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International WorkshopHanyang University, Sunchon University
Universal Manufacturing Platform (UMP)
for Global CNC Machining
Professor Stephen Newman & Dr Aydin Nassehi
Advanced Machining Processes & Systems Research Group (AMPS)
IdMRC University of Bath, UK
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International WorkshopHanyang University, Sunchon University
1. The Drivers for Interoperability
2. Current Status of CNC Interoperability
3. Universal Manufacturing Platform (UMP) for CNC
3.1. New Data Models
3.2. Abstraction of Resources3.3. Integrated Data Communications
4. Challenges in the Implementation of the UMP
Contents
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Boeing 787 part and sub-assembly manufacturers (Source: Adapted from the Seattle Times)
Drivers for Interoperabil ity : Global Manufacturing
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International WorkshopHanyang University, Sunchon University
Drivers for Interoperability : Global Manufacturing
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Drivers for Interoperability : Legacy Parts
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Drivers for Interoperability : Metalworking SME
Adaptable Manufacturing :the flexibility and agility of a manufacturing enterprise in handling changes inresources, jobs and strategies
Resource fluidity :the ability to use different available resources interchangeably with minimum effort
Interoperability :
the ability to seamlessly transfer information from one computer system to anotherwhile maintaining the integrity of the information
Metalworking SME Shopfloor
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International WorkshopHanyang University, Sunchon University
1. The Drivers for Interoperability
2. Current Status of CNC Interoperability
3. Universal Manufacturing Platform (UMP) for CNC
3.1. New Data Models
3.2. Abstraction of Resources
3.3. Integrated Data Communications
4. Challenges in the Implementation of the UMP
Contents
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International WorkshopHanyang University, Sunchon University
Current Method of NC Part Programming
N10 G00 Z10. 000
N15 G91 G0 Z200
N20 T5 D1 WW
N35 G00 X0. 000
N40 G00 Z5. 000
N50 S3183. 000N55 M03
N60 F1477. 000
N65 G00 X60. 000
N70 G00 Z5. 000
N75 G00 X60. 000
N80 G01 Z- 0. 500
. . .
ISO6983
CAD/CAM
NC Machine Tool
Post-Processor
%
N05 G54
N30 G90 M5
N45 M08
language describessimple movementsand switchinginstructions
Low level of data:
Standard doesnot support complexgeometries (e.g.spline interpolation)
Machine-specific
part programmegenerated bypostprocessor
One-way:No feedback of data
to planning department
ISO 6983, G code
Vendor-specificextensions
No possibility to changecomplex NC programmesat shopfloor level
No idea of geometry being machined or tolerances !
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International WorkshopHanyang University, Sunchon University
Lack of Interoperability in Conventional CAx Process Chain
Current Status of CNC Interoperability
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International WorkshopHanyang University, Sunchon University
Introducing STEP-NC (ISO 14649)
Its a new data model for Intelligent CNCs
Part geometry and the process plan is defined
Entities are based on STEP AP224 machining features
It is a hierarchical data model that is interpreted by thecontroller, not a linear programming language like ISO 6983
Well structured hierarchy based on a Workplan with
Workingsteps Tool paths and tool functions (speeds and feeds etc) do not
need to be defined.
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International WorkshopHanyang University, Sunchon University
Intelligent ControllerBi-directional
Data flow
CAD/CAM
Pocket 1
-plunge
-roughing
-finishing
Hole1
-pre-drilling
-drilling
ISO 14649
HEADER;
HEADER: FILE_DESCRIPTION ((EXAMPLE OF NC PROGRAMME FOR MILLING: SLOT,
POCKET, HOLE.'),'1');
FILE_NAME ('tape.STP',$,('ISO14649'),(''),A. Nassehi','University of Bath', 'UK');
FILE_SCHEMA (('MACHINING_SCHEMA','MILLING_SCHEMA'));
ENDSEC;
DATA;
#1=WORKPIECE('PART2',#2,0.1,$,$,$,(#200,#201,#202,#203,#204));
#2=MATERIAL('LM25','ALUMINIUM',($));
.#9=CLOSED_POCKET('pocket1',#1,(#40,#41,),#74,$,$,$,$,$,(),$,#17,#160)
#10=ROUND_HOLE('hole1',#1,(#42,#43,),#76,#146,$,$,$,$,$,$,#147,$,#18,$,$)
#19=PROJECT(''EXECUTE EXAMPLE2''),#20,(#1,)
#20=WORKPLAN('EXAMPLE2',(#21,#22,#23,#24,#25,#26,#27,#28,#29,#30,),$,#71);
#21=MACHINING_WORKINGSTEP('ROUGH_POCKET1',#86,#9,#40);
#22=MACHINING_WORKINGSTEP('FINISH_POCKET1',#86,#9,#41);
#23=MACHINING_WORKINGSTEP('DRILL_HOLE1',#87,#10,#42);
#24=MACHINING_WORKINGSTEP( 'REAM_HOLE1',#87,#10,#43);
#25=MACHINING_WORKINGSTEP('ROUGH_SLOT1',#88,#11,#44);#26=MACHINING_WORKINGSTEP('FINISH_SLOT1',#88,#11,#45);
#41=BOTTOM_AND_SIDE_FINISH_MILLING($,$,'FINISH_POCKET1',#51,15.0,$,#97,#61,#70,$,$,2.0,1$);
#42=DRILLING($,$,'DRILL_HOLE1',#52,1$,$,#98,#62,#70,$,$)#43=REAMING($,$,'REAM_HOLE1',#53,1$,$,#99,#63,#70,$,$,.F.,$,$)#50=CONTOUR_BIDIRECTIONAL(0,0,.F.,0,0,0,0);#51=CONTOUR_PARALLEL(4.0,5.0,.T.,CW,$,CONVENTIONAL);#52=DRILLING_TYPE_STRATEGY($,$,$,$,$,2.0,2.0,20$);
#53=DRILLING_TYPE_STRATEGY(75.0,5$,2.0,5$,8.0,1$,$,20$);#60=MILLING_TECHNOLOGY($,TCP,$,2.0,$,0.3,.F.,.F.,.F.);
#71=SETUP(SETUP1,#72,#85,(#83,));#72=AXIS2_PLACEMENT_3D('SETUP1',#164,#165,#166);
#83=WORKPIECE_POSITIONS(#1,#84,$);#96=MILLING_CUTTING_TOOL('TAPERED_ENDMILL_20MM',#126,(#106,),(5$),8$,#91,$);#125=MATERIAL('EM05C05','HSS/CO',($));#126=TAPERED_ENDMILL(#136,4,null,.F.,$,$);#136=TOOL_DIMENSION(2$,$,$,$,1.5,$,$);
#159=TOLERANCED_LENGTH_MEASURE($,null,$,$);#160=POLYLINE('pocket1',(#205,#206,#207,#208,#209,#210,#211,));#200=CARTESIAN_POINT('CLAMPING_POSITION1',($,2$,25.0));#217=CARTESIAN_POINT('SLOT3_2',(1$,2$,$));ENDSEC;
STEP-NC (ISO14649) Physical File Structure
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International WorkshopHanyang University, Sunchon University
Geometry
Operation Op Sequence
NC Functions
Tool Path
Post Processor
NC Functions
Tool Path
NC Functions
Tool Path
NC Functions
Tool Path
NC Functions
Tool Path
NC Functions
Tool Path
NC Functions
Tool Path
G & M codeG & M code
ISO 6983ISO 6983
CAD/CAMCAD/CAM
CNCCNC
ControllerController
Geometry
Workingsteps Workplan
NC Functions
Tool Path (Optional)
STEP NC
STEPSTEP--NCNC
ISO 14649ISO 14649
Geometry
Workingsteps Workplan
NC Functions
Tool Path
STEP-STEP-NC--
UniUni--DirectionalDirectional
Information FlowInformation Flow
BiBi--DirectionalDirectional
Information FlowInformation Flow
Low LevelLow LevelG & M DataG & M Data
High LevelHigh Level
CAD/CAPP &CAD/CAPP &
CAM DataCAM Data
Part GeometryPart Geometry
&&
ManufacturingManufacturingDataData
Tool PathTool Path
DataData
A Comparison of STEP-NC and G&M Codes
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International WorkshopHanyang University, Sunchon University
CNC MachinesCAM Software
UNIGRAPHICS
MasterCAM
DelCAMPowerMill
STEP,
STEP-NCfile
1Bridgeport MachineSTEP-NC Controller
Mazak MachineSTEP-NC Controller
DMG MachineSTEP-NC Controller
Wadkin MachineSTEP-NC Controller
2
3
1
2
3
Key
Unigraphics STEP-NC interface
MasterCAM STEP-NC interface
PowerMill STEP-NC interface
Bi-Directional data transfer
The vision of STEP-NC replacing the postprocessors
STEP-NC View for CNC Interoperabili ty
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International WorkshopHanyang University, Sunchon University
Total Interoperability in a CAx Network
From the CAx chain to Interoperable CNC Manufacture
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International WorkshopHanyang University, Sunchon University
1. The Drivers for Interoperability
2. Current Status of CNC Interoperability
3. Universal Manufacturing Platform (UMP) for CNC
3.1. New Data Models
3.2. Abstraction of Resources
3.3. Integrated Data Communications
4. Challenges in the Implementation of the UMP
Contents
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International WorkshopHanyang University, Sunchon University
Information loss in theState of the Art CAx chain
Manufacturing informationRetention utilising UMP
A Universal Manufacturing Platform
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International WorkshopHanyang University, Sunchon University
UMP Vision
CAD
CAM
CNC
CNC
Multiple views ofinformation
Multiple views ofinformation
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International WorkshopHanyang University, Sunchon University
UMP Vision
CADCAM
CNC CNC
An Integrated DatawarehouseAn Integrated Datawarehouse
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UMP : Encoding Manufacturing Information
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UMP : Resource Abstraction
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UMP: Connection
AbstractionAgentAbstraction
AgentAbstractionAgentAbstraction
Agent
Manufacturing Network
CarrierAgent
Legacy CNCInterface PC
CAM System
MonitorAgent
CNC with PCbased controller
Monitor
Agent
RS232MonitorAgent
CAD System
MonitorAgent
CarrierAgent
Agent DirectorySystem
Director
Agent
Abstraction
Agent
MonitorAgent
STEP-NCcompliant CNC
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Overview of Universal Manufacturing Platform
ENCODING:Manufacturing Datawarehousea repository for product, resourceand process models
ABSTRACTION:Manufacturing Knowledgebaseand Interfacesmaintains integrity of the data in
the data warehouse and performsinformation transformations
CONNECTION:
Communication Huballows various interfaces to CAxsystems to pass information to thelower layers
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CAx interfaces of the Universal Manufacturing Platform
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International WorkshopHanyang University, Sunchon University
An example of CNC Interoperability
Siemens 840D CNC & Legacy Fanuc CNC
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UMP CNC Interoperable Demonstration
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International WorkshopHanyang University, Sunchon University
1. The Drivers for Interoperability
2. Current Status of CNC Interoperability
3. Universal Manufacturing Platform (UMP) for CNC
3.1. New Data Models
3.2. Abstraction of Resources
3.3. Integrated Data Communications
4. Challenges in the Implementation of the UMP
Contents
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International WorkshopHanyang University, Sunchon University
User Advantage butNo advantage to Vendors with Interoperability??
Knowledge and information standards Product modelling for manufacturing applications
Manufacturing resource modelling
Machine specific manufacturingprocesses simulation
Interoperable CNC controllers
Challenges in the Implementation of UMP
Getting NC Operators to TRUST the Platformthus
Creating a Culture Shift toenable Interoperable CNC Manufacture
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International WorkshopHanyang University, Sunchon University
UMP represents a paradigm shift to horizontal platformsin CNC manufacturing(DEC, IBM => Web based)
UMP enables the realisation of plug and produceinteroperable CNC manufacturing
UMP has numerous advantages to users, who generatea market pull for vendors to adopt a new interoperablemanufacturing vision
UMP will support global interoperable manufacturingnetwork where products are designed anywhere and
manufactured anywhere Ubiquitous Manufacturing
Conclusions
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Any Questions ???