United States Department of CommerceUnited States Department of CommerceNational Institute of Standards and TechnologyNational Institute of Standards and Technology
Manufacturing Engineering LaboratoryManufacturing Engineering LaboratoryIntelligent Systems DivisionIntelligent Systems Division
Case Study in the Challenges Case Study in the Challenges of Integrating CNC Production of Integrating CNC Production
and Enterprise Systems and Enterprise Systems
John Michaloski
NIST
ISA EXPO October 2005
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
OMAC HMI Working Group Perspective OMAC HMI Working Group Perspective
Asset Mgt
MachineCapabilities
View Control
Human
OMACModel
(Data andEvents)
C ontro lle r
Machine ControllerHMI Subsystem
MachiningFeedback
Plant
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
ProblemProblem“Design Anywhere, Build Anywhere, Support
Anywhere” requires worldwide enterprise connectivity across design, manufacturing, distribution, and maintenance.
David Humphrey, ARC Advisory Group, commented, “… customers really want: real interoperability between production and enterprise systems with little or no integration.”
Can we realize real interoperability between production and enterprise systems with little or no integration, using OMAC and OPC concepts?
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
OPC Integration TechnologyOPC Integration Technology
Asset Mgt
MachineCapabilities
View Control
Human
OMACModel
(Data andEvents)
C ontro lle rO P C
S erver
Machine ControllerHMI Subsystem
O P CC lien t
MachiningFeedback
Plant
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
OMAC HMI OPC StrategyOMAC HMI OPC StrategyOPC does I/O based on item tags
OPC does not define application item tag names OMAC could standardize on required item tags List of needed OMAC HMI data items based on application
requirements
Strategy is to create named item tags since OPC provides communication mechanism, but no application layering
Item tags could be groups by purpose: DA, commands, machine configuration, maintenance/diagnostics, etc.
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
Axis Siemens Fanuc(methods)
Okuma
AxisAbsolutePosition $AA_IM[X]/Channel/MachineAxis/actToolBasePos
cnc_absolute OPC//Position/ActualPostion/ActualPositionAxisXX.Position
AxisDistanceToGo $AA_DTEB[X]/Channel/State/acDteb[x]/Channel/GeometricAxis/progDistToGo
cnc_distance OPC//Position/TargetPosition/TargetPositionAxisXX.Position
AxisFollowingError /Nck/servoDataFl32[1] N/A NA
AxisLabel $MN_AXCONF_MACHAX_NAME_TAB[n]/Channel/MachineAxis/name
cnc_rdsvmeter()label
OPC//Position/TargetPosition/TargetPositionAxisXX.Name
AxisLoad /Channel/MachineAxis/aaLoad[] cnc_rdsvmeter OPC/Position/TargetPosition/TargetPositionAxisXX.Load
Data Point MappingData Point Mapping
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
Mill
QCInspect
Rem ill
Assem ble
20 R ight W ing Parts23 Left W ing parts
Out of tolerance
Candidate App: Boeing LE Part AccountingCandidate App: Boeing LE Part Accounting
Real-time integration of cost data into ERP subsystems has been difficult, as traditionally, factory floor equipment have been "islands of automation."
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
GoalGoalTo do simple proof of concept part accounting, from
CNC to ERP. The project will attempt to determine if we can do this with minimal integration effort using OPC/OMAC.
CNC data will provide answers to the following questions: When is a new part being milled? – using part program
name. How long did it take to mill the entire part? – using cycle
start on/off as indication of milling/not milling How many pieces have been scrapped? Using count of
repeated parts
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
PlanPlan Use the backup machine, an Okuma MCV 4020 milling machine
that is managed by M&PT in the Boeing Renton lab, while the production 737 Leading Edge (LE) Panel project CNC machine is undergoing PM.
Apply Common Human Machine Interface (HMI) concepts using OPC connectivity built on M&PT OKUMA CNC to output appropriate tags by the CNC to the ERP system (BAAN) and provide the cost data on demand via the web front end.
Use Okuma OPC connectivity to output desired tag information that will then be enabled to send tag data to an upstream ERP system to provide cost data of making 737 LE panels.
2 MONTH TIMEFRAME!
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
DeliverablesDeliverablesDemonstrate connectivity of production equipment
using OPCDevelop an interface document that would identify
right variables /tags to upload the manufacturing information to the ERP system.
Record part accounting data to reflect machine activityDocument issues involved in “seamless” integration
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
Okum a MCV 4020 CNC+ OPC Server
Baan ERP
OPC Client
737 LE panels
Tim estam ped Data
System ArchitectureSystem Architecture Systems
Okuma MCV 4020 CNC Okuma PC-Based P100 Controller Ethernet Network
Software Okuma OPC Server Microsoft VB.Net and COM/DCOM Baan Erp
Machine.CycleStart
Program.ProgramName
Program.PartCount
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
Idyllic System ArchitectureIdyllic System Architecture Systems
Okuma MCV 4020 CNC Okuma PC-Based P100 Controller Ethernet Network
Software Okuma OPC Server Microsoft VB.Net and COM/DCOM Baan Erp
CNC + OPC Server
ERP
737 LE panels
Machine.CycleStart
Program.ProgramName
Program.PartCount
Tim estam ped Data
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
OPC ServerOPC Group
OPC Item1
OPC Item2
OPC Item5
OPC Group
OPC Item2
OPC Item4
Automation/VB Scripting
Custom/C++
•DA
•Events
•History
•Browse
CNC
OPC ArchitectureOPC ArchitectureIO Items
OPC Item1CycleStart
OPC Item2Program
OPC Item3Ready
OPC Item4Alarm
OPC Item5PartCount
OPC Item6Ready
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
Actual Production Test ArchitectureActual Production Test Architecture Systems
Okuma MCV 4020 CNC Okuma PC-Based P100 Controller
Software Okuma OPC Server Local Visual C++ OPC COM Application logging part accounting to .CVS file Visual Basic Scripting to Excl
M achine.CycleStartProgram .Program Nam eProgram .PartCount
CNC + OPC Server
OPC C lientSaves to
.CVS to F ileSystem
737 LE panels
Tim estam ped DataExcel VBS Excel
F ile
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
CVS FileCVS FileLine Number, Start Time (Y),End Time (Z),Setup Time (min),Machining Time(min),Install Time,Total Time
(min),Part Count,Burn Rate,Shop Cost,Panel Cost,Total Cost1803-L01.MIN,Tue Aug 30 03:09:29 2005,Tue Aug 30 03:14:55 2005,1.03,4.39,3,8.42,1,10,21.05,30,41.051803-L02.MIN,Tue Aug 30 03:17:31 2005,Tue Aug 30 03:22:16 2005,0.17,4.59,3,7.76,1,10,19.4,30,49.41803-L03.MIN,Tue Aug 30 03:23:52 2005,Tue Aug 30 03:29:53 2005,1.24,4.77,3,9.01,1,10,22.525,30,42.5251803-L04.MIN,Tue Aug 30 03:32:02 2005,Tue Aug 30 03:36:29 2005,0.1,4.36,3,7.46,1,10,18.65,30,518.651803-L05.MIN,Tue Aug 30 03:38:53 2005,Tue Aug 30 03:43:23 2005,0.07,4.44,3,7.51,1,10,18.775,30,48.7751803-L06.MIN,Tue Aug 30 03:45:40 2005,Tue Aug 30 03:50:16 2005,0.42,4.17,3,7.59,1,10,18.975,30,48.9751803-L07.MIN,Tue Aug 30 03:53:44 2005,Tue Aug 30 03:58:08 2005,0.15,4.26,3,7.41,1,10,18.525,30,48.5251803-L08.MIN,Tue Aug 30 04:00:29 2005,Tue Aug 30 04:05:35 2005,0.12,4.97,3,8.09,1,10,20.225,30,40.2251803-L09.MIN,Tue Aug 30 04:06:38 2005,Tue Aug 30 04:10:57 2005,0.08,4.24,3,7.32,1,10,18.3,30,48.31803-L10.MIN,Tue Aug 30 04:12:38 2005,Tue Aug 30 04:16:57 2005,0.07,4.24,3,7.31,1,10,18.275,30,4W8.275
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
Excel FileExcel FileLine Number Start Time (Y) End Time (Z) Setup Time (min)Machining Time(min)Install TimeTotal Time (min) Part Count
1857-L01.MIN Tue Aug 16 15:26:55 2005 Tue Aug 16 15:27:51 2005 0.58 0.35 3 3.93 11857-L02.MIN Tue Aug 16 15:27:51 2005 Tue Aug 16 15:28:27 2005 0.24 0.35 3 3.59 11857-L03.MIN Tue Aug 16 15:28:27 2005 Tue Aug 16 15:44:48 2005 16.01 0.35 3 19.36 11857-L04.MIN Tue Aug 16 15:44:48 2005 Tue Aug 16 15:45:26 2005 0.28 0.35 3 3.63 11857-L05.MIN Tue Aug 16 15:45:26 2005 Tue Aug 16 15:45:59 2005 0.19 0.35 3 3.54 11857-L06.MIN Tue Aug 16 15:45:59 2005 Tue Aug 16 15:46:30 2005 0.17 0.35 3 3.52 11857-L07.MIN Tue Aug 16 15:46:30 2005 Tue Aug 16 15:47:01 2005 0.16 0.35 3 3.51 11857-L08.MIN Tue Aug 16 15:47:01 2005 Tue Aug 16 15:47:32 2005 0.17 0.35 3 3.52 11857-L09.MIN Tue Aug 16 15:47:32 2005 Tue Aug 16 15:48:00 2005 0.12 0.35 3 3.47 11857-L10.MIN Tue Aug 16 15:48:00 2005 Tue Aug 16 15:48:34 2005 0.21 0.35 3 3.56 11857-L11.MIN Tue Aug 16 15:48:34 2005 Tue Aug 16 15:49:13 2005 0.3 0.35 3 3.65 11857-L12.MIN Tue Aug 16 15:49:13 2005 Tue Aug 16 15:49:46 2005 0.21 0.35 3 3.56 11857-L13.MIN Tue Aug 16 15:49:46 2005 Tue Aug 16 15:50:15 2005 0.12 0.35 3 3.47 11857-L14.MIN Tue Aug 16 15:50:15 2005 Tue Aug 16 15:50:44 2005 0.12 0.37 3 3.49 11857-L15.MIN Tue Aug 16 15:50:44 2005 Tue Aug 16 15:51:13 2005 0.14 0.35 3 3.49 11857-L16.MIN Tue Aug 16 15:51:13 2005 Tue Aug 16 15:51:59 2005 0.4 0.35 3 3.75 11857-L17.MIN Tue Aug 16 15:51:59 2005 Tue Aug 16 15:52:34 2005 0.24 0.35 3 3.59 11857-L18.MIN Tue Aug 16 15:52:34 2005 Tue Aug 16 15:53:10 2005 0.24 0.35 3 3.59 11857-L19.MIN Tue Aug 16 15:53:10 2005 Tue Aug 16 15:53:45 2005 0.23 0.35 3 3.58 11857-L20.MIN Tue Aug 16 15:53:45 2005 Tue Aug 16 15:54:22 2005 0.28 0.35 3 3.63 11857-L21.MIN Tue Aug 16 15:54:22 2005 Tue Aug 16 15:55:00 2005 0.28 0.35 3 3.63 11857-L22.MIN Tue Aug 16 15:55:00 2005 Tue Aug 16 15:55:33 2005 0.19 0.35 3 3.54 11857-L23.MIN Tue Aug 16 15:55:33 2005 Tue Aug 16 15:56:17 2005 0.38 0.35 3 3.73 11857-R01.MIN Tue Aug 16 15:56:17 2005 Tue Aug 16 15:56:53 2005 0.26 0.35 3 3.61 11857-R02.MIN Tue Aug 16 15:56:53 2005 Tue Aug 16 15:57:30 2005 0.26 0.35 3 3.61 11857-R03.MIN Tue Aug 16 15:57:30 2005 Tue Aug 16 15:58:03 2005 0.17 0.37 3 3.54 11857-R04.MIN Tue Aug 16 15:58:03 2005 Tue Aug 16 15:58:42 2005 0.3 0.37 3 3.67 11857-R05.MIN Tue Aug 16 15:58:42 2005 Tue Aug 16 15:59:22 2005 0.31 0.35 3 3.66 11857-R06.MIN Tue Aug 16 15:59:22 2005 Tue Aug 16 15:59:56 2005 0.21 0.35 3 3.56 11857-R07.MIN Tue Aug 16 15:59:56 2005 Tue Aug 16 16:00:27 2005 0.17 0.35 3 3.52 11857-R08.MIN Tue Aug 16 16:00:27 2005 Tue Aug 16 16:01:01 2005 0.21 0.35 3 3.56 11857-R09.MIN Tue Aug 16 16:01:01 2005 Tue Aug 16 16:01:33 2005 0.19 0.35 3 3.54 11857-R10.MIN Tue Aug 16 16:01:33 2005 Tue Aug 16 16:02:06 2005 0.19 0.35 3 3.54 11857-R11.MIN Tue Aug 16 16:02:06 2005 Tue Aug 16 16:02:37 2005 0.17 0.35 3 3.52 11857-R12.MIN Tue Aug 16 16:02:37 2005 Tue Aug 16 16:03:15 2005 0.28 0.35 3 3.63 11857-R13.MIN Tue Aug 16 16:03:15 2005 Tue Aug 16 16:03:47 2005 0.17 0.35 3 3.52 11857-R14.MIN Tue Aug 16 16:03:47 2005 Tue Aug 16 16:04:24 2005 0.28 0.35 3 3.63 11857-R15.MIN Tue Aug 16 16:04:24 2005 Tue Aug 16 16:05:03 2005 0.3 0.35 3 3.65 11857-R16.MIN Tue Aug 16 16:05:03 2005 Tue Aug 16 16:05:43 2005 0.31 0.35 3 3.66 11857-R17.MIN Tue Aug 16 16:05:43 2005 Tue Aug 16 16:06:23 2005 0.3 0.37 3 3.67 11857-R18.MIN Tue Aug 16 16:06:23 2005 Tue Aug 16 16:07:02 2005 0.28 0.37 3 3.65 11857-R19.MIN Tue Aug 16 16:07:02 2005 Tue Aug 16 16:07:37 2005 0.24 0.35 3 3.59 11857-R20.MIN Tue Aug 16 16:07:37 2005 Tue Aug 16 16:08:07 2005 0.14 0.35 3 3.49 11857-L09.MIN Tue Aug 16 16:08:07 2005 Tue Aug 16 16:08:41 2005 0.23 0.35 3 3.58 11857-R14.MIN Wed Aug 17 14:50:13 2005 Wed Aug 17 14:50:33 2005 0.33 0 3 3.33 1
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
PortabilityPortabilityThis works! Now the bigger test…Is the application code portable across CNCs and OPC
technology providers as promised?Replace Okuma with GE/Fanuc 16i and Use KEPWare
OPC Server.
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
CNC Connectivity with OPC Demonstration Location: Booth #1210October 25-27, 2005
Sponsors: ISA and Open Modular Architecture Controller (OMAC) Users Group
Taking the Next Step in CNC Technology
E vo lu tion o f N C M ach ines
Util
ity
Paper Tape NC
CNC
Fully Integrated CNC
Hardw ired NC
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
Demo “Highlights”Demo “Highlights” “Same” OPC Application Software
to run on GE/Fanuc 16i simulator – demonstration in ISA Booth 1568 Boeing/NIST tested same OPC
client on different OPC Servers – different OPC tags via ini file
Show ease of access and connectivity
Promote better/easier CNC-Factory Floor integration
OPC widely adopted Industrial “Standard”
Potential for new Apps is Wide Open
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
“Lessons Learned”“Lessons Learned” Networks don’t
XP/SP2 and DCOM security don’t mix. File sharing immune
.Net not ready for prime time Nothing is ever easy…
Okuma midnight resetting of PartCount. “Unsolicited” (Asynchronous) DA – necessary but non-trivial Enum issues,
e.g., Auto Mode: Okuma=0, MDSI=2, 840D=1 Variant issues
Empty versus Zero problem. No alarm returns empty variant. BSTR “0” <> 0
Thankful for loads and loads of OPC utilities
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
Next StepsNext StepsOMAC HMI will be further promoting CNC-ERP open
connectivity Porting to other CNC vendors and OPC technologyActively seeking collaboration partners among the
OPC, ERP and CNC vendors and end-users
NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division
Questions?Questions?Thank you.