The future of control technology is here

CNCs are at the hub of the digital thread that extends from cutting tools to ERP systems. These functions are made possible by technology such as the State Monitor. Photo courtesy of Heidenhain Corp.

The way operators interact with their machines at the control is about to change. These changes can be small, like controls that are reminiscent of computer tablets like Apple’s iPad®; or they can be large, like Athena, a voice-activated, interactive control technology.

These next-generation controls were on display at the recent International Manufacturing Technology Show (IMTS), an event that attracted 129,415 people to Chicago’s McCormick Place in September.

Connectivity, automation, and the digitization of manufacturing are converging at the control to create a new way to interact with and run the machine tool.

Voice-controlled system

Athena, the first voice-operated assistant for machine tools, will remind users of digital assistants Siri, Google, and Bixby: It enables operators to interact with machine tools using voice commands.

Developed by manufacturing technology company iTSpeeX, Athena resides on a local, on-premise computer, eliminating the costs and security issues often associated with cloud-based software.

Additionally, it works on numerous machines, regardless of brand. As a result, this control has the potential to be a true industry standard for assistant technology.

The integration of this machine assistant can address industrywide challenges, including a severe shortage of skilled workers. By providing a simple, common interface, the software can significantly reduce the time and investment required to train novice machinists while making the most of the talents of skilled operators.

“In developing Athena, iTSpeeX wanted to help manufacturers maintain our commitment to machinists,” said Athena Chief Architect Dan Bagley. “Athena is representative of the kind of innovation our industry needs to attract a new generation of machinists and push manufacturing into a bright future.”

Manufacturers both large and small are being confronted by a skills gap that has the very real potential to limit the industry’s growth and profitability.

“The labour issue is real, and [all] manufacturers are living with it every day,” said Don Lane, CEO of Makino, the machine tool builder that demonstrated Athena at IMTS. “As an industry, we must work together on solving the problems being caused by the skills gap. I believe breakthrough technology like Athena will revolutionize manufacturing by making it easier to both learn about and use a machine tool, as well as to efficiently operate one on a day-to-day basis.”

New functions of the Heidenhain TNC 640 control include the ability to import a part file, view a 3-D model, and zoom and rotate the image using the touchscreen. Photo courtesy of Heidenhain Corp.

Designed to run an EDM or CNC machine, the system’s voice commands combined with intelligent-learning technology help owners reduce training requirements by providing new operators with a digital assistant.

By increasing the number of new operators that can now run complex machines, veteran operators will have more time for difficult tasks, including complicated setups and machine maintenance.

The system can report machine status, control all machine tool operations, coach the operator on standard procedures or operations, and calculate helpful information that would otherwise not be readily available to the operator.

Focus on connected systems

Controls that empower operators to make immediate improvements to the machining process help reduce scrap and lower cycle times.

In today’ job shops workers don’t have the luxury of scrapping multiple first-run parts to refine and perfect a program. They need the first part to be a good part every time, but achieving this goal has become a bigger challenge partly because designers can now increase part complexity to take advantage of expanding machine capabilities.

“Job shops have to keep pace with new control technology to keep scrap rates low,” said Gisbert Ledvon, TNC business development manager, Heidenhain Corp., before the doors opened at IMTS. “Continuing to use outdated controls for complex parts is like Einstein’s definition of insanity. If you expect different and better results, then explore the new control and CAD/CAM technologies.”

CNCs are an integral part of the digital thread that now connects the ordering of raw materials, the machining process, the billing cycle, and everything in between.

While controls are becoming easier to use, they’re also becoming much more powerful. Graphic interfaces and comprehensive connectivity have expanded CNC functionality so operators can make intelligent decisions and take immediate action on the shop floor.

Connected controls

Being able to load a part file or program into a CNC via the USB port was a good advancement for its time. Now, controls connected to CAD/CAM systems allow the operator to access part files, data, and setup sheets without ever leaving the machine, and do so in a secure environment.

Of course, personnel working remotely from the CNC, whether in the engineering or QC department or at another facility, also want to capture, analyze, and act on CNC-related data. Traditional types of data available from CNCs include machine status, current program running, spindle speed, availability, utilization rate, and errors.

Non-conventional data sources now include tooling; workholding; and individual machine parts such as pumps, motors, and encoders, thanks to an increased use of sensor technology all connected using the industrial internet of things (IIoT).

“Control manufacturers have placed a greater focus on importing more data into the machine control via MTConnect-enabled devices,” said Ledvon. “Correspondingly, they have developed software applications that graphically present information, so shop owners can more easily make good decisions.”

For maximum flexibility, information can remain strictly within a user’s firewalls, accessed via the cloud, or both.

New machine controls now enable operators to switch the NC program between the desired functions.

This gives job shops the freedom to decide how and when they want to combine machining methods, an important development necessary to keep pace with the expanded functions available from 5-axis multitasking machines. Other improvements include connecting controls to vision systems that can compare the current image to a reference image and spot any deviation from a perfect setup.

“It functions much like the face recognition feature of your iPhone®. If something doesn’t look exactly right, the control will find it,” said Ledvon.

Examples include a missing hole for the next threading application, a broken drill in the part, a part that is not clamped correctly in a vise or on a pallet, a wrong engraved part number, and a wrong part on the pallet.

Touch for continuous improvement

While machine learning and artificial intelligence may ultimately minimize the need for humans to interact with controls, those developments remain over the horizon. For the coming decades, Heidenhain believes that engaging operators is essential for optimizing the machining process.

As a result, new control functions include the ability to import a part file, call up a 3-D model, zoom and rotate on the display using touchscreen controls, select portions of the file to modify, and automatically generate new code.

“If operators discover a missing part feature or need to modify the cutting path to avoid a collision, they can make changes without engineering support,” said Ledvon. “Operators working on second or third shift tell us how they finished a batch of parts on time or minimized the number of bad parts because of new control capabilities. Operators also provide immediate feedback to CAD/CAM and quality control systems.”

Ledvon further noted that those working on smaller production runs need to cut the first part correctly every time.

“New control technology makes cutting more accurate and shops more productive by eliminating sources of waste, such as cutting multiple bad parts in order to fine-tune the cutting path,” he said.