Automatic Data Collecting and Application of the Touch Probing System on the CNC Machine Tool

For realizing automatic data collecting of the touch probing system on the CNC machine tool and practicing the application technology of big data from the CNC machining process, a special NC program was developed on the Siemens 840D SL controller to record data with a defined text format, and they were uploaded onto the host computer automatically. With the help of DB management software in the host PC, data obtained were sent into the MES database regularly, and then automatic data collecting of manufacturing process information was realized. With the big data technology, three applications based on big data technology have been listed. They are duo active error detection on the probing system, geometrical accuracy monitoring, and management of the cutting parameter and tool life. Tests of cutting on the platen of an injection molding machine with a PAMA SR3000 floor-type CNC boring-milling machine proved that the new technology achieves its design objectives.

Data acquisition and data mining in the manufacturing process of computer numerical control machine tools

Networks of five-axis machine tools produce huge amounts of process data. These data directly reflect the running condition of the machine tool but are seldom used to examine the machine performance. This study proposes a new data acquisition method based on the Object linking and embedding for Process Control protocol without any additional monitoring equipment. The data collection principle is explained, and a client is developed based on the SIEMENS 840D system. Considering less influence on the manufacturing process, a communication architecture for the machine network is designed with a special computer transmitting the data to the server. A compression algorithm is applied to reduce the storage capacity of massive amounts of data. Finally, a method for predicting the future performance of the machine tool is proposed using similarity analysis of the time series. A Petri net model is also established to diagnose possible failure causes. These methods significantly improve the machine tool reliability and find potentially important information from the data in the manufacturing process.

Thermal Error Modeling of the CNC Machine Tool Based on Data Fusion Method of Kalman Filter

This paper presents a modeling methodology for the thermal error of machine tool. The temperatures predicted by modified lumped-mass method and the temperatures measured by sensors are fused by the data fusion method of Kalman filter. The fused temperatures, instead of the measured temperatures used in traditional methods, are applied to predict the thermal error. The genetic algorithm is implemented to optimize the parameters in modified lumped-mass method and the covariances in Kalman filter. The simulations indicate that the proposed method performs much better compared with the traditional method of MRA, in terms of prediction accuracy and robustness under a variety of operating conditions. A compensation system is developed based on the controlling system of Siemens 840D. Validated by the compensation experiment, the thermal error after compensation has been reduced dramatically.

Ethernet-Based Data Acquisition Technology of Open CNC System

It describes the development and the present situation of the open CNC system technology. Taking the FANUC30i and Siemens 840D CNC system as an example ,it does an explicit research on data acquisition of the CNC system based on the Ethernet. It proposes a solution with high practicability and low cost for the users who want an online monitoring and alarming system of the CNC system.

Development of the Software for Ball Nut Grinding Process Based on Siemens 840D System

Based on the analysis of the grinding model and grinding process of ball nut, the grinding process software for ball nut is developed by using VB programming language and Access database technology. Afterwards, the software is integrated into the Siemens SINUMERIK 840D System. As a result, it realizes the database management of grinding parameters and the automatic generation of machining program, thereby simplifying the process of CNC operation and improving the production efficiency greatly.

The Development of Measurement and Control System for a Machine Tool

In order to satisfy the magnetic rheological polishing process, we established a measurement and control system based on SIEMENS 840D numerical control system. The structure of the system are introduced in detail, i.e. the four component modules, the seven component units establishing the hardware platform, and the three component parts establishing the electric control system design. The measurement and control system presented in this paper provides guidance for the relevant products.

Table-Based Compensation for 5-Axis Machine Tools

This paper presents a 5-axis machine tool compensation method that uses tool tip measurements recorded throughout the joint space to construct a set of compensation tables. The measurements can be taken using a laser tracker, permitting rapid measurement at most locations in the joint space. To compensate the machine tool, the measurements are used to identify a kinematic model, and then that model is used to construct an optimal set of compensation tables. The kinematic model is composed of the nominal, or ideal, kinematics with additional (unknown) six degree of freedom errors inserted between each of the joints. The error kinematics are identified using the measurement data and a maximum likelihood estimator. The identified model is then projected onto a joint-compensation space that maps to the compensation tables in the machine tool controller. Simulations of the approach are provided using measurement data from a Flow International 5-axis machine tool equipped with a Siemens 840D controller. The simulation results show a mean residual error of .076 mm, which is a 76.8% reduction from the uncalibrated machine tool.

Application of Siemens 840Di System in the Reconstruction of KISC Roll Collar Grinder

This work studies the reconstruction of high-speed roll grinder for sculptured surfaces with high feed rates. Experiments and predictions were focused on representative surfaces of dies and molds, whose geometric complexity and complexity distribution were modified parametrically. CNC programs for machining these surfaces were executed in a HERKULES HSF2CNC machining center with a SIEMENS 840D controller, with different levels of programmed feed rate. Discrepancies between programmed and actual feed rates were evaluated. A mechanistic approach for roll grinder in high-speed milling of sculptured surfaces is proposed. The mechanistic model construction is based on: (a) the frequency distribution of linear interpolation path lengths in the CNC program and (b) a characterization of the machine tool for brisk and smooth movements. Two case studies were used to demonstrate the effectiveness of the proposed approach. The reconstruction model is capable of the manufacturing.