, guard rails, windowsills, and other appli-cations.

In order to meet the requirements of its customers, the family-run company uses a manual press brake with a pressure of 180 tons, squaring shears for 12-millimeter-thick sheet metal, and CNC plasma shearing equipment. The production hall has also housed the Sinumerik-controlled punching machine for 20 years. Liebing recalls: “In the early 1990s, I spent around DM 70,000 on the secondhand machine, although I was not at all certain whether we would be able to make proper use of it. Thanks to some sizable orders, however, it worked out okay and the machine paid for itself within a few years.”

The metal construction company’s order books are still full today. The TC20A is used once a week on average, as it can be used to punch up to 10- millimeter-thick sheet metal or 5-millimeter high-grade steel. The programming is carried out by the junior director. The master metal engineer has

Lieb

ing



Stalkwas SC, Poland p

35 Years and Still Rolling

A Sinumerik CNC machine has spent the past 35 years making ball valve

components in a Polish factory and is still going strong.

Stalkwas is a small engineering company located in the town of Poznań, some 250 kilo-meters west of Warsaw, with a history going

back over 40 years. The company supplies wholesale steel to engineering companies and undertakes precision founding of complex components. Stalk-was is also a leading specialist supplier of the balls used in ball valves. These balls are made from acid-proof steel in a range of sizes and custom specifica-tions. Starting from a stamped-out piece, a sequence of turning, milling, and finishing operations is per-formed to tight tolerances to fabricate each ball.

Stalkwas has manufactured these balls for many years, originally using fully manually operated lathes and other tools. In 1975 the company invested in a Sinumerik 520K CNC machine, a member of the Sinumerik 500C family first introduced in 1973. This was the first-ever CNC machine made available for turning and milling applications.

Early adopterDespite being an early adopter of CNC technology in 1975, Stalkwas was able, after the initial training period, to undertake the CNC implementation using its own personnel. Stalkwas turned a manufacturing process that was previously slow and subject to human variability into one with high repeatability and consistently high precision.

After 35 years the Sinumerik 520K is still in service producing ball valve components. Over time, the Stalkwas engineers have learned to exploit every facet of the functionality of the CNC machine. In particular, they take advantage of the ability of the 520K to provide smooth movement of all tools using different kinds of interpolation (both linear and

circular interpolation) and threading, including taper thread.

No retirement yetStalkwas has no plans to replace the Sinumerik 520K. Despite having worked for 35 years, it still provides the benefits of low production costs and consistent throughput. However, the company does intend in

the future to buy a new machine tool with the capability to make a whole ball-valve ball, including the prefinishing and finishing processes. The truth is, you cannot ask a 35-year-old machine to do every-thing, but it almost does. p

» We bought the machine because

it was one of the best numerical

controls on the market. A lot

of its functions are still used in

modern machine tools.«Nasza Strona, Stalkwas

infocontact


Stal

kwas



CNC-Technik Leidig, Germany p

Oldie with Youthful Élan

The machine tool manufacturer Steinel built the BZ30, one of the first CNC milling centers controlled by a computer-based Sinumerik

550C, in the early 1970s. A machine from this series built in 1976 is still in day-to-day use, together with the original Siemens CNC with punched-tape tech-nology. The small company CNC-Technik Leidig uses the machine to manufacture precision individual parts and small-scale production parts for various industries, with the rotary table acting as a fourth axis.

Although the company, owned by master engineer Rolf Leidig, has been in existence as long as the Steinel BZ30, he has only owned the machine since 1986. As he explains: “When I first took over the company I was unable to afford a machine of this kind. Ten years later, I had to pay a lot of money, DM 64,000, for my setup. But I’ve never regretted it because the investment enabled me to save money.” With the BZ30 he didn’t have to change any tools, only the workpieces – giving him more time for other tasks. Moreover, the 3-axis milling center can be used universally, is productive, and is still a high-precision piece of equipment.

Technical perfection for high machining qualityThat appears to be the view of his customers, many of whom come from the classic mechanical engi-neering, automotive, commercial vehicle, and motorcycle sectors. He is appreciated by both classic

High reliability and precision are what Rolf

Leidig particularly appreciates about his

34-year-old Steinel BZ30 3-axis milling center,

with the equally old Sinumerik 550C PLC, on

which, among other things, he produces

individual and small-scale production parts

for DTM motorsport.

car clubs and highly modern suppliers to DTM motor-sport. “We specialize in the manufacture of small series and a broad range of individual parts in which chips fly about all over the place. It goes without saying that we need complete reliability, high sur-face quality, and low production tolerances,” says Leidig.

In addition to the competence of the master engi-neer, the machines with which he performs all turning, boring, and milling work are crucial to high production quality. “Bread-and-butter machine” is how he still refers to the old Steinel BZ30 CNC mill-ing center with the Sinumerik 550C. In order to prevent wear-related inaccuracies, Leidig had the machine’s geometry reworked in 1993. Only 2 out of a total of 20 tank steel rollers had to be replaced. The machine can still reach rapid-feed speeds of 8 meters per minute and a movement accuracy of less than 0.03 millimeters in all axes. Another high-light of Leidig’s Steinel BZ30 is the fast 24x tool changer, which uses the program to convert a new tool within about three seconds (chip-to-chip time).

Foundation stone laid for the CNC ageIn addition to the stable basic construction and solid mechanical structure of the BZ30, the good produc-tion results are based on the high-quality measuring

The punched-tape programs created on the PC are inserted into the machine’s CNC and then production is startedLe

idig


system by which the Sinumerik 550C monitors the movement of the drives every 8 milliseconds. It also ensures reliable actuation of the axes.

The Sinumerik 550C is one of the first CNC genera-tion (Sinumerik 500C), which in 1973 laid the foun-dations for the CNC age. The PLC is based on a standard process computer – a technology that enables a saving of about two-thirds of the hardware previously required and additional functions to be integrated. The Sinumerik 550C’s path PLC with a closed-loop circuit achieves a resolution accuracy of 2 micrometers and can process several G-functions in the main records. In the Sinumerik equipped with two 8-kilobyte magnetic core memories, the storing program can hold about 10 kilobytes and large punched-tape NC programs with up to 1,000 indi-vidual records.

At CNC-Technik Leidig, the director himself is respon-sible for creating the punched-tape programs on an external computer. He creates simple molds in the traditional way using the ISO programming language. For complex workpieces, Leidig usually receives data in DXF format, which is then converted and adapted accordingly. However, using CAD soft-ware the master engineer is also able to create complex programs based on design drawings. He writes them in G-code, carries out minimal adjust-ments for the machine, punches the program out on

his punched-tape writer, inserts it in the CNC, and upgrades the machine with the necessary tools, and then the production process can begin.

Service only used twice in 24 yearsLeidig is particularly impressed with the reliability of the Sinumerik 550C, for which he has only had to call the service twice in the past 24 years. “That’s really good. I can always rely on the Siemens control unit. It never fails,” says Leidig, recalling the last time he called on the service in 2004. “One of the two emergency stop switches had broken, causing a complete software failure. At the time, the service engineer Günter Reichart was able to restore the software in a very short period of time. He also showed me how I can import the software again myself if necessary.” Since then, this has been neces-sary every couple of years on average, as the com-puter’s magnetic core memory malfunctions sporad-ically around these time intervals. However, when you know what to do, the problem can be resolved in a few minutes. p

infocontact


Rolf Leidig really appreciates the high quality and reliability of his Sinumerik 550C from 1976. He has only needed to call on Siemens service on two occasionsLe

idig


Grob-Werke GmbH & Co., Germany p

Pioneer in Metal Processing

Some years ago, Grob-Werke GmbH & Co. KG, one of the most important suppliers in the automotive sector, had the idea of making its

extensive production expertise available to users in other industries and developing a new stand-alone machine tool from which every metal processing company could benefit. The result was the G350 horizontal 5-axis machining center, which was warmly received and encouraged the Mindelheim-based company to come up with a larger version as

The G350 and G550 horizontal 5-axis machining centers from Grob offer not only an

unusual machine concept, but in the Sinumerik 840D sl and the Sinumerik MDynamics

technological package they also offer the PLC technology of the future.

quickly as possible – the new G550. In good Grob tradition, both machining centers are provided with a Sinumerik CNC.

Unusual concept with numerous advantagesThe great interest in the Grob centers is explained by their uniqueness: compared with the typical struc-ture of 5-axis machines, they are of a horizontal rather than a vertical design and have both axes of rotation in the workpiece, which affords certain

In the new, horizontal G-series, Grob is looking to Sinumerik 840D sl and the innovative Sinumerik MDynamics technological package

The horizontal spindle arrangement means that tool service lives are around 30 percent longer than those of comparable vertical machining centers

S i n u m e r i k T o d a y – a n d t h e S t o r y C o n t i n u e s

All

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s: G

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advantages. For example, there are no problems with chips, as they cannot remain on the workpiece but fall down freely instead.

The compact dimensions of 4 by 2.5 by 2.6 meters are one of the strengths of the new G-series. Accord-ing to operators, the service lives achievable are around 30 percent longer than those of comparable vertical machining centers. However, with its com-pactness, the new 5-axis machine from Grob has a very long Z-path, which is 675 millimeters (G350) or 1,020 millimeters (G550), respectively.

Customer experiences with the machine have been consistently positive to date. The easily accessible work area, which comes into its own particularly with small series and frequent changes of work-pieces, wins particular praise, as does the CNC – a Sinumerik 840D sl, which, with the ShopMill graphi-cal user interface, is particularly suited to clear working. The head of Grob electrical design, Peter Steger, says: “We use many Siemens PLCs in modular production systems for the automotive sector, and we are very satisfied with the performance, quality, and service. It goes without saying that we will also be offering our new G-series with this CNC.”

Good surface quality appreciated by premium motorcycle manufacturersA new software version from Siemens will be used in the future on the G-series with the Sinumerik technological package MDynamics, the launch of which has already been actively supported by the Mindelheim-based machine tool maker as the pilot user. The new standard user interface and the new Advanced Surface motion guidance ensure that even finer surface finishes will be achieved in an even shorter machining time than before. Steger, who is currently configuring three production systems for the automotive industry with the new Sinumerik software, says: “With the two different areas of standard machines and modular systems, a standard interface and an identical programming and configu-ration environment are particularly advantageous in our company. It will make configuration, commis-sioning, and service easier in the future.”

Initial demonstrations of the new software impressed those at Grob, as they did the first cus-tomers of the company. For example, after extensive tests of the new technological package, BMW Motor-rad has ordered two G550 machining centers with Sinumerik MDynamics for cylinder head machining. In addition to the new innovative Advanced Surface motion guidance, it was the new user interface, Sinumerik Operate, which is particularly clear and simple to operate, that was the deciding factor for the premium motorcycle manufacturer. The new menu navigation system is now similar to that of a normal PC. Christian Heiß, who is responsible for application engineering in the area of standard machines, is evidently satisfied: “Siemens has con-tinued to improve its graphical representations and

has also developed an explorer structure that con-tains practical functions such as copy and paste with which we are familiar from the day-to-day use of PCs.Machine operators can work more intuitively with the new Sinumerik user interface.”

The switch is made particularly easy for users who have already worked with ShopMill or ShopTurn. With ShopMill the operator receives a graphically animated interface for simple dialog programming, the structure of which is self-explanatory, so that technicians without any programming experience can learn how to use it in a short period of time. However, programming in programGuide as G-code with cycle support and pure DIN programming are also possible.

Another advantage of the new software is a virtual “second” NC core, the SimNCK. It enables new machining programs to be fully simulated on the machine while it cuts a different workpiece. This ability to perform two tasks in parallel is of particular advantage when working with complex workpieces, because even individual cycles can be tested step-by-step and a safe program run can be guaranteed in advance. p

infocontact


» In terms of the menu navigation

system, the new standard user

interface of Sinumerik is very similar

to that of a normal PC. This means

that machine operators can work

even more intuitively with it.«Christian Heiß, application engineer for standard machines at Grob


S i n u m e r i k T o d a y – a n d t h e S t o r y C o n t i n u e s

Sinumerik innovations p

Dream Team for Perfect Molds

Whether in the automotive or aerospace industry, power engineering, medical technology, job-shop manufacturing,

tool making, or mold making, complex or filigree molds represent great challenges for machine tool automation systems. There is a demand for perfect surface finish, precision, quality, and, last but not least, greater speed combined with incredibly simple operation and an integrated process chain.

Compact, powerful, simpleThe new Sinumerik 828D compact CNC is tailored exactly to the needs of sophisticated workshop machine tools. Whether used for turning or milling applications, the “powerhouse in the compact class” boasts compact dimensions, top performance, ease of operation, and uncomplicated service. The robust enclosure without fans and hard disks is completely maintenance-free, while integration of the latest NV-RAM memory modules allows user data to be buffered without a costly buffer battery. Extremely accurate machine designs with ± 0.1 micrometer precision are ensured by 80-bit NANOFP accuracy.

State-of-the-art PC and communications technology – from context-sensitive online help to the Animated Elements and Easy Message functions –

Siemens offers three powerful innovations for precision machining, perfect

surfaces, and high process reliability: the Sinumerik 828D ultracompact CNC,

technological packages with Sinumerik MDynamics, and the Sinumerik

Operate standard user interface.

are integrated into the new CNC. Animated Elements support the user during input by means of moving image sequences, which not only facilitate CNC programming but also increase process reliability. The Easy Message function keeps users up to date on the processing status of their machines by sending text messages to their cell phones.

The Sinumerik 828D plays out its strengths when milling free-form surfaces. Equipped with the Sinumerik MDynamics technological package (see below), it enables not only flawless surfaces but also maximum machining flexibility.

High quality meets speedUsers have access to Sinumerik MDynamics techno-logical packages consisting of CNC hardware, intelli-gent CNC functions, and CAD/CAM solutions for 3-axis to 5-axis machines for perfect milling, both in the compact class for the Sinumerik 828D and the premium segment for the Sinumerik 840D sl.

A highlight of the technological packages is the new intelligent Advanced Surface motion guidance, which guarantees an optimal workpiece surface at top machining speed for HSC-milling complex parts and free-form surfaces. An optimized “look ahead”

Körb

er

ShopMill, and ShopTurn user interfaces for this purpose – the system is of an even simpler design than before. It means that for all Sinumerik PLCs there is now a standard interface that ensures clear, intuitive operation with presentation in the familiar Windows look&feel.

Whether work step programming is in ShopMill or ShopTurn, Sinumerik high-level language with programGuide, or ISO code with cycle support, with Sinumerik Operate the operator benefits from short programming, setup, and machining times, as well as maximum flexibility and ISO code compatibility in every programming type. The tool and program management system has also been optimized by a tool list with a configurable display and the Ani-mated Elements graphic representation function, which now supports the operator during input with moving image sequences.

Conclusion: With Sinumerik innovations, manufac-turers of demanding workpieces are best prepared for a constantly changing market. Complicated individual parts with a fine surface finish (medical technology or tool making and mold making) can be produced just like series parts in the workshop or the automotive industry, where speed and high productivity levels are of the utmost importance. p

feature contributes to perfect surface finish, accu-racy, and increased speed. The new, optimized compressor also ensures exact contour accuracy and top machining speeds. Automatic harmonization of the speed profiles on adjacent milling paths by the CNC also produces higher surface quality.

In addition, Sinumerik MDynamics offers other inno vative functions. The most important of these are a new tool and program management system, innovative measuring functions in JOG for setting up the machine, programming functions such as ShopMill work step programming and programGuide, and innovative technology cycles and functions such as the Cycle800 swivel cycle, measuring cycles, or the new efficient Cycle832 high-speed setting, which all enable the processing strategy to be adapted more quickly.

Last but not least, the technological package sup-ports the production sequence of the workpiece across the entire CAD/CAM/CNC process chain. Optionally, there is also the Volumetric Compensa-tion System (VSC) for 3-axis and 5-axis machines. This system enables, for the first time, all geometric errors of a machine tool to be compensated for by the PLC alone.

Innovative operating conceptSinumerik offers the new Sinumerik Operate user interface for all operation and programming. A uniform HMI system with configurable user interface was created from the familiar HMI Advanced,

PublisherSiemens Aktiengesellschaft, Gleiwitzer Str. 555, 90475 Nuremberg, Germany

Drive Technologies Division CEO Klaus Helmrich

Editorial Responsibility in Accordance with the German Press LawArno Hoier

Responsible for Technical ContentsBernd Heuchemer

ConceptChristian Leifels

Editorial CommitteeIvonne Luthardt

© 2010 by Siemens Aktiengesellschaft Munich and Berlin. All rights reserved by the publisher.

Publishing HousePublicis Publishing, Part of Publicis ProP.O. Box 32 40, 91050 Erlangen, GermanyTel.: +49 (0) 91 31 / 91 92-5 01Fax: +49 (0) 91 31 / 91 92-5 [email protected]

Editorial staff: Gabriele Stadlbauer

Layout: Stefanie Eger

DTP: Mario Willms

Copy editor: Marion Schwab

Job number: 002800 27453

Cover picture: © Siemens AG

Printed by: Wünsch, Neumarkt, Germany

Circulation: 10,500

Order number: E20001-MC210-B100-X-7600

Printed in Germany

This edition was printed on environmentally friendly chlorine-free paper.

The following products are registered trademarks of Siemens AG:ShopMill, ShopTurn, SIMATIC, SIMODRIVE, SINAMICS, SINUMERIK, SINUMERIK MDynamics, SINUMERIK Operate, SINUMERIK Safety IntegratedIf trademarks, technical solutions, or similar are not included in the list, it does not imply that they are not protected.

The information provided in this magazine contains merely general descriptions or characteristics of performance which in case of actual use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract.

motion world July 2010 – special: 50 Years of Sinumerik

Highly demanding surface processing operations are possible with the Sinumerik 828D, Sinumerik MDynamics technology packages, and the Sinumerik Operate interface

info www.siemens.com/sinumerik

Answers for industry.

50 years SINUMERIKFrom 1960 to the present day – the SINUMERIK® CNC system has continuously been setting milestones for 50 years in the history of CNCs with innovative developments. This is currently the case with the SINUMERIK 828D for the shopfloor. Whether in turning or milling – it sets new standards with regard to ruggedness, performance and ease-of-use in the class of compact CNCs. And the new SINUMERIK MDynamics technology packages contain our accumulated competence, particularly in the field of 3-axis and 5-axis milling. www.siemens.com/sinumerik

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SINUMERIK 828D and SINUMERIK MDynamics

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