Making connections with CNCs

IoT connectivity driving new control technology forward at EMO

Networked machine tools allow production data to be reviewed in real time. Photo courtesy of Heidenhain.

It’s all about connectivity.

That was one of the themes at this year’s EMO show in Hannover, Germany.

Technology giant Siemens gave a demonstration of machine tool connectivity by linking roughly 240 machine tools on display at the tradeshow to the cloud. To set up this network, the company relied on its Manage MyMachines application, and attendees could observe production in real time on a sea of machine tools.

The machines were linked to MindSphere, the company’s cloud-based, internet of things (IoT) operating system. The IoT links machine tools, computers, and other equipment for the purposes of data collection, operating status updates, and quality assurance. Manage MyMachines is the company’s first MindSphere app for machine tools.

The EMO demonstration was a vivid example of how far CNC systems have advanced in recent years. Initially designed to automate the machining process, controls now play a leading role in enhancing shop floor connectivity to the IoT. These networks give machine operators access to tool management, enterprise resource planning (ERP) software, and overall equipment effectiveness (OEE) numbers – basically any data that helps boost productivity, efficiency, and quality, while reducing errors and downtime.

“We start at the CAD/CAM design of your part and go down the whole process chain,” said Ramona Schindler, business development manager for digitalization of machine tool systems for Siemens Industry.

Siemens has numerous connectivity products, as do companies such as Heidenhain and Mitsubishi, among others. In Siemens’ case, these systems include the Sinumerik 800 series of CNCs; new Sinumerik HMI software; and MindSphere, the Siemens cloud system for industry.

There are many forms and concepts of connectivity, and each manufacturer has unique technology.

“You have to see our connectivity or digitalization in three layers,” said Schindler. “There is the lowest layer, when you are talking about the digitalization of the machine itself. This means you are having digitalization opportunities right at your machine tool. You don’t have to go into the cloud, but you can. We call this the Sinumerik Edge.”

It is a new, high-performance hardware and software system that allows machine tool operators to analyze data during production in real time. Anyone using this system can transfer non-sensitive, pre-processed data to MindSphere for storage and future reference.

Manage MyMachines links machine tools to the cloud, enabling manufacturers to view machining production remotely. Photo courtesy of Siemens Industry.

The second level is called the Sinumerik Integrate platform, which includes the Manage MyMachines MindSphere apps Manage MyTools, Analyze MyPerformance, Analyze MyCondition, and Analyze MyWorkpiece/Toolpath.

Analyze MyPerformance allows manufacturers to make OEE calculations and determine the impact of measures made to boost efficiency. As demonstrated at EMO, Manage MyMachines networks machine tools, making it easier to gather collective performance and operating status data. Using Analyze MyCondition, operators can monitor machine tools that are linked to a local server. Analyze MyWorkpiece/Toolpath is designed to boost productivity and part quality by scrutinizing NC programs and other forms of data using 3-D technology, among other features.

If tools have RFID tags, the system can alert operators when tools are reaching the end of their lifespan and are likely to fail during the next job.

“The highest layer is MindSphere, the cloud platform from Siemens. It’s not only for machine tools. It’s for everything,” said Schindler.

Connectivity Creates Awareness

“There’s always the benefit of having analytics and [being able] to see what’s happening in your production. Getting the knowledge, the overview, and what’s happening, the insight into your production, you get to see what’s really happening on your shop floor,” said Schindler.

Precision measurement and control equipment manufacturer Heidenhain also demonstrated its networking concept at EMO 2017. Called Connected Machining, this technology networks each step from design to the delivery. This is achieved via the company’s TNC control.

The TNC 640 is the latest in this product line. In addition to milling, this control can be used for mill/turn applications. It uses the Heidenhain Serial Controller Interface (HSCI), the company’s digital interface hardware platform. The control, suitable for 5-axis and 3+2 machines, has Ethernet connectivity as a standard feature.

“With Connected Machining, we basically help the operator access all the data he needs to do the next job or [change] the priority of the job,” said Gisbert Ledvon, TNC business development manager at Heidenhain’s North American headquarters in Schaumburg, Ill.

How It Works

The system works by using calibrated tools that are scanned and loaded into the tool magazine, a process recorded by the control. Using a function called Remote Desktop Manager, the operator can then access CAM information. Another feature, called Batch Process Manager, lets operators schedule production jobs. The control checks to see if all the tools needed to accomplish these jobs have been loaded. If tools are missing, a report is issued. The control also offers an estimate on machining time.

Tool management data is transmitted via a Heidenhain DNC interface. This interface also establishes a link to ERP programs.

New CNCs, such as those in the Sinumerik 800 series, have the ability to connect machines in an ever-growing system of hardware and software. Photo courtesy of Siemens Industry.

Then a software program called StateMonitor collects data from networked machine tools. This data can be viewed in real time on computers, smartphones, tablets, and other devices linked to the plant network. It also connects to the company network via the DNC interface.

The software offers production status updates, said Ledvon.

“It can tell you how efficient your machining is. It will tell you if the spindle is running [and] what feed rate you’re running at,” he added.

The system also generates messages as the process proceeds. Error messages, messages to maintenance staff, messages to the operator, messages to the programmer, and messages to the manager can all be sent.

Another feature on the new control automatically tracks cutting tool use. If a cutting tool is reaching the end of its useful lifespan, the system will warn operators to switch to a new tool. Tool orders can then be placed, if need be.

According to Ledvon, plant-based networks involving these CNCs are closed systems that are very difficult for an outside force to access, and therefore very secure.

Human Element Still Important

For all the cutting-edge technology involved, there is a very human side to enhanced CNC connectivity.

Boosting CNC connectivity might lure more young people onto the shop floor, said Ledvon.

Networked machine tools also give operators more responsibility, making them more engaged in the machining process, he stated.

“We need to think about ways to bring younger people back into the shops. If you’re just standing in front of a machine, loading and unloading the machine, just pushing buttons, you’re not going to get these kids into the manufacturing world. And even if you say, OK, you’re going to be a programmer, if the programmer never really programs anything on the machine or understands how the machine functions, he will not be a good programmer,” said Ledvon.

The TNC 640 control is used for milling and mill/turn applications. Photo courtesy of Heidenhain.

Shop owners, particularly in small companies, need to be aware of their employees’ reactions when expanding CNC connectivity, however.

“When you talk to smaller shops, they are a little bit resistant for a couple reasons. Managers need to convince their staff [that CNC connectivity] is not impacting their job. It makes their job easier, makes them more efficient, and basically secures their job,” said Ledvon. “Instead of saying we want to make sure you’re running these five machines and I want an 80 per cent increase in efficiency otherwise we’ll put a robot in here, we’ve got to be a little bit sensitive to the operator.”

Shops might soon have to embrace enhanced CNC connectivity or go bust and get left behind.

“I believe we will not have a choice. [Connectivity is needed] to look at the efficiency of our equipment, how we’re utilizing it, and how we can optimize it. You want to see an ROI very quickly, and the only way you can really do that is to have an automatic monitoring system on the machine and connectivity to a network,” said Ledvon.

Contributing writer Nate Hendley can be reached at nhendley@sympatico.ca.

Heidenhain, 847-490-1191, www.heidenhain.us

Siemens Industry, 800-879-8079, www.industry.usa.siemens.com