New initiative to foster technology co-operation to innovation.

First phase of this initiative is focused on enabling part manufacturers to start production preparation before machine delivery.

Meet at the Machine is a new initiative from Siemens, designed to bring together machine builders, software and automation technologies to accelerate innovation across the machine tool industry and help manufacturers achieve productivity faster. It provides a framework for Siemens and machine builders to jointly deliver integrated machining solutions that address real manufacturing challenges. The initiative is designed to make manufacturing customers more productive and enhance quality and performance. It brings engineering software, automation hardware and machine expertise together in one solution, helping machine builders deliver differentiated value.

Manufacturers today face increasing complexity, workforce shortages and growing pressure to become productive faster. While advances in software, automation and digitalization continue to create new opportunities, many manufacturers still face challenges connecting those technologies into efficient production workflows.

Siemens believes the next step in machining innovation is creating a continuous digital thread that connects engineering, programming, virtual validation and execution to deliver next-level productivity starting from the first machine power-on. By improving the flow of data across the part manufacturing lifecycle, organizations can reduce complexity, accelerate ramp-up and create a foundation for continuous improvement.

“Manufacturing truth has always ultimately been at the machine,” said Mark Hindsbo, head of Operations Software at Siemens. “By bringing together engineering software, automation hardware and machine expertise, we enable our customers and users to be productive faster, accelerate return on investment and reduce ramp-up time by up to 50 percent.”

Built in collaboration with TRAK Machine Tools, the first phase of this initiative is focused on enabling part manufacturers to be productive from day one. It addresses one of the most common challenges manufacturers face when purchasing a new machine: the time required to move from machine delivery to productive machining. The solution combines software, automation and machine expertise into a connected workflow that allows manufacturers to program, simulate and validate production while a machine is still being built.

“When our customers invest in a new machine, their goal is to achieve productivity and business results as quickly as possible,” said Steve Pinto, president, TRAK Machine Tools. “Meet at the Machine creates a new model for collaboration focused on customer outcomes, and we are proud to be the first partner helping bring this vision to life.”

Traditionally, many programming, validation and training activities begin only after a machine is installed. The new initiative shifts these activities earlier in the process, allowing manufacturers to prepare for production before physical machine delivery and helping reduce ramp-up time.

Through the initiative, Siemens plans to work with machine builders to develop future solutions that address key manufacturing challenges through collaborative innovation.

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@siemensindustry @prototrak @Siemens @siemens_press #PAuto #MachineBuild #Manufacturing

Hardware gateway for industrial edge and cloud applications

Softing's edgeGate simplifies access to Programmable Logic Controllers (PLC) and Computerized Numerical Controllers (CNC). It enables seamless and secure data integration into advanced management systems such as Enterprise-Resource-Planning (ERP), Manufacturing Execution System (MES) or Supervisory Control and Data Acquisition (SCADA). This integration is available for both new and established facilities. Communication via OPC Unified Architecture (OPC UA) ensures a robust and reliable connection.

Additionally, edgeGate provides Message Queuing Telemetry Transport (MQTT) functionality. This feature facilitates the direct integration of machine data into private or public IoT cloud applications. The MQTT implementation is generic and compatible with multiple cloud providers. Like the OPC UA standard, MQTT supports a range of security mechanisms including encrypted connections, certificates, and user authentication. These features collectively enhance data security significantly.

It is practically maintenance-free and allows connection to controllers without interfering with existing systems. Supported controllers include Siemens Simatic PLC, Siemens Sinumerik controller, Fanuc CNC controller, Modbus TCP, Allen-Bradley PLC, or OPC UA Client machine data. It provides a simple web interface for fast application configuration as well as an additional security layer and communication encryption.

The capabilities of edgeGate can be expanded by integrating the edgeConnector products from Softing Industrial which offer similar functionalities in a Docker-based software version. Another compatible product is Softing’s Docker-based edgeAggregator software which provides a powerful OPC UA data integration layer.

"We are pleased to offer a hardware solution that complements our Docker-based software offering," says Abel Jimenez, Product Manager at Softing Industrial Automation. "edgeGate simplifies the connection of PLC and CNC controllers to management systems with robust communication functions such as OPC UA and MQTT and increases efficiency. edgeGate offers a comprehensive data integration solution that can stand alone or be extended by Softing's Docker-based edgeConnector and edgeAggregator software."

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@SoftingIA @mepaxIntPR #PAuto #Manufacturing

Real-time qualified industrial PCs.

Today, more and more industrial customers are using PC (Personal Computer) technology for high end sophisticated real-time control applications. These computers have high CPU processing capabilities in relation to their costs when compared to software and hardware development for dedicated platforms.

Typical applications where such PCs are used are:

• CNC and Motion Control
• Robotics and PLC applications
• Medical applications like surgical robots or computer tomographs
• Real-time data acquisition

Regular PCs are designed for standard office use while such industrial applications need hardware which is more suitable to their respective environment: Industrial PCs (IPCs)!

These Industrial PCs fulfill various requirements like mechanical robustness, power consumption, connectivity, storage.

However, some control systems require hard real-time latency predictability while the processors of the x86 architecture today have sophisticated power saving mechanisms which may have serious impact on the requested determinism. These CPUs also have a special protection and correction mode known as system management mode (SMM). This mode is not traceable by the operating system and is a source of unpredictability in the system. Also other features that may be controlled in the BIOS may have an influence on the IPC's real-time behavior like Hyper Threading or GPU settings.

Thus, one of the IPC selection criteria will be the real-time capabilities of the respective solution. Especially in the case applications have the need to run the Microsoft Windows operating system in conjunction with a real-time extension or real-time hypervisor software solution, this becomes an important and sometimes challenging selection criteria.

For that purpose, acontis has developed a standard scheme to determine and compare the real-time capabilities of Industrial PCs. 

An excerpt of different IPCs from various vendors have been pre-validated for real-time use.

Appropriate BIOS settings as well as real-time results are published here on their website.

@PresseBox #acontis #IndustrialPC

VFD manufacturer drives ahead!

Invertek Drives is expanding following significant growth in global sales.said the investment will create an expansion to its global variable frequency drive (VFD) manufacturing and distribution centre, along with the development of a new Application Centre.

It will create 85 new jobs over the next 12 months on top of the 280 people already employed at the global HQ in Mid Wales and follows a major recruitment drive over the past year in both its production and research and development departments.

The company designs and manufacturers VFDs used for the accurate control of electric motors used in many applications and industries globally. These range from conveyors to CNC machines, HVAC and ventilation systems, to water pumping applications The VFDs are also major contributors to creating energy savings and reducing associated CO2 emissions in processes by making electric motors more efficient, cutting energy use by between 30% and 50% in many cases. They control the speed of motors, pumps and fans, ensuring they operate at optimum speeds. They control the speed of motors, pumps and fans, ensuring they operate at optimum speeds.

Shaun Dean, CEO of Invertek Drives, and who is also Senior Vice President of Sumitomo Heavy Industries and CEO of Power Transmission and Controls Group (EMEIA Business HQ), said: “We’ve seen significant growth in sales and turnover over the past 18 months despite the global pandemic.

“Invertek’s approach to maintaining strategic stock of components has ensured we’ve been able to continue manufacturing our Optidrive range of VFDs despite the global supply chain problems currently facing many manufacturers.

“We continues to commit to investing heavily in the innovation, development and manufacturing of VFD technology. The expanded manufacturing facility will allow us to increase production from 350,000 units a year to 600,000.

“This is part of our drive to create the leading next generation VFD technology that will help to further reduce energy use and associated CO2 emissions globally.

We will add three new production lines each consisting of six Global Assembly Cells (GACS) allowing the increase in production."

Around eight billion electric motors consume nearly 50 per cent of the electricity produced in Europe. Globally, 40 per cent of electricity is used to power industry, with two-thirds of this used by electric motors. And yet less than 20 per cent of electric motors are controlled by VFDs.

@Invertek_Drives #Wales #Pauto #HVAC

Cloud-based CNC monitoring to shop floor.

Tech Manufacturing, a supplier of machined metal parts for aerospace clients such as Boeing, Lockheed Martin, and Bombardier, with their 5-axis CNC machines already running 24 hours a day up to 7 days a week, looked to Moxa for smarter operation and real-time machine performance data. The company's goals were to raise production capacity, reduce lead times for their clients’ largest and most urgent orders, and expand the useful service life of their existing machines.

“We needed a better understanding of how our machines were actually performing for us in real-time. Live and historical machine performance data would also help us identify technical or process issues that were detrimental to productivity,” said Jerry Halley, Chief Engineer of Tech Manufacturing, and one of the company's 70 employees.

Purchasing additional machines would, of course, be one way to achieve this. But Halley was interested in finding a smarter, more efficient approach that did not require a large capital investment. That "smarter way" was a CNC monitoring system that would collect, analyze, and visualize necessary performance metrics. Before taking the next step, however, Halley carefully weighed the productivity gains of such a system against the cost and effort of deployment, especially if it involved a new and unfamiliar server-based IT infrastructure. The ideal system would be easily deployed without specialized IT equipment, knowledge, or effort, and would not require repeated software installation, updates or configuration.

New Life To Older Machines
Tech Manufacturing selected Shop Floor Automations, one of the most prominent systems integrators in North America, to assist with a cloud-based CNC monitoring system. Each of Tech Manufacturing's CNC machines were connected to the existing local area network, so no additional IT infrastructure was required.

For legacy machines that did not have a readily available Ethernet port, Shop Floor Automations provided an easy-to-deploy solution that was developed based on Moxa NPort® W2150A and W2250A wireless device servers that permit communications software to access serial and Ethernet devices over the wireless LAN. Being wireless the device servers required far fewer cables and lets users roam between several access points. As such, the servers offered an excellent solution for devices that are frequently moved from place to place, as is the case in many factory settings.

“Getting our CNC machines connected and monitored has made it much easier for us to deliver on our clients’ build-to-print orders with maximum efficiency and minimum lead time. It is a lot easier to get connected than a lot of people may realize,” said Halley.

With the local network connected to the Internet, CNC machine performance data at Tech Manufacturing can now be easily viewed and analyzed by cloud-based software such as Scytec DataXchange or Predator Machine Data Collection. Key performance metrics are organized on a visual dashboard so the company's owners and machine operators are able to see exactly how productive each cell is performing, down to the machine level.

Using a cloud-based monitoring system, Tech Manufacturing was able to minimize their upfront cost and deployment effort, explained a representative from Shop Floor Automations: “Many clients perceive it to be difficult and expensive to set up a CNC monitoring system. However, with today’s cloud-based solutions, you can be set up in less than a day, with almost zero additional IT infrastructure or maintenance effort.”

With the system now up and running, a live dashboard has made it easy for Tech Manufacturing to identify critical productivity issues. For example, one immediate finding was that set-up times on certain machines were unnecessarily long, leading to hours of lost productivity every day. By rearranging setup sequence and on/off times, Halley quickly achieved significant productivity gains with those machines.

Having comprehensive machine performance data on hand also provided an additional benefit: better service from CNC manufacturers. Service calls are now backed by a rich set of historical data, making it easier to identify and troubleshoot potential hardware issues.

“Manufacturers have became more willing and able to provide support when we need it because we have the data to show abnormal operation,” noted Halley.

@MoxaInc #Aerospace #Automation

Condition monitoring for CNC tools.

NUM has launched innovative artificial intelligence software that provides CNC machine tool users with highly cost-effective condition monitoring capabilities.

Compatible with all of NUM’s latest-generation Flexium+ CNC systems, the NUMai software package is a complete, fully integrated solution for CNC machine tools – it does not require any additional sensors, and runs on the same industrial PC as the CNC system’s HMI (human-machine interface).

NUMai software can be utilised as soon as a machine tool has been commissioned and is ready to start production, or on a machine that is already being employed for production purposes. The software initially acquires all pertinent operating data over a period of time, typically a number of hours, while the machine is being used for normal production tasks. Ideally, a diversity of part programs is run, involving a variety of different machining conditions, in order to ensure that the data is as comprehensive and reliable as possible.

The collected data is used to teach a neural network so that any deviation from the ‘good’ machine behaviour and performance can then be detected and predicted; a suitable PC program for subsequent online performance monitoring and diagnostic purposes is generated automatically.

During the software’s development, NUM beta tested the technology on a CNC milling machine equipped with three axes and a spindle, which required a neural network comprising 36 neurons with three hidden layers. In this particular instance, 396 parameters needed their values to be accurately defined; this required the acquisition of more than 2 million ‘known good’ data points and 300 iterations of the teaching phase, which took about four hours per axis.

NUMai condition monitoring software capitalises on the inherent flexibility of NUM’s latest-generation Flexium+ CNC platform. As standard, every Flexium+ CNC system includes a PC which can handle data from the servo drives’ measurement points, a PLC that has direct access to machine parameters, and an NCK oscilloscope feature capable of reading values in real-time. All system communications are handled by FXServer, using fast real-time Ethernet (RTE) networking.

During everyday use in the production environment, NUMai software runs in the background on the industrial PC that forms part of the machine tool’s CNC system, continuously monitoring and evaluating the machine’s performance. Any discrepancy or deviation beyond user-defined thresholds is notified to the PLC, which decides what action should be taken – from a simple advisory message to an emergency disengagement.

The new NUMai condition monitoring software option can be installed and used on any Flexium+ CNC system running NUM’s Flexium software version 4.1.10.10 or higher. 

@NUM_CNC #Pauto #CNC

Software wizard for workpiece probe measurement.

CNC machine tool operators now have an easy means of performing probe measurements of parts and tools on the shop floor

A new software option from CNC specialist NUM dramatically simplifies measurement cycles during CNC machining processes. Designed expressly for ease-of-use, the software employs graphical guidance techniques to completely dispense with the need for CNC machine operators to have any G-code programming experience. It is likely to be of especial interest to machine shops seeking to enhance their process verification or increase the throughput of precision parts.

Supplied in the form of a software wizard for use with any of NUM’s latest-generation Flexium+ CNC systems, the new option accommodates all standard probe measurement cycles for parts and tools. For maximum versatility, there are 17 different workpiece measurement routines and four probe calibration routines, plus two fixed probe calibration and cutter length pre-setting routines. The system also offers six measurement routines specifically for use on milling machines.

Each routine provides unambiguous guidance throughout its respective measurement cycle, effectively automating the process. The user is first prompted to specify the technological data for the measurement, such as the feed rate and probing speed, followed by preparatory data such as the approach and starting positions, and input and output data specific to the selected cycle.

Once a measurement cycle has been initiated by the operator, all probe positioning can be handled completely automatically by the CNC machine. The probe stylus is fully protected against collision with the part in the working environment, with any error being signalled to the CNC system and causing an immediate stop. The software includes full management of the RTCP (rotation tool centre point) function, to handle inclined coordinates inside the measurement circle.

NUM’s probe measurement guidance option brings a new level of flexibility to CNC machine tool use. Its advanced capabilities include complex tasks such as measuring the width of a rib/web and the mid-point for a paraxial probing movement, measuring the diameter and centre of a bore or a boss by means of four points, measuring the angle of an oblique surface by probing along the third axis, and vectorial measurement of a bore or boss by three points.

#PAuto @NUM_CNC #CNC

Software framework tool for CNC machine tools.

NUM has launched a powerful new software framework tool that enables users of CNC machine tools to generate and test ISO part programs offline. The tool looks set to win across-the-board approval in busy machine shops, where an uninterrupted workflow can provide a key productivity advantage.

The new Flexium Office framework software runs under Windows 7/8 or 10 on any standard PC. It allows any of NUM’s technology HMIs (Human-Machine Interfaces) to be used for specific projects – without requiring access to the target CNC machine tool. The corresponding ISO part program can be created offline, and can also then be tested offline using NUM’s Flexium 3D simulation software, before being transferred to the target machine.

NUM’s application-specific technology HMIs form part of the company’s Flexium CAM (Computer-Aided Manufacturing) software suite. The HMIs cover every type of CNC machining operation, including hobbing, shaping, milling, threaded wheel grinding and cylindrical grinding.

After selecting the most appropriate technology HMI for the task, the user simply carries out basic data definition tasks for the project in hand, using the highly intuitive tools and workflow commands provided by Flexium Office. Multiple projects can be started and saved at any time – allowing collaborative team development if desired – and the framework software provides support for 14 languages. As soon as the user is satisfied with the process and workflow of a project it can be used to generate the corresponding CNC part program – entirely automatically.

The CNC program can either be transferred directly to a nominated machine in the production plant, usually via a TCP/IP network, or input to the Flexium 3D simulation software for thorough evaluation before being issued for production purposes. The key advantage of simulation is that it enables users to optimise any ISO-code part program offline, further helping to maximise productivity by leaving the CNC machine tool free for manufacturing purposes.

This simulation software is extremely powerful. It provides full visualisation of the tool centre point path and workpiece material removal, backed by automatic checking for collisions between machine components, the tool and the workpiece. The software creates a dynamic colour image, showing the workpiece as a 3D volume than can be rotated and viewed from any perspective.

Flexium Office framework software runs on any standard PC and has no special graphics handling requirements. It needs approximately 30 MB of free space on the PC’s hard disk or SSD, and a minimum of 4 GB of RAM due to the Flexium 3D simulation software. For maximum performance, an i3 or i5 dual core processor configuration is recommended.

#PAuto @NUM_CNC

Vibration control system for CNC machine tools.

NUM has launched an innovative accelerometer-based active vibration control system for CNC machine tools. Primarily designed to improve machining by virtually eliminating tool head vibration, the system further helps increase productivity by maximising material removal rate (MRR) and can also provide valuable real-time feedback for predictive maintenance purposes.

Vibration damping off  (top) and on

NUM’s active vibration control system is a very cost-effective solution that provides unprecedented dynamic damping capabilities. Most competitive accelerometers on the market are only capable of low frequency sampling rates and require additional signal conditioning electronics before they can be connected – usually via Fieldbus – to the CNC or PLC system. Typically, acceleration data can only be retrieved once every 20 milliseconds, which is inadequate for vibration damping purposes on machine tools. The accelerometer in NUM’s new system is sampled every 100 microseconds, which means that it can be used for closed loop control at bandwidths approaching several hundreds of Hertz.

The small flange-mounting accelerometer transducer can easily be attached to the machine’s tool head and has a sensitivity of 0.02 g (1.96 m/sec/sec), with a measurement range of plus/minus 2 g (plus/minus 19.6 m/sec/sec). The transducer connects directly to the digital servo drive, obviating the need for any additional signal conditioning circuitry.

The active vibration control system utilises the drive embedded macros (DEM-X) option that is available on NUM’s MDLUX high performance digital servo drives. This option enables real-time macros to be embedded within the drive in order to manipulate its regulation algorithms. The output signal from the accelerometer transducer can thus be used to directly influence the behaviour of the speed servo control loop. All MDLUX servo drive modules use advanced DSP control techniques to maximise the CNC kernel-to-drive servo bus speed, and feature high loop bandwidths and special acceleration algorithms for uncompromised speed and positioning accuracy.

One of the most interesting applications of NUM’s new active vibration control system concerns Tool Centre Point (TCP) vibration due to the various vibration modes of a machine tool's mechanical structure. Until now, even if the machine is equipped with a high resolution encoder (integrated in the servo motor) it has been impossible to damp the TCP vibration, simply because it is not measured. Although complex system modelling and state-space control could possibly provide some effective results, the complexity is very high and the compensation robustness is quite weak. For example, in the case of a small parameter change, such as inertia, the effect of the compensation would be lost entirely.

However, by using NUM’s new active vibration control system to measure and dynamically alter the TCP acceleration in each of the main X, Y and Z axis directions, it is now possible to damp the vibration very accurately. Using this approach, tool head vibration can effectively be eliminated, significantly reducing tool wear and maximising the MRR of the machining process.

All acceleration data is processed within the drive in the digital domain, which means that it can be cyclically transmitted to the Flexium+ NCK and stored in the NCK buffer. The data can then be uploaded to the Windows operating system for further evaluation, or for use with NUM’s process monitoring software. It is especially useful for preventive maintenance applications, where it can provide early indication of potential machine problems before they become expensive repair tasks. Typically these include detecting spindle vibration caused by bearing problems, detecting the onset of performance deterioration such as increased friction or backlash, and detecting excessive tool wear or breakage.

#PAuto @NUM_CNC

Intelligent CNC gear hobbing machine.

NUM and Taiwan’s Feng Chia University have jointly developed an intelligent CNC gear hobbing machine with an advanced electronic gearbox that completely eliminates the time overheads of changing mechanical gears on traditional machine tools.

Development of the machine began in 2014, under the initiative of Professor Ruihong Xu, who works for the Bachelor’s Program in Precision System Design at the College of Engineering in Feng Chia University. Professor Xu is responsible for a number of industry-university collaborative research and development projects at the university.

Following detailed discussions between NUM and Professor Xu about the potential machine control possibilities of its latest Flexium+ CNC system – which offers an advanced precision electronic gearbox – the company donated a series of CNC controllers to the university in 2014. With the assistance of other providers, the intelligent CNC gear hobbing machine, which utilises five-axis electronic gear synchronisation techniques, is now complete. It is currently being exhibited in the first floor laboratory of Feng Chia University’s College of Engineering.

The open architecture of NUM’s Flexium+ CNC makes it an ideal platform for research and development projects such as this. The human-machine interface (HMI), together with loop programs for gear machining, have been specially created by Professor Xu, who was previously in charge of HMI development at HOTA Industrial Mfg. Co., Ltd. He continues to foster tight collaboration between the university, HOTA, Hiwin Technologies Corp. and NUM.

The new intelligent gear hobbing machine is based on a significant upgrade to a traditional NC gear hobbing machine that featured a mechanism provided by Chang Feng Gear Machinery Co. Ltd. Developed under the Industry 4.0 planning and design concept, it offers powerful expansion capabilities through use of a CNC-PC communication framework. Facilities for monitoring parameters such as spindle speed, temperature and motor current have been added. Transmission of network data, calculation of cloud data, analysis and prediction can be performed via suitably equipped tool wear monitoring systems. This facilitates online compensation and product measurement, to provide optimal cutting parameters and precision.

Founded in 2008, NUM Taiwan Ltd. is a subsidiary of NUM, and is based in Taichung, where many machine factories are located. NUM Taiwan Ltd. is responsible for businesses throughout south-east Asia, Korea and Japan, including CNC project development, after-sales service, education, and training. The company offers a variety of special machining software for gear applications, including an electronic gearbox function (five-axis synchronisation transmission) and an automatic tooth alignment function, which are essential for CNC gear hobbing applications. NUM Taiwan also actively supports Professor Xu in the development of teaching aids for PLC programming, parameter acquisition and machine commissioning.

According to Professor Xu, “NUM has complete applications related to CNC and gear machines, backed by abundant engineering knowledge and resources. During this development, NUM was willing to help us solve problems, and to provide relevant training to help us integrate our human-machine interface with the Flexium+ controller. The company also spent considerable time on on-site commissioning, in order to let students become fully conversant with the system. NUM’s CNC systems provide exceptional expandability. We can easily access the information relevant to the machine and share the information via the network. Furthermore, the electronic gearbox system included in the Flexium+ CNC system is superior to the traditional tooth matching gearboxes. It can achieve high precision and output without spending time on changing gears, and without the back clearance problems that occur in gears with traditional tooth matching.”

@NUM_CNC #Pauto @Wordsun_Ltd 

Set-up of automated cells made simple.

Sinumerik 828 controllers from Siemens offer a simple solution for connecting robots to machine tools. This represents an integral part of automated production cells set-up. To perform handling tasks, different types of robots designed by different manufacturers can now be connected to machines fitted with CNC controllers Sinumerik 828D using the Sinumerik Integrate Run MyRobot/EasyConnect interface. This enables companies of any size to set up automated cells even on serial machines cost-effectively and without any major effort – even with different types of CNC controls using the same standard interface. Features for the simple optimization of work processes on machine tools, mobile condition monitoring and remote maintenance round off the new solution for setting up automated cells.

Sinumerik Integrate Run MyRobot/EasyConnect is based on a standard defined by the German Machine Tool Builders' Association (Verein Deutscher Werkzeugmaschinenfabriken, VDW) and the German Engineering Association (Verband Deutscher Maschinen- und Anlagenbau, VDMA) for connecting robots or handling systems to machine tools. To make it as easy as possible to use the interface, Siemens has merely taken over the main elements of the comprehensive standard. The robots are connected through an Ethernet (Profinet RT) or using I/O signals.

Using the new interface, operators can easily synchronize processes between the machine tool and robots, thereby positioning efficient processes in the automated production cell.

Fully automated work processes are another important aspect of setting up automated cells covering all aspects of machine tools, starting off with preparatory work through to accessing all the necessary information and data at the machine and efficiently operating the machine right up to using mobile terminal equipment for visualizing machine conditions. Siemens provides a comprehensive range of smart operation features. Smart touch technologies are thus being integrated into the production environment. At the same time, operators can access network memories and can inspect contract documents at the user interface. The concept also includes an application for preparatory work at the PC, for instance, for creating partial programs.

Functions facilitating remote diagnosis of machine tools are the third component of the solution for setting up automated cells. With Sinumerik Integrate Access MyMachine, Siemens provides convenient and reliable functions for remote diagnosis using a corporate network or Internet access. The basic Access MyMachine/P2P application facilitates the exchange of data with connected machines from a Windows PC. An IP address is used for addressing purposes within the plant network. Operators can access the machine over the Internet or outside the plant network if the application is appropriately configured. The comprehensive Sinumerik Integrate Access MyMachine/Ethernet (ASP) provides a quick overview of the machine history in addition to machine access. The Sinumerik controller permits uploading and downloading machine data, files, trip recorders, and configurable PLC traces. Text message (SMS) or e-mail notifications in cases of unusual machine conditions are also possible. ASP grants cost-effective monitoring of fault states and comprehensive integration of in-house service and maintenance processes.

Clamping force measurement over machine control!

The Siemens Sinumerik CNC controllers have been getting the maximum productivity out of each machine for over 50 years.

Now they have another partner on their side: the Hainbuch Testit software. It is available on a data carrier for installation on Siemens CNC controllers [Sinumerik 840 D sl plus PCU50]. This means that a separate laptop is not needed anymore and manufacturing with "theoretical clamping forces" is also a thing of the past. Thanks to Testit, the operator always knows which clamping forces exist and where, and the actual maintenance status of the clamping device. And given the safety standard DIN EN 1550, it is a "must have". This means: The Testit clamping force gauge together with the Siemens CNC controller executes a target-actual comparison of the maintenance status of a clamping device. If the limit values are underranged, a warning message is output.

Trust is good, control is better
Based on his apprenticeship a machine operator or programmer has been taught to work in such a manner that a workpiece does not get destructed, e.g. when programming the manufacturing steps he builds in a lot of safety measures to minimize this risk. However, in reality, effective measurement data regarding the holding forces of a clamping device, and also in regards to the clamping forces of the clamping cylinder itself can only be obtained as vague reference values. A machine operator who knows how dependent the holding forces of a clamping device derive from its current maintenance status are, or from the centrifugal force losses while turning with jaw chucks, is extremely sceptical of such makeshift calculations and hence builds in a high safety value. Machining of easily deformable components is also extremely critical. Usually only a very small margin of holding force is available. If an item is clamped too strongly, a sensitive component will be excessively deformed. Applying to little clamping force results in an inefficient set-up for rational machining.

Safe results - even with mandrels
However, the globalization of markets requires an optimum of the machining process. Those who face stiff competition can no longer afford to manufacture just by »feeling«. Measurement data is demanded! It not only functions perfectly for outer diameters and during rotation, it also precisely measures the holding force of mandrels for inner diameters.

Open-source communications standard facilitates data-driven manufacturing #PAuto @NUM_CNC

NUM has developed a new communications interface option for its CNC systems that fully complies with the open MTConnect interoperability standard. Known as NUMConnect, the interface can be fitted to new or existing systems and simplifies the integration of CNC machine tools with third party manufacturing management software. It enables users to implement powerful productivity-enhancing real-time data collection and retrieval facilities for production monitoring and analysis purposes.

NUMConnect allows CNC machine tool builders to add further value to their products very easily and cost-effectively, by providing uncompromised connectivity for manufacturing data. Manufacturers are increasingly making use of data retrieved from CNC machine tools on the shop floor to improve the efficiency of their production processes. However, until recently, the lack of a vendor-neutral data communications standard within the industry meant that CNC machine tool companies could only provide their customers with proprietary solutions for collecting and retrieving manufacturing data.

To compound the problem, most CNC systems have a closed architecture and only provide a data link via their PLC, limiting data collection to the PLC’s scan rate. The inflexibility of this approach – which also demands custom client software for each machine type – drove an industry initiative to bring Internet style connectivity to manufacturing equipment.

MTConnect is an open, royalty-free communication standard that can be used by anyone and it is rapidly becoming the preferred choice of the machine tool industry. The standard is managed by the MTConnect Institute – a not-for-profit organisation that seeks to improve the use of real-data in manufacturing industries. A growing number of machine tool manufacturers are adopting the standard, which is also now supported by many leading suppliers of enterprise resource planning (ERP), manufacturing operations management and production dashboard software. NUM was one of the first CNC manufacturers to offer an MTConnect compliant interface for an entire product range which does not require the use of third-party or custom adapters. The company originally introduced the interface on its Axium product line in 2008 and is now making it available as an option across its entire range of CNC systems.

The underlying technology of the MTConnect standard is the same as that used by the World Wide Web. It is based an Extensible Markup Language (XML) for capturing data that is readable by both humans and machines, with the format of all data transfers defined by hypertext transfer protocol (HTTP). NUM’s open architecture CNC systems already use similar software technology for their human-machine interface (HMI), which is based on HTML and JavaScript and employs standardised server functions to facilitate the exchange of data between the CNC kernel, PLC, drives and motors. As a consequence, NUMConnect can read anything that is capable of being displayed on the CNC system’s HMI, regardless of whether it is in analog or digital format. Even detailed low level machine data, such as motor, drive or encoder error messages, can be retrieved and used for monitoring machine performance, preventative maintenance or diagnostics.

Developed by NUM Corporation in the US, NUMConnect is fully compliant with the latest 1.3.0 version of the MTConnect standard and is available ready fitted or as a retrofit option for all of the company’s Axium, Flexium and Flexium+ CNC systems, as well as its earlier generation Power 1000 series. The software can be installed on any standard PC equipped with Windows XP or later, and it runs in the background on any NUM industrial PC panel. As a member of the MTConnect Technical Advisory Group (MTCTAG), NUM Corporation is committed to keeping NUMConnect up-to-date with the latest developments in the standard and to helping machine builders best exploit its benefits.

The NUMConnect software interface essentially comprises two main components: an MTConnect Adapter and an MTConnect compliant information provider or lightweight webserver known as an ‘Agent’. The Adapter collects data from the CNC system, associates it with defined MTConnect data items, filters out any duplicates and then pushes the data to the Agent, where it is held in a buffer store until overwritten by fresh information. To help minimise response times, MTConnect does not require the establishment of a formal data transfer session, and under normal use there are no log-on or log-off sequences. When the Agent receives a request for information from any client application software, it transfers the appropriate data over the network, using HTTP. The system is inherently secure; MTConnect is a read-only standard designed to facilitate the retrieval of data from manufacturing equipment – it does not control or instruct a CNC machine tool to take action.

NUM’s CNC systems are renowned for their open architecture hardware and software, which provides machine builders with unlimited customisation opportunities and simplifies machine integration. These same attributes also make the systems a popular platform for educational purposes – NUM’s products are used by several leading universities to familiarise engineering students with CNC technology and advanced machining techniques.

As Steven Schilling, General Manager of NUM Corporation US, points out, “Our policy is to use open, industry standard interfaces wherever practicable and the new NUMConnect interface option is a case in point. We believe that MTConnect compliant communications will become widespread, to the point where the technology will be regarded as the ‘Bluetooth of manufacturing’. NUMConnect will help our customers, who tend to be small to medium sized OEMs, to compete with some of the larger players in the market by producing CNC machine tools that are ready for the trend towards even smarter manufacturing.”

Clamping force measurement over machine control!

The Siemens Sinumerik CNC controllers have been getting the maximum productivity out of each machine for over 50 years. Now they have another partner on their side: the Hainbuch Testit software.

Key advantages:
► Clamping force measurement for O.D. and I.D. clamping
► Can be used rotating [under RPM] and for stationary applications
► Direct input onto the Siemens CNC controller

It is available on a data carrier for installation on Siemens CNC controllers [Sinumerik 840 D sl plus PCU50]. This means that a separate laptop is not needed anymore and manufacturing with »theoretical clamping forces« is also a thing of the past. Thanks to Testit, the operator always knows which clamping forces exist and where, and the actual maintenance status of the clamping device. And given the safety standard DIN EN 1550, it is a »must have«. This means: The Testit clamping force gauge together with the Siemens CNC controller executes a target-actual comparison of the maintenance status of a clamping device. If the limit values are underranged, a warning message is output. Perfect, don’t you think?

Trust is good, control is better
Based on his apprenticeship a machine operator or programmer has been taught to work in such a manner that a workpiece does not get destructed, e.g. when programming the manufacturing steps he builds in a lot of safety measures to minimize this risk. However, in reality, effective measurement data regarding the holding forces of a clamping device, and also in regards to the clamping forces of the clamping cylinder itself can only be obtained as vague reference values. A machine operator who knows how dependent the holding forces of a clamping device derive from its current maintenance status are, or from the centrifugal force losses while turning with jaw chucks, is extremely sceptical of such makeshift calculations and hence builds in a high safety value. Machining of easily deformable components is also extremely critical. Usually only a very small margin of holding force is available. If an item is clamped too strongly, a sensitive component will be excessively deformed. Applying to little clamping force results in an inefficient set-up for rational machining.

Safe results - even with mandrels
However, the globalization of markets requires an optimum of the machining process. Those who face stiff competition can no longer afford to manufacture just by 'feeling'. Measurement data is demanded! It not only functions perfectly for outer diameters and during rotation, it also precisely measures the holding force of mandrels for inner diameters.

CNC and 3D simulation software for mechanical engineering courses!

Purdue University’s  College of Engineering has chosen to equip one of its key educational laboratories with NUM's open-architecture CNC systems and 3D simulation software. The equipment will provide students with hands-on CNC programming experience and help to familiarise them with advanced CNC machine tool operation and control techniques, using a powerful combination of virtual machines and physical high performance CNC demonstrator systems.

Purdue University is one of the USA’s leading academic research institutions and hosts one of the nation’s largest engineering faculties. Its College of Engineering comprises 14 schools and departments – each specialising in a particular engineering discipline – and is currently undergoing further major expansion. As part of the expansion, Purdue University is upgrading the mechanical engineering laboratory at the university’s main campus. This laboratory is principally used for teaching students the basics of CNC control and programming, and introducing them to machine-based manufacturing processes and techniques. It is currently equipped with several 2-axis CNC demonstrator machines based on NUM 760 and 10xx series CNC systems, together with a NUM 2D simulator.

Left Steven Schilling , MD, NUM Corporation,
& Yung C. Shin, Professor of Mechanical
Engineering at Purdue, in front of the
university’s historic Heavilon Hall clock.

According to Professor Yung C. Shin, who oversees all CNC-related education and research activities at the School of Mechanical Engineering, “When we set up the mechanical engineering lab in the 1990s, we looked at CNC systems from many manufacturers. However, most of the systems were like black boxes so their operation was difficult to understand, which was far from ideal when we wanted to teach the basics of CNC control. We therefore decided to base our educational platform on NUM’s CNC systems, primarily because of their open architecture and the fact that the NUM was enthusiastic about helping us to use their products in this role. The openness of NUM’s CNC, especially with regard to NC code and I/O facilities, enables us to clearly demonstrate the exchange of data between the PLC, CNC and drive electronics, and simplifies integration with other lab equipment. Also, many of the CNC machines that we use in our manufacturing research labs are based on NUM CNC systems, so there is a high commonality of coding.”

NUM has acted as a CNC partner to the School of Mechanical Engineering for some 24 years. Steven Schilling, General Manager of NUM Corporation in Naperville, Illinois, points out the importance of such long-term support for educational establishments, “The staff at Purdue always have access to our technical support people and receive engineering help whenever they need to reconfigure or reprogram CNC systems for new projects. This close cooperation ensures that the Purdue’s laboratory CNC equipment has the latest features and tools to aid students in developing new machining technologies.“

Many of the CNC machines
in Purdue are based on
NUM CNC systems, such as this
laser-assisted machining system
 for ceramic materials

The latest upgrade to the mechanical engineering laboratory’s CNC equipment is extensive. NUM has supplied two Flexium 68 CNC systems configured for milling applications, each with an NCK (Numerical Control Kernel), PLC, HMI and 3D simulator hardware and software, plus additional simulator dongles for four PCs. Flexium 68 provides a very versatile foundation for educational and research applications such as this, where the type of machine and the control approach change over time. As standard, the NCK accommodates up to 5 axes/spindles on a single channel, with full interpolation on 4 axes. Single NCK options can expand this to 32 axes/spindles in up to 8 channels, with up to 32 interpolated axes, while multi-NCK configurations can handle more than 200 axes.

To help improve ergonomics, the laboratory has installed two desktop consoles for human-machine interaction. Each console is equipped with a NUM FS152i operator panel and an MP04 machine panel, fitted with CAN interfaces. The operator panels feature 15 inch LCD screens and integral industrial PCs with solid state drives, run an embedded version of Windows, and are connected to the university’s Ethernet network. Each console can be used for simulation or for controlling the laboratory’s CNC demonstrator machines.

NUM has also supplied all the motors, drives, power supplies and associated hardware for two additional 2-axis demonstrator machines. Both of these combine latest-generation bi-axis NUMDrive C servo drives with BPH brushless servo motors. One of these machines uses the HP version of the drive with high performance control loops, to facilitate research into applications involving very fast or precise kinematics.

Using Flexium, Purdue University’s students and post-graduate researchers can now investigate CNC techniques to a very detailed level. All CNC, servodrive, I/O and PLC setup and programming is performed using a unified software toolset to help shorten the learning curve, increase productivity and work satisfaction, and encourage collaborative effort. The system’s inherent open architecture has multiple advantages. Application-specific HMIs (Human-Machine Interfaces) can be easily created or modified using industry-standard editors and languages such as HTML, JavaScript, Visual Basic, Delphi, C or C++, while the PLC can be programmed using any IEC 61131-3 compliant object-oriented graphical or textual language. In addition, students who need low-level control of the NCK – for example, for real-time axis transformations – can use dynamic operators in the code, while techniques such as real-time compensation can be developed using embedded loop control macros in the servo drives.

The Flexium 3D graphical simulation capabilities that Purdue University is installing in the mechanical engineering lab will improve work flexibility significantly. Until now, the simulation software required physical connection to the CNC system – which meant that only one student at a time could use it – and was limited to basic 2D simulation of path lines. The lab now has six separate simulator stations – two on desktop consoles and four on standalone PCs – each capable of true 3D workpiece simulation in standalone mode, without needing access to a CNC system. A further six networked PCs are also being installed, allowing students to perform simulation at different locations.

Students are now able to simulate and optimise any ISO-code part program that they have written, with full visualisation of the tool centre point path and workpiece material removal, backed by automatic checking for collisions between machine components, the tool and the workpiece. The simulation software currently supports 3-5 axis turning and 3-axis milling/drilling, as well as water jet and plasma contour cutting, and can be transferred between applications very easily. It creates a dynamic colour image, showing the workpiece as a 3D volume than can be rotated and viewed from any perspective.

Purdue University plans to make the new CNC facilities available to students in the autumn, as Professor Shin explains, “We need to be able to provide more students with hands-on experience of CNC programming and visualisation as soon as possible. There is now a resurgence in the domestic automation market thanks to new processes like additive manufacturing, and CNC programming skills are once again in short supply. Students are excited by CNC programming when they can see the results of their efforts – whether that's on a simulator, a CNC demonstrator or machine tool – which is why our new facilities are such an important educational tool. Some 65% of our graduates go on to pursue careers in manufacturing – and many have become professors in their own right. I like to think that when they set up their own laboratories they will remember the grounding that we gave them.”

Safety for specialist CNC machine builders

NUM has released a sophisticated system-wide functional safety architecture for its CNC system, providing an exceptionally scalable solution that can be applied very easily to almost any type of machine tool - regardless of complexity or number of axes. Known as NUMSafe, it includes a dedicated safety PLC, safe input and output modules, and digital servo drives with built-in safe motion monitoring. It is compatible with NUM's new-generation Flexium+ CNC platform.

According to NUM's Chief Technical Officer, Massimiliano Menegotto, "Functional safety is becoming a mandatory requirement for most types of machine tool, independent of the machine's performance, accuracy and complexity. As well as improving operator safety, it also increases machine productivity and availability. NUMSafe's inherent scalability and versatility of control gives OEMs a simple solution, regardless of whether the end product is a basic 3-axis machine, or some highly complex machine with a hundred-plus axes for an application such as rotary transfer machining."

Until relatively recently, designers wishing to implement even basic functional safety schemes on CNC machines were forced to use electromechanical safety technology such as special contactors and relays. This approach involved significant extra component and wiring costs, as well as increased machine development and build times. By integrating safety functionality across the entire CNC platform NUMSafe minimizes the need for additional hardware and simplifies software development, to OEM's considerable advantage. Furthermore, end users benefit from a strong increase in machine productivity because it is no longer necessary to power off the complete machine every time there is an element of human interaction; instead, protection can be ensured by dedicated functions which limit the movement, speed and position of axes.

A key advantage of the NUMSafe architecture is that safe devices such as the safety PLC and I/O modules can be contained within the same standard terminal line up as other elements of the control system. All communication between the machine's control system, operator panel and servo drives is handled via EtherCAT field bus, using a Fail Safe over EtherCAT (FSoE) protocol to ensure integrity of safety-related data. NUMSafe complies with the EN ISO 13849-1 machinery safety standard up to PL e, and with the EN 61800-5-2 functional safety standard for variable speed drives, up to SIL 3.

To help machine builders minimize development time the application programs for the safety PLC are created using the same suite of powerful software tools that is used to commission the entire system, including the CNC, PLC, drives and I/O modules. The logic of the safety application is programmed using function blocks such as 'E-Stop', 'Operation Mode', 'AND', 'OR, etc, linked to safe inputs and outputs.

Complex safety functions can be set up easily by chaining function blocks. For example, requesting the machine operator to perform an action requiring use of both hands - such as operating two control switches simultaneously - to prevent exposure to moving parts, and verifying this before allowing execution of any motion command, only requires a couple of instructions. The safety application is a self-contained program; as soon as the developer is satisfied with its logic it can be downloaded to the safety PLC.

NUM's latest NUMDrive X digital servo drives, which are available in mono- and bi-axes versions, can incorporate a safe motion monitoring module that operates in conjunction with the safety PLC to oversee and control all safety-related aspects of drive and motor behaviour. By allowing safety functions to be implemented on individual machine axes, and only where required, this modular approach helps reduce system cost. Furthermore, NUM offers two versions of the module, enabling designers to match their application needs very precisely. Both versions feature redundant channel architecture and use cross-monitoring techniques to ensure data integrity.

The basic safe motion monitoring module provides a Safe Torque Off (STO) function; this is the most commonly used safety function and ensures that the drive can longer command the motor to generate torque, with continuous monitoring to prevent unexpected start-up. In addition to STO, the extended version of the module implements the EN 61800-5-2 compliant functions of Safe Operating Stop (SOS), Safe Stop 1 (SS1), Safe Stop 2 (SS2), Safely­Limited Speed (SLS) and Safely-Limited Position (SLP) either by means of safe homing and incremental encoders, or by employing certified absolute encoders such as those used with NUM's new line of innovative single-cable servo motors.

Used singly or in combination, these functions enable designers to implement a wide range of machine safety concepts. For example, SS2 safely monitors that the braking of an axis is as quick as possible in the event of an emergency. This can be followed by the SOS function to instruct the drive/motor to maintain a fixed position by generating a degree of holding torque, but not to move - the axis is monitored continuously to ensure that it remains stationary.

Another cost-saving benefit of NUM's safety architecture is that there is no need for an additional encoder on machine axes that implement safety functions. Motor feedback can be derived from safe encoders which return position and redundant position data to the drive using a secure certified protocol, or, in the case of synchronous motors, any standard sin/cos encoder.

Almost unlimited configuration flexibility for machine tool manufacturers

A new generation of its CNC platform has been introduced by NUM, providing machine tool manufacturers with an exceptionally flexible and scalable solution for safe control of machine tools.

NUM's new multi-processor
touch-sensitive operator panel
supports a fully customisable HMI
and virtual keyboard.

Known as Flexium+, the modular safety-equipped platform enables OEMs to standardise on a single cost- and performance-optimised CNC architecture for a vast spectrum of machine types - from small machines with a few axes to large multi-cell manufacturing equipment with over 200 axes and spindles. In this way, the open architecture of the CNC platform can dramatically lower development and support costs, and speed time to market.

Flexium+ builds on the architecture of NUM's Flexium CNC - the fastest-growing and most successful CNC kernel in NUM's 50 year history. To provide even greater versatility, dynamic performance and accuracy, the platform's hardware includes new digital servodrive modules with integrated safety, a safety PLC module, safe input and output modules, and a multi-processor operator panel with touch-sensitive screen. New support software includes a precision operating system and soft automation PLC, complete with a fully customisable human-machine interface (HMI) that recognises touch gestures, an extensive suite of optional machining functions, and a powerful 3D simulator for part program verification and visualisation of machining processes.

A choice of three CNC kernels, Flexium+ 6, Flexium+ 8 and Flexium+ 68, enables machine designers to deploy technically and economically optimised solutions for different machine tool applications. Flexium+ 6 and Flexium+ 8 will control up to four interpolated axes and a spindle, where Flexium+ 8 is dedicated to machines which need a higher degree of flexibility. Flexium+ 68 supports larger and more complex machine control applications and provides up to eight CNC channels, each accommodating up to nine interpolated axes and as many as 32 spindles. In total, a single Flexium+ 68 CNC kernel can accommodate 32 connected devices, any of which can be interpolated axes or spindles. This universal control approach simplifies spindle/C-axis commutation and provides an excellent foundation for multi-spindle applications such as transfer machines.

"Being able to use one CNC architecture across a complete range of machines gives a very large payback, especially for the many small to medium sized machine tool builders that support a broad range of applications using limited design resources", says NUM's CEO Peter von Rueti.

An enhanced part program structure enables machine designers to take full advantage of the new CNC hardware's versatility. Each channel runs its own part program asynchronously and operates autonomously, much as if it had a dedicated CNC kernel, or it can be synchronised to other channels. Control of one or more axes or spindles can be passed from one channel to another on-the-fly to maximise use of available hardware resources.

In each channel, four spindles can be operated in a master/auxiliary arrangement, with real-time control of their speed, direction and indexing. This simplifies implementation of complex machining operations. The master handles advanced CNC functions such as maintaining CSS (constant surface speed) while the workpiece changes diameter during processing, or continuously tracking angular position during thread cutting, with the three auxiliary spindles handling associated higher speed machining.

Multiple Flexium+ 68 CNC kernels can be interconnected via real-time Ethernet, which enables the realisation of control systems with more than 200 interpolating axes. The ability to drive multiple CNC kernels and control this number of axes with a single automation PLC is a unique advantage of NUM's CNC architecture.

To help OEMs implement rigorous machine safety schemes, Flexium+ introduces a comprehensive system-wide safety architecture known as NUMSafe. All critical system operations are overseen by a new safety PLC module. In conjunction with new NUM safe I/O modules and servodrives - which incorporate safe motion monitoring circuitry - the safety PLC enables machine designers to implement high integrity safety functions with very few additional components.

NUMSafe is inherently scalable, requires minimal extra wiring and uses a Fail Safe over EtherCAT (FSoE) protocol to ensure integrity of all safety-related data. The architecture complies with the EN ISO 13849-1 machinery safety standard up to PLe, and with the EN 61800-5-2 functional safety standard for variable speed drives, up to SIL 3.

Available in single- and dual-axis versions, the new digital servodrives - NUMDrive X - offer a choice of two performance levels, with outputs from a few amps to 200 Arms. Their high degree of functional integration makes them one of the smallest drives of their type on the market. To further simplify design-in, the drives' safe motion monitoring board is available in a basic version with Safe Torque Off functionality, and in an extended version which adds Safe Operating Stop, Safe Stop 1, Safe Stop 2, Safely­Limited Speed and Safely-Limited Position functions.

NUMDrive X servodrives are significantly faster than NUM's earlier-generation NUMDrive C products. Advanced DSP control increases CNC-drive servobus speed by 100 percent. Together with improvements to the drives' bandwidth - by as much as 25 percent - and enhanced acceleration algorithms, this means machine designers do not need to sacrifice resolution during extended axis travel, or trade traverse rate against positioning accuracy. Overall CNC resolution and accuracy are further improved by a numerical processor in the CNC kernel; the software has been enhanced to utilise high precision format, allowing for finer interpolation and speed control.

To speed development of part programs, Flexium+ provides a unified suite of software tools with a consistent look and feel. All CNC, servodrive, I/O, automation PLC and safety PLC functions are set up and programmed using a single tool; the automation PLC offers a choice of IEC 61131-3 compliant graphical and textual programming languages, while the safety PLC is programmed using simple function blocks and Boolean operators. Unlike competitive CNC platforms, Flexium+ also offers a fully customisable HMI, allowing OEMs to add value to their machines through improved ergonomics. Dual touch gestures such as 'wipe', 'expand' and 'rotate' can be incorporated to capitalise on NUM's new touch-sensitive operator panel, while virtual keys can replace physical keys to further simplify machine operation and reduce build costs.

Manually-written or CAM-generated part programs can be verified and optimised easily and quickly using NUM's powerful Flexium 3D graphical simulation software on an offline PC. Alternatively, the software runs on the new operator panel, taking full advantage of its multi-core processor PC and 19-inch screen, and interacting with the machine's CNC unit, to simulate part programs either before they are run, or simultaneously with part processing. Users can visualise the path of the tool centre point, simulate material removal and check for collisions. As standard, the software can simulate a wide variety of machining functions including grooving, thread cutting and tapping on 3- to 5-axis turning machines, milling and drilling on 3-axis machines, and contour cutting.

An exceptionally diverse range of application support software covers machining functions such as grinding, turning, milling and cutting, as well as gear hobbing, shaping and finishing. The latest additions include new functions for water-jet and plasma cutting machines, using innovative 'tilted nozzle management' algorithms to prevent under- or over-cut edges by automatically compensating for the conical shape of the beam.

The Flexium+ CNC platform is backed by NUM's extensive portfolio of motors. NUM is also introducing two new ranges of brushless axis motors designed specifically for use with the new NUMDrive X servodrives. These drives incorporate an innovative digital encoder interface which dispenses with the need for a separate cable by carrying encoder power and data on a two-wire link embedded into the motor cable. The new SHX and SPX brushless axis motors have a single connector and cable, simplifying installation and reducing wiring costs significantly.

10,000 CNC

The 10,000th model of NUM's new-generation CNC kernel, Flexium, has been produced. This major milestone has been achieved within just three years from launch - marking a spectacular success for a mid-level CNC provider that serves mainly specialised machine tool builders.

Peter von Rueti of NUM holding the 10,000th Flexium CNC kernel, with members of the manufacturing team at the company's Italian facility in Cuggiono

"Machinery OEMs tend to be very conservative in introducing new technology, and we anticipated that volume sales of our new CNC kernel would not kick-in until typically years four to five of its lifespan," says Peter von Rueti, CEO of NUM. "2011 proved us wrong. We're one of the longest-established CNC companies and we have never seen such a rapid design-in. Annual sales of Flexium have even overtaken those of our previous-generation CNC kernel, Axium, which controls machine tools produced by dozens of world-leading OEMs."
NUM started shipping the Flexium platform in 2008. NUM attributes its rapid success to both performance and business factors.

For some OEMs it's the power of Flexium's soft PLC controller that attracts. For most though, it's the scalability feature of the platform, which allows it to be applied economically to small machines with up to five axes and spindles, or much larger machines with up to 200 axes. These attributes mean that machine tool OEMs are able to use the same control system across their complete range of machine designs - greatly reducing the workload on the engineering development team.

Another aspect of the CNC kernel's success is related to the rise of Asian markets, and the particular way in which NUM works with clients. A partnership ethos has always been at the heart of NUM's business philosophy. This is proving particularly advantageous in Asia where NUM's willingness to provide young machine tool OEMs with in-depth engineering support on aspects such as writing software and tuning machines has won significant new customers.

"Being able to use the same CNC to power a complete range of machines gives a large payback, and today over half of our leading customers have made that choice and use our CNC platform exclusively," adds von Rueti. "The machine tool market has an enormous middle ground of specialised OEMs who build machines in annual quantities measured in tens to hundreds. A typical engineering department at these machine builders might number just five to 10 people. For this level of company, using one universal CNC platform can easily save the cost of employing one or two additional engineers"

Software savings are becoming even more critical as the role of software in machinery design continues to expand. Twenty to thirty years ago software accounted for as little as just 5% of a machine's cost. NUM thinks the value of software deployed in the average machine tool today has risen to the 10-20% range, and the machine's electronics, engineering and software combined count for well over 50%. Being able to maintain just one PLC, and one user interface dramatically reduces the workload on busy engineering departments, and allows both faster deployment of new features to customers, and a simpler means for an OEM to create unique 'look and feel' branding.

"With the rapid rise of Asian and Latin American economies, competition in the machine tool sector is getting more intense, and we view control and user interface software as playing a critical role in adding value and differentiating a company's branding," adds von Rueti. "Making it easier for machine builders to adopt one universal CNC platform and software system was a key factor behind the development of Flexium, and we are expecting this capability to continue driving higher than average growth over the next 5 to 10 years."

There are two distinct segments in today's CNC marketplace: three 'tier one' suppliers that account for most of the high volume manufacturers of common machinery types such as mills, and a larger group of middle ranking vendors - including NUM - that serve mainly smaller volume and specialist machine builders. NUM believes that this market is on the verge of a shake up: over the next decade many machine builders will gravitate towards those vendors providing much richer software tools and support. The success of the Flexium platform is already proving this to be the case, and it has brought NUM into direct competition with the highest volume suppliers - especially in the Asian market.

Two versions of the Flexium CNC kernel provide economic solutions for different sizes of machine. Flexium 6 is cost-optimised for standalone machines with up to five motion axes and spindles. The more powerful Flexium 68 handles up to 32 interpolated axes, divided into as many as eight coordinated groups. If more axes are required, to support very large equipment projects such as a multi-cell production line, Flexium 68s may be interconnected using a real-time Ethernet link. This allows the Flexium 68 system to be expanded to control over 200 interpolated axes, as well as further positioning axes and I/O. Software flexibility is at the core of Flexium. The platform gives machine tool OEMs complete control over the look and feel of the machine. The system's PLC is programmed according to IEC 61131-3 standards, and offers a choice of development software, providing machine control programming environment in forms to suit individual programmers. Flexium's man-machine interface is also completely adaptable, and can be easily programmed using standard tools such as HTML, Java Script, or one of the PC-based rapid software development environments. This flexibility, which allows users to add their own unique 'look and feel' branding to each machine, is in stark contrast with some competitive platforms, which have fixed user interfaces that may only be modified by the vendor. NUM's long-established range of drives and motors complement Flexium with a motion control capability that is highly optimised for machine tool applications.

CNC system automates machine!

An advanced application-specific CNC system from NUM has helped machine tool manufacturer Sinico to create a fully automated 9-axis rotary transfer cut-off and end-finishing machine for manufacturing volume batches of parts from metal bars and tubes. Thanks in part to the high speed of the CNC system, the new machine is considerably faster than Sinico's previous-generation machine.

The rotary transfer stage of the
TOP 2000ri employs a powerful
NUM BPH brushless motor capable
of generating 36 Nm of torque.

Sinico's new TOP 2000ri machine is the latest in a long line of flexible chip-removing machine tools, used by manufacturers for a wide variety of processes that include cutting, facing, chamfering, boring, centring, turning, drilling, threading, tapping and milling. The machines also handle shaping operations such as flaring, tapering, rolling, pressing, marking and knurling. Manufacturers use the machines to produce parts for an exceptionally diverse range of applications including hydraulic components, electric motors, industrial chains, power transmission, earth moving machinery and automotive components, as well as contract machining.

The performance of Sinico's new TOP 2000ri is impressive - the entire loading and setting of blank bars or tubes takes just 9 seconds, compared to 21 seconds on previous-generation machines; since this operation is repeated many times during a production run, it helps improve throughput significantly. Capable of accommodating tubes from 8 to 120 mm in diameter and bars from 8 to 80 mm, the machine can accept feed material up to 6.5 metres in length and produce parts up to 640 mm in length. These attributes, combined with its fast changeover capabilities, make the machine a supremely flexible solution for manufacturers producing a wide diversity of parts.

Sinico has used NUM CNC systems on a number of machines and the two companies have a history of collaborating on the development of new cutting and shaping techniques. In this instance, Sinico chose to base all of the TOP 2000ri's motion control functions on NUM equipment for two key reasons. First, it needed the flexibility and multi-axis capabilities of NUM's new-generation Flexium 68 CNC system to accommodate the machine's fast throughput and changeover characteristics. Secondly, it wanted to continue partnering with a company prepared to offer a fast and reactive service for collaborative software development.

All power supplies, drives and motors - including five high power spindle motors - were also supplied by NUM. The main rotary transfer stage of TOP 2000ri, which clamps and loads cut-to-length material into the end-finishing stages, is driven by a large NUM BPH brushless motor capable of generating up to 36 Nm of torque. This high speed stage feeds up to four workstations sequentially, making 90 degree moves in less than 0.4 seconds. The finishing stages of the machine employ five asynchronous AMS series spindle motors, each rated at 9 kW, plus a further eight NUM brushless motors for various position control tasks.

On the control side, there are seven single-axis NUMDrive C units, six rated at 130 A, and one at 14 A. There are also three dual-axis 50 A NUMDrive C units. The drive rack is powered by a NUM 120 kW regenerative regulated power supply together with an auxiliary power supply. Overall control of the machine is handled by NUM's new Flexium 68 CNC system.

The application-specific software for the Flexium CNC system was developed by NUM in conjunction with Sinico, using the CoDeSys hardware manufacturer-independent IEC 61131-3 programming system. This approach enabled engineers to easily share development. The application-specific HMI uses a NUM FS152i P2 control panel, featuring a touch-sensitive screen and an integrated industrial PC, together with a customised keyboard and a hand wheel for making small parameter adjustments easily and quickly. The code for the HMI was developed by Sinico, using standard Visual Basic to call routines from the NUM-supplied libraries.

The entire process flow on the TOP 2000ri is synchronised by NUM's advanced new CNC kernel, Flexium CNC. This is over four times more powerful than the fastest version of NUM's well-known Axium controller, which has been a popular choice for machine tool applications for many years. The HMI is specifically designed to present machine operators with a clear portrayal of each manufacturing stage, so that they can familiarise themselves easily with the entire process. A large number of different setup parameters can be stored and recalled at any time, enabling a changeover of the part being manufactured to be accomplished in very short timescales. This minimises machine 'dead' time and helps maximise overall productivity.

The TOP 2000ri features Sinico's patented AVTC system, which continuously varies the feed rate to the machine's cut-off stage to ensure that a constant volume of material is removed. The software automatically generates an ISO program for the ideal cutting speed curve, depending on the dimensions of the bar being processed and the shape that has been specified. This reduces cutting times to an absolute minimum and helps to increase the life of the saw blade.