A novel methodology for cross-technology interoperability in CNC machining

In CNC part programmes, the lack of standardisation for representing part geometry and semantics of manufacturing operations leads to the necessity for existence of a unique part programme for each machine. Generating multiple programmes for producing the same part is not a value adding activity and is very time consuming. This wasteful activity can be eliminated if users are given the ability to write an NC program for a specific machine and robustly convert the program to syntax suitable for another CNC machine with a different structure. This, cross-technology interoperability, would enable for parts manufactured on old CNC machines using legacy code to be manufactured on new CNC machines by automatically converting the programmes. Every NC programme is written based on various categories of information such as: cutting tool specifications, process planning knowledge and machine tool information. This paper presents an approach for cross-technology interoperability by refining high-level process information (i.e., geometric features on the part and embedded manufacturing resource data) from NC programmes. These refined items of information stored in compliance with the ISO14649 (STEP-NC) standard may then be combined with new manufacturing resource information to generate NC code in a format that is compatible with machines based on different technologies. The authors provide a framework for this process of identification, semantic interpretation and re-integration of information. The focus of this paper is on asymmetric rotational components as the initial application area. To demonstrate the proposed cross-technology interoperability approach, a C-axis CNC turn–mill machine and a 4 axis CNC machining centre have been used with a simple test component.     

STEP-NC compliant process planning as an enabler for adaptive global manufacturing

Manufacturing firms are seeking more efficient methods of CNC manufacture. ISO14649 informally known as STEP-NC has been proposed as a high-level hierarchical manufacturing information model as a replacement for the low-level machining instructions of ISO6983 and RS274D. In this paper, the applicability of STEP-NC as an enabler for creating an adaptive global manufacturing system is examined. The overall framework of the system is presented followed by an outline of its information requirements. Suitability of STEP-NC to support each requirement is then studied with the necessary additions highlighted. Finally, a test component is used in conjunction with a prototype of the advanced global manufacturing system to demonstrate the applicability of the STEP-NC standard to support manufacturing information in such a system.     

Process control in CNC manufacturing for discrete components: A STEP-NC compliant framework

With today's highly competitive global manufacturing marketplace, the pressure for right-first-time manufacture has never been so high. New emerging data standards combined with machine data collection methods, such as in-process verification lead the way to a complete paradigm shift from the traditional manufacturing and inspection to intelligent networked process control. Low-level G and M codes offer very limited information on machine capabilities or work piece characteristics which consequently, results in no information being available on manufacturing processes, inspection plans and work piece attributes in terms of tolerances, etc. and design features to computer numerically controlled (CNC) machines. One solution to the aforementioned problems is using STEP-NC (ISO 14649) suite of standards, which aim to provide higher-level information for process control. In this paper, the authors provide a definition for process control in CNC manufacturing and identify the challenges in achieving process control in current CNC manufacturing scenario. The paper then introduces a STEP-compliant framework that makes use of self-learning algorithms that enable the manufacturing system to learn from previous data and results in eliminating the errors and consistently producing quality products. The framework relies on knowledge discovery methods such as data mining encapsulated in a process analyser to derive rules for corrective measures to control the manufacturing process. The design for the knowledge-based process analyser and the various process control mechanisms conclude the paper.     

Standard process monitoring and traceability programming in collaborative CAD/CAM/CNC manufacturing scenarios

The paper focuses on collaborative STEP-based CAD/CAM/CNC supply chains to program and automate machining process data monitoring and traceability activities. A traceability interface (traceability nc_functions) is defined for the new CNC programming standard ISO STEP-NC. CAM systems will be able to program monitoring and data access activities by inserting traceability nc_function calls in CNC programs. On the shop floor, controllers will automatically interpret these nc_functions to access process data while machining and will relate data records with the corresponding machining operations in a STEP-NC part program. With both types of information—process data and standard machining program (STEP-NC part program)—spread and technologically heterogeneous engineering systems will have full knowledge about what has happened in production. Traceability data access automation will assure data reliability. The paper describes a traceability scenario where standards such as MTConnect and ISA-95 support, rather than interfere with, the STEP-NC traceability proposal.     

Novel strategies for global manufacturing systems interoperability

This paper reviews some of the most recently reported research into novel strategies for global manufacturing systems interoperability. Such research can be categorised as addressing four broad topic areas: the sensing manufacturing enterprise; semantics and knowledge management in manufacturing; service orientation and the need for negotiation; and business interoperability. Thus we identify a spectrum of research from the management of hardware and virtual sensing devices, through the semantic interpretation of the data and information generated by these, and its utilisation to support the collaborative manufacturing network lifecycle through service oriented software, and ultimately the provision of effective business interoperability. This study includes conceptual, theoretical, empirical and technological contributions, illustrated by real examples and demonstrating the novelty in comparison with previously reported results. The paper concludes elaborating final considerations on novel strategies for global manufacturing systems interoperability.     

基于STEP-NC的数控系统体系结构的研究

分析了当前主流开放式数控系统的本构模型,建立了系统内部的信息流模型,根据非实时、弱实时和强实时区分信息流。综合考虑数控系统的功能模型、信息流模型,建立STEP-NC数控系统的层次模型为模型应用层、制造规划层和实时控制层。给出了基于PC和嵌入式系统分层架构的STEP-NC数控系统结构。     

Dimensional metrology interoperability and standardization in manufacturing systems

Dimensional metrology is an important part of any manufacturing system. It consists of distinct components and requires a large, diverse, and interconnected knowledge base. How to pass information seamlessly with minimal cost and minimal data loss between different components of a dimensional metrology system is a major issue that concerns software and hardware vendors, standards developers, and customers. This paper focuses on the four main elements of a dimensional metrology system: product definition, measurement process plan definition, measurement process execution, and analysis and reporting of quality data. The activities and software modules that are involved in these elements are discussed. Key issues that cause interoperability problems are identified. These issues are discussed as they relate to the current situation in dimensional metrology standards development. The STEP (ISO 10303) standards are the product of an international effort to achieve interoperability for manufacturing systems. Extending STEP is an appropriate way to solve the interoperability problem within dimensional metrology systems. Further development of STEP standards is proposed so that Geometric Dimensioning and Tolerancing (GD&T) information already available in STEP can be linked with manufacturing feature information, measurement technology, and measurement results. The proposed STEP data model is an attempt to provide a standard that will support automatic measurement process plan generation for in-process on-machine measurement. Some case studies are under way to test the model.     

高性能数控系统解释技术的研究与实现

针对高性能数控系统中解释器面临的要求,通过深入分析现有数控系统中解释器及与之交互的任务控制器的主要功能及实现方法,指出其在高速高精加工时存在的不足,在此基础上设计并实现了一种高效的NC代码解释机制;然后,对现有数控系统进行了基于STEP-NC的改造,提出了面向网络化制造STEP-NC数控系统的基本框架,并重点介绍了基于XML的STEP-NC程序解释器的设计与实现.     

A Unified Manufacturing Resource Model for representing CNC machining systems

Standard information representation in the manufacturing business has always focused on products with information relating to their design, geometry and required processes. However there is no standardized information model available to represent the manufacturing equipment used to produce such products. This equipment contributes as a significant investment in setting up a CNC manufacturing facility and is considered as a major asset of the business. Thus the authors see a need for an effective model to represent such equipment particularly the most expensive assets namely CNC machining systems. Such a model could represent the machine resource and also its additional auxiliary devices such as workpiece and cutting tool changing mechanisms, bar feeders, pallet/gantry systems and robotic arms. These devices can function with a CNC only when the controller's resource data model can represent their functionality. Currently every machine tool and auxiliary device manufacturer promotes their own resource data models; resulting in a plethora of representation methods which are bespoke and incomplete in terms of representing the entire system's resources. This paper proposes a Unified Manufacturing Resource Model termed UMRM. UMRM not only has the novel capability to provide the information to define the various elements of the CNC machining system, but also has the added capability to provide support for automation of process planning decision making.     

Ontological approach for products-centric information system interoperability in networked manufacturing enterprises

Standardisation initiatives (ISO and IEC) try to answer the problem of managing heterogeneous information, scattered within organizations, by formalising the knowledge related to products technical data. While the product is the centred object from which, along its lifecycle, all enterprise systems, either inside a single enterprise or between cooperating networked enterprises, have a specific view, we may consider it as active as far as it participates to the decisions making by providing knowledge about itself. This paper proposes a novel approach, postulating that the product, represented by its technical data, may be considered as interoperable per se with the many applications involved in manufacturing enterprises as far as it embeds knowledge about itself, as it stores all its technical data, provided that these are embedded on a common model. The matter of this approach is to formalise of all technical data and concepts contributing to the definition of a Product Ontology, embedded into the product itself and making it interoperable with applications, minimising loss of semantics.     

STEP-compliant CNC system for turning: Data model, architecture, and implementation

STEP-NC, a new data model for CAD-CAM-CNC chain, is expected to encompass the whole scope of e-manufacturing. The new data model formalized as ISO 14649 is under development by ISO TC184 SC1 and SC4 for the replacement of the old standard so-called G&M codes, formalized as ISO 6983 which has been used since the 1950s. As the new data model is being established, development and implementation of STEP-compliant CAD/CAM/CNC system based on the new data model is drawing worldwide attention. Several systems have been reported in such international conventions as the ISO Expert Committee Meeting. Up to the present time, all the STEP-CNC systems are intended for milling operation. In this paper, the authors first present STEP-compliant CNC system for turning system including the data model, followed by a generic architecture and functionality. Implementation results obtained from a prototype system called TurnSTEP have been provided. Based on the results, the authors are convinced of the validity of the STEP-NC data model together with the effectiveness of the STEP-CNC system for turning.     

Advanced CNC system with in-process feed-rate optimisation

Tight quality requirements and stringent customer demands are the main thrust behind the development of new generation machine tool controllers that are more universal, adaptable and interoperable. The development of some international standards such as STEP and STEP-NC presents a vision for intelligent CNC machining. Implementation of STEP-NC enabled Machine Condition Monitoring (MCM) is presented in this paper. The system allows optimisation during machining in order to shorten machining time and increase product quality. In the system, an optiSTEP-NC, an AECopt controller and a Knowledge-Based Evaluation (KBE) module have been developed. The aim of the optiSTEP-NC system is to perform initial feed-rate optimisation based on STEP-NC data to assist process planners in assigning appropriate machining parameters. AECopt acts as a connector between the process planner and machining environment with the intention to provide adaptive and automatic in-process machining optimisation. KBE based-MTConnect is responsible for obtaining machining know-how. Optimisation is performed before, during or after machining operations, based on the data collected and monitored such as machining vibration, acceleration and jerk, cutting power and feed-rate.     

Formalizing interoperability for test case generation purpose

This study deals with interoperability testing of protocol implementations. The objective is to define a method for automatic test derivation based on formal definitions. First, the notion of interoperability criteria is introduced. They formally describes the conditions that two implementations must verify in order to be considered interoperable. Then, based on the equivalence of two of the defined interoperability criteria, we propose a method to derive automatically interoperability test cases that avoids the state-space explosion problem.     

Recent trends of manufacturing technology in Japan

Japanese industries have advanced manufacturing technology for thorough rationalization of manufacturing processes. This paper describes the historical background which brought the advancement of the Japanese manufacturing technology and the present status of the manufacturing technology in the automotive industry and the precision industries which are the leading industries in Japan at present. The Kanban system of Toyota Motor Co., automatic assembly and inspection line for watch production developed by the Seiko group and automatic mask aligner of Canon Inc. are explained in more detail. As for automatic machining technology and the automatic material handling technology, the present status of the NC machine tools and the robots is described. With respect to the research and development for the future, the project research of Flexible Manufacturing System Complex Provided with Laser and the VLSI Technology Research Association are introduced.     

Smooth time-optimal tool trajectory generation for CNC manufacturing systems

An optimization approach is proposed in this paper for generating smooth and time-optimal path constrained tool trajectory for Cartesian computer numerical control (CNC) manufacturing systems. The desired smooth time-optimal trajectory generation (STOTG) problem is formulated as a general optimal control problem. And axis jerk (derivative of acceleration with respect to time) constraints are introduced into this problem to remove discontinuities of the acceleration profiles. The desired smoothness of the trajectory can be accomplished by adjusting the values of jerk constraints. A control vector parameterization (CVP) method is applied to convert the optimal control problem into a nonlinear programming (NLP) problem which can be solved conveniently and effectively. The third derivative of the path parameter with respect to time (pseudo-jerk) and jerk act as optimization variables. The pseudo-jerk is approximated as piecewise constant, thus for at least second-order continuous parametric path, the resulted optimized trajectory with respect to time is also at least second-order continuous. Sequential quadratic programming (SQP) method is used to solve the NLP problem, through which numerical solution is obtained. Non-smooth (i.e. without considering jerk constraints) time-optimal trajectory generation (non-STOTG) problem is also considered in this paper for the purpose of comparison. Solutions of time-optimal trajectory generation (TOTG) problems for two test paths are performed to verify the effectiveness of the proposed approach.     

CAXA数控车床自动编程注意要点及难点解析

CAXA系列软件已经具有了非常丰富的功能,其应用范围涵盖了制造业的多种领域。CAXA系列软件的应用可以有效的解决手动编程过程中需要处理的大量计算问题,从而很大程度上缩短了编程所需的时间,同时可以减少人为错误,提升了编程效率和编程质量。本文主要对CAXA软件在自动编程中几点注意问题,并就几个难点问题进行解析。     

Towards interoperability of i* models using iStarML

Goal-oriented and agent-oriented modelling provides an effective approach to the understanding of distributed information systems that need to operate in open, heterogeneous and evolving environments. Frameworks, firstly introduced more than ten years ago, have been extended along language variants, analysis methods and CASE tools, posing language semantics and tool interoperability issues. Among them, the i* framework is one the most widespread. We focus on i*-based modelling languages and tools and on the problem of supporting model exchange between them. In this paper, we introduce the i* interoperability problem and derive an XML interchange format, called iStarML, as a practical solution to this problem. We first discuss the main requirements for its definition, then we characterise the core concepts of i* and we detail the tags and options of the interchange format. We complete the presentation of iStarML showing some possible applications. Finally, a survey on the i* community perception about iStarML is included for assessment purposes.     

A STEP-compliant process planning system for CNC turning operations

Over the last 50 years, there have been many significant enhancements in computer aided systems which have influenced the CNC technology. One area that can be considered as a bottleneck to these CNC enhancements, and in particular to interoperability in CNC manufacturing is G&M part programming (ISO 6983). To overcome this bottleneck, the new standard ISO 14649, known as STEP-NC, is being developed to provide detailed information on component design, process planning and machining strategies to manufacture parts for the next generation of intelligent CNCs. This standard forms the basis of a new paradigm shift in the CNC domain to support digital modelling of CNC manufacturing resources. The research in this paper aims to identify major issues and develop new software tools to demonstrate the feasibility of interoperable CNC manufacturing based on STEP-NC. Besides the literature review on recent research and development on STEP-NC, this paper proposes a Process Planning System (PPS) with surface roughness chosen as the process planning objective. PPS consists of five modules: program reader, process planner, STEP-NC CAD viewer, STEP-NC CAM viewer and program writer. The reader is responsible for interpreting the geometry and the manufacturing data from a STEP-NC text file into a stored data list. The process planner uses this data list and enables users to evaluate surface roughness based on a mathematical model. Through the STEP-NC CAD viewer, the part geometry can be shown and via the STEP-NC CAM viewer the toolpath can be verified. Finally, the writer converts the stored STEP-NC data of the system into an updated STEP-NC file. An example case study component is used to demonstrate the PPS and show the interfacing of the STEP-NC data.     

The challenge of networked enterprises for cloud computing interoperability

Manufacturing enterprises have to organize themselves into effective system architectures forming different types of Networked Enterprises (NE) to match fast changing market demands. Cloud Computing (CC) is an important up to date computing concept for NE, as it offers significant financial and technical advantages beside high-level collaboration possibilities. As cloud computing is a new concept the solutions for handling interoperability, portability, security, privacy and standardization challenges have not been solved fully yet. The paper introduces the main characteristics of future Internet-based enterprises and the different CC models. An overview is given on interoperability and actual standardization issues in CC environments. A taxonomy on possible connecting forms of networked enterprises and cloud-based IT systems with reference on interoperability is introduced, parallel presenting four use cases as well. Finally, an example of connecting cloud and NE is presented as an effective application of cloud computing in manufacturing industry.     

A novel open CNC architecture based on STEP-NC data model and IEC 61499 function blocks

Modern manufacturing industries demand computer numeric controllers, having higher level input languages than outdated G-code, and less proprietary vendor dependencies. IEC 61499 is a new standard for distributed measurement and control systems, that enables portability and interoperability of embedded controllers, along with the ease of their mapping to arbitrary distributed networking hardware configurations. This paper demonstrates that the IEC 61499 reference architecture can be successfully used to create a computer numeric controller, offering interoperability, portability, configurability, and distribution characteristics. The layered CNC-FB architecture is proposed, which simplifies the design of a CNC machine controller with the architecture layers responsible for data processing, data storage and execution. In combination with the object-oriented Model-View-Control design pattern, the CNC-FB architecture supports the design framework, in which simulation of the machining becomes natural and inherent part of the design process, with seamless transition from simulation to actual machining. The implemented controller was tested in both the model and on an actual milling machine.