June 2008 Edition
CONTROLLING INTEREST
Randy Pearson
Siemens Energy & Automation
Simulation Software and New Technologies
Machine and control simulation, and technologies like Wi-Fi, have moved from emerging technologies into useful tools on the shop floor
In the last column ["Simulation Test Drives Provide
Detours Around Trouble," Controlling Interest, MAN, Vol. 42, No. 4, April 2008,
p. 16], I wrote about some aspects of how a shop’s uptime can be maximized.
Here are a few more.
Uptime and machine use in any shop, big or small, are
determined by run duration, burden rate, material cost, part size, and other
factors. Nothing, however, is as critical as a shop’s ability to finish the
first part as quickly and as accurately as possible, then let the onboard
control manage the cycle.
Regardless of shop size, there are scenarios in which
operators run a part while simultaneously setting up the next job, then
transferring the program to the machine control, whether via Ethernet, USB
stick, or Wi-Fi – a wireless technology that’s fast becoming available in many
shops.
The Future is Now
Simulation software can run on most Windows-based PCs and help increase an operator’s knowledge while shortening the learning curve
A number of the vocational and technical education schools
have CAD students upload programs via wireless. That "way of the future" is
here, today.
Another emerging technology is machine/control simulation
software. Control-identical and advanced machine brand simulation software is on
the market now so programmers and operators alike can "cut" parts offline, by
factoring all the machine variables, clearances, and tool paths. Simulation of
the cut starts when the "cycle start" is hit and the virtual reality of the
machining event sequence takes place.
Because the actual machine kinematics are built into the
program, there are few approximations in the simulation and a reliable
visualization is achieved.
Milling, turning, and mill/turn operation visualizations are
possible with many of the programs now on the market, and most function on any
Windows XP PC. Virtually every machine tool type can be stored in the library,
including EDM, laser, waterjet, ultrasonic, and more, since all the movement
calculations are based on theoretical axes.
On average, a program can be proved out in two to three hours using simulation software versus 20 hours on the shop floor.
Job Comparison
Another upside of the simulation software is the shop’s
ability to compare jobs on different machines, and even different technologies,
to achieve the optimum work schedule. Machine A might run a part in 22 minutes,
while Machine B does it in 18 minutes. By finding the optimal machine for the
job, before any metal is cut, shops can raise their efficiency as well as
tighten the quote process.
Using simulation software before facing the reality of cutting a part, shops can not only work out the bugs in a program, but test to see which machine in the shop can do the job most efficiently
Even fine details such as rapids can be accommodated, as the
software reads the feasibility of the cutter path, and can spot bad calculations
at the front end.
On average, a program can be proved out in two to three hours
using simulation software, versus 20 hours on the shop floor. That’s the best
argument I can imagine for an operation to investigate – and invest in – this
technology.
Other Benefits
An additional benefit is that there will be a dramatic
decrease in a shop’s scrap rate. Just as important, shop operators will find
that their learning curve on a machine or program is much shorter, because most
of the software simulates the actual control on the particular machine.
Randy Pearson is the Siemens sales support manager for U.S. dealers and OEMs.
His special interest is the training aspect on CNC machine tools, through the
various seminars and classes the company conducts at votech schools, on-site at
shops, as well as the Siemens training facilities around the country.
What do you think?
Let us know by e-mail from our website at
www.ModernApplicationsNews.com
or e-mail the editor at
pnofel@nelsonpub.com.