PneuViz: MTConnect Compliant Compressed Air Monitoring Application

2012 ◽  
Author(s):  
Sri Atluru ◽  
Amit Deshpande ◽  
Sam Huang ◽  
Ron Pieper
Keyword(s):  
Manufacturing Industry ◽  
Metal Cutting ◽  
Numerical Control ◽  
Compressed Air ◽  
Sensor Data ◽  
Shop Floor ◽  
Cnc Machine ◽  
Manufacturing Facility ◽  
Customer Order ◽  
Cutting Operation

Compressed air is regarded as the fourth largest utility in the manufacturing industry behind electricity, natural gas and water. It is used in a wide variety of pneumatic, mechanical and maintenance applications in every manufacturing facility. However, very little efforts have been made in trying to monitor and optimize the utilization of compressed air. Hence, a project was conducted to study and analyze the utilization of compressed air under various scenarios that are typical during metal cutting operation in a manufacturing facility. PneuViz application was developed using LabVIEW programming package to monitor and analyze the results. PneuViz was seamlessly linked with the MTConnect data being broadcasted on the corporate network. PneuViz provides drill down capability to analyze cost of compressed air on a per part, per machine, and per customer order. Monitoring the utilization of compressed air by a stand-alone Computer Numerical Control (CNC) machine as well as the overall utilization on the shop floor was facilitated by the use of a sensor system comprising of a flow meter, Data Acquisition Device (DAQ), and a power sensor (load meter). MTConnect was used to enable plug-and-play functionality across the various machines on the shop floor. This was implemented by developing a system of MTConnect adapters that were able to capture the raw sensor data and broadcast it over the Ethernet network. Subsequently, analysis was carried out over various scenarios to determine the cost, energy and carbon footprint impact of the compressed air usage on the manufacturing shop floor.

scholarly journals A Low-Cost Vision-Based Monitoring of Computer Numerical Control (CNC) Machine Tools for Small and Medium-Sized Enterprises (SMEs)

Sensors ◽  
2019 ◽  
Vol 19 (20) ◽  
pp. 4506 ◽  
Author(s):  
Hyungjung Kim ◽  
Woo-Kyun Jung ◽  
In-Gyu Choi ◽  
Sung-Hoon Ahn
Keyword(s):  
Open Source ◽  
Machine Tools ◽  
Low Cost ◽  
Computer Numerical Control ◽  
Numerical Control ◽  
Smart Factory ◽  
Cnc Machine Tools ◽  
Shop Floor ◽  
Cnc Milling ◽  
Cnc Machine

In the new era of manufacturing with the Fourth Industrial Revolution, the smart factory is getting much attention as a solution for the factory of the future. Despite challenges in small and medium-sized enterprises (SMEs), such as short-term strategies and labor-intensive with limited resources, they have to improve productivity and stay competitive by adopting smart factory technologies. This study presents a novel monitoring approach for SMEs, KEM (keep an eye on your machine), and using a low-cost vision, such as a webcam and open-source technologies. Mainly, this idea focuses on collecting and processing operational data using cheaper and easy-to-use components. A prototype was tested with the typical 3-axis computer numerical control (CNC) milling machine. From the evaluation, availability of using a low-cost webcam and open-source technologies for monitoring of machine tools was confirmed. The results revealed that the proposed system is easy to integrate and can be conveniently applied to legacy machine tools on the shop floor without a significant change of equipment and cost barrier, which is less than $500 USD. These benefits could lead to a change of monitoring operations to reduce time in operation, energy consumption, and environmental impact for the sustainable production of SMEs.

scholarly journals A Novel Geometric Error Compensation Method for Gantry-Moving CNC Machine Regarding Dominant Errors

Processes ◽  
2020 ◽  
Vol 8 (8) ◽  
pp. 906
Author(s):  
Hong Lu ◽  
Qian Cheng ◽  
Xinbao Zhang ◽  
Qi Liu ◽  
Yu Qiao ◽  
...  
Keyword(s):  
Manufacturing Industry ◽  
Spline Interpolation ◽  
Total Error ◽  
Geometric Error ◽  
Least Square ◽  
Numerical Control ◽  
Cnc Machine ◽  
Novel Structure ◽  
Type Machine ◽  
Multi Body

Gantry-type computer numerical control (CNC) machines are widely used in the manufacturing industry. A novel structure with moveable gantry is proposed to improve the traditional gantry-type machine structure’s disadvantage of taking up too much space. Geometric errors have direct impacts on the actual position of the tool, which significantly reduces the accuracy of machines. Errors of different components are always coupled and have uncertain effects on the total geometric error. Thus, it is essential to find an effective way to identify the dominant errors and do targeted compensation. First, a novel identification method using value leaded global sensitivity analysis (VLGSA) is proposed to find the dominant errors. In VLGSA, weighting factors which show the influence of the error range are used to modify the multi-body system (MBS) error model. Results show that the dominant errors in three directions respectively contribute 80%, 86% and 85% of the total error in their directions. Then, errors identified by VLGSA are modeled by least-square linear fitting and B-spline interpolation methods, respectively, according to the feature of error data. Finally, the models are applied in a new real-time compensation system developed on the Beckhoff TwinCAT servo system. Experimental results from the gantry-type CNC engraving and milling machine show the proposed method can help figure out the most dominant errors and reduce around 90% of the total error.

Study on Design Proposal of Computerized Numerical Control Machine Networking

2013 ◽  
Vol 748 ◽  
pp. 699-703
Author(s):  
Zhang Lei
Keyword(s):  
Network Management ◽  
Manufacturing Industry ◽  
Production Management ◽  
Numerical Control ◽  
Network System ◽  
Cnc Machine ◽  
Engineering Technology ◽  
Enterprise Technology ◽  
Speed Up ◽  
Design Proposal

At present, the majority of enterprise technology management and production management have entered the network era. The demand for people who are occupied in 3D product design, numerical control advanced engineering technology is gradually increased. In order to speed up the production development of factories, we need to greatly improve the productivity of CNC machine. Therefore, CNC networking and management is imperative. This article describes background of the implementation of the numerical network management as well as its necessity. According to the industry characteristics of design and manufacturing and production management, this paper analyzes proposals on the network management system of CNC and describes the main functions of the machine network system and the results after the implementation. The network system of CNC is to improve the productivity of CNC machine, and give references to the application of CNC machine networking in large machine manufacturing industry.

scholarly journals Optimization of Process Parameters in CNC Turning of Aluminum 7075 Alloy Using L27 Array-Based Taguchi Method

Materials ◽  
2021 ◽  
Vol 14 (16) ◽  
pp. 4470
Author(s):  
Mohammad Nishat Akhtar ◽  
T. Sathish ◽  
V. Mohanavel ◽  
Asif Afzal ◽  
K. Arul ◽  
...  
Keyword(s):  
Taguchi Method ◽  
Process Parameters ◽  
Manufacturing Industry ◽  
Metal Removal ◽  
Removal Rate ◽  
Numerical Control ◽  
Cnc Machine ◽  
Machined Surface ◽  
Aluminum 7075 ◽  
7075 Alloy

With the advent of the industrial revolution 4.0, the goal of the manufacturing industry is to produce a large number of products in relatively less time. This study applies the Taguchi L27 orthogonal array methodological paradigm along with response surface design. This work optimizes the process parameters in the turning of Aluminum Alloy 7075 using a Computer Numerical Control (CNC) machine. The optimal parameters influenced the rate of metal removal, the roughness of the machined surface, and the force of cutting. This experimental investigation deals with the optimization of speed (800 rpm, 1200 rpm, and 1600 rpm) and feed (0.15, 0.20, and 0.25 mm/rev) in addition to cutting depth (1.0, 1.5, and 2.0 mm) on the turning of Aluminum 7075 alloy in a CNC machine. The outcome in terms of results such as the removal rate of material (maximum), roughness on the machined surface (minimum), along with cutting force (least amount) were improved by the L27 array Taguchi method. There were 27 specimens of Al7075 alloy produced as per the array, and the corresponding responses were measured with the help of various direct contact and indirect contact sensors. Results were concluded all the way through diagrams of main effects in favor of signal-to-noise ratios and diagrams of surfaces with contour diagrams for various combinations of responses.

Analysis and Research of Reliability Technology of CNC Machine Tools

2013 ◽  
Vol 584 ◽  
pp. 208-213 ◽  
Author(s):  
Zhe Liu ◽  
Jing Chuan Dong ◽  
Tai Yong Wang ◽  
Bo Li ◽  
Yu Long Cui
Keyword(s):  
Machine Tool ◽  
Manufacturing Industry ◽  
Modern Society ◽  
Numerical Control ◽  
Cnc Machine Tools ◽  
Cnc Machine Tool ◽  
Cnc Machine ◽  
Revolutionary Change ◽  
Control Machine Tool ◽  
High Productivity

From the middle of the 20th century, CNC(Computer numerical control) machine tool has brought a revolutionary change to the mechanical manufacturing industry. CNC machine tool is a kind of highly mechatronics product. It has the Characteristic of high precision and high productivity. Therefore it develops quite fast and improves various kind of the quality of the products. It speeds up the development of machinery industry. In order to meet the requirements of the processing accuracy and speed of modern society, the structure and components of the machine have also become complicated. In order to protect the safety of operators and reduce time of machine repaired as well as improve efficiency, the requirements of the reliability of CNC machine tool should be greatly improved. This study will briefly introduce the concept of reliability and put forward some measures to improve the reliability.

Adjustment of Mill CNC Parameters to Optimize Cutting Operation and Surface Quality on Acrylic Sheet Machining

2013 ◽  
Vol 377 ◽  
pp. 117-122 ◽  
Author(s):  
Kuswara Setiawan ◽  
Sihar Tigor Benjamin Tambunan ◽  
Pram Eliyah Yuliana
Keyword(s):  
Surface Quality ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Numerical Control ◽  
Cnc Machine ◽  
Excessive Heat ◽  
Spindle Rotation ◽  
Acrylic Sheet ◽  
Cutting Operation

Acrylic is easy to machine. In addition to the advantages derived from the use of mill Computer Numerical Control (CNC) machine on acrylic sheet, there are at least two serious problems that need attention especially in cutting a small part with many vertices. These problems are the presence of excessive heat due to friction between the cutting tool with acrylic sheet on high RPM of spindle rotation, and soft acrylic flakes trapped in crevices of the cutting tools’flute.Generally, the cutting process using a mill CNC machine often is a practice of trial and error. At least nine basic technical parameters need to be optimized. The effectiveness of the parameter values are determined by observing and measuring the actual cutting time using mill CNC machine at given parameter settings, surface texture quality, the level of clarity of the cuts, characteristics of chip formation, and edge roughness.The experimental results showed that the adhesion of acrylic sheet and cutting tools is relatively low. However, the heat of cutting tool due to high spindle rotation, low feed rate, and relatively low melting point of acrylic, tend to form very small, soft, and hot flakes. The acrylic chips have great potential entering the crevices of cutting tools’ flutes, and reducing the cutting power significantly. In other condition, the cutting tool could even be broken if feed rate is too high. Some technical values of these parameters are recommended to obtain optimal CNC based cutting operation and surface quality on acrylic sheet.

scholarly journals Testing Tool Material on Scratch Tester

2021 ◽  
Vol 9 (12) ◽  
pp. 1926-1930
Author(s):  
Saurav Salunke
Keyword(s):  
Manufacturing Industry ◽  
Metal Cutting ◽  
Cutting Tools ◽  
Tool Material ◽  
Workpiece Material ◽  
Research Article ◽  
Base Parameters ◽  
Tool Coating ◽  
Testing Tool ◽  
Cutting Operation

Abstract: In manufacturing industry cutting tools are considered as the backbone of the metal cutting operation. In metal cutting operation there is relative motion between the tool and the workpiece. As the tool material is harder than the workpiece material, there is deformation of the workpiece which acts as a base for the formation of chips. If we observe the process of metal cutting, we can easily find out that there is a considerable amount of heat generated during the machining operation. As there is a point of interface between the tool and the workpiece, there is absorption of generated heat into both the tool as well as work material. Due to the absorption of the heat there is distortion in the tool material. In this research article we have taken the base parameters as speed, load and stroke and the output parameter is taken as the load which breaks the coating of the tool. Keywords: tool coating, scratch tester, speed, stroke, coating.

Computer Numerical Control Machine Tool and its Development Trend

2013 ◽  
Vol 774-776 ◽  
pp. 1458-1461
Author(s):  
Huan Yun Wang ◽  
Xiu Fen Liu
Keyword(s):  
Machine Tools ◽  
High Speed ◽  
Manufacturing Industry ◽  
High Reliability ◽  
Development Trend ◽  
Numerical Control ◽  
Cnc Machine Tools ◽  
Cnc Machine ◽  
Control Machine Tool ◽  
Comprehensive Level

CNC machine tools are the key equipment in the equipment manufacturing industry, which is related to the national economic construction and strategic position, and is an important symbol reflecting the national comprehensive level. This article analyzes the emergency and characteristics of CNC machine tools and its development trend such as high precision, high speed, high reliability, complex, intelligent, flexibility, integration and openness.

Statistical Process Monitoring With MTConnect

2012 ◽  
Author(s):  
Sri Atluru ◽  
Amit Deshpande
Keyword(s):  
Statistical Analysis ◽  
Process Monitoring ◽  
Manufacturing Industry ◽  
Numerical Control ◽  
Cnc Machine ◽  
Statistical Process ◽  
Extensible Markup ◽  
End Mills ◽  
Communications Protocol ◽  
Statistical Process Monitoring

Statistical Process Control (SPC) techniques are used widely in the manufacturing industry. However, it is sometimes observed that a deviation that is within the acceptable range of inherent process variation does not necessarily conform to specifications. This is especially true in the case of low volume; high precision manufacturing that is customary in aerospace and defense industries. In order to study the limitations posed by conventional SPC techniques in such manufacturing environments, a study was undertaken at TechSolve Inc., Cincinnati to develop a standalone SPC tool. The SPC tool so developed effectively communicates with an on-machine probe and analyzes the collected data to carry out a statistical analysis. MTConnect, a new-generation machine tool communications protocol, was used in developing the communication interfaces with the on-machine probe on a Computer Numerical Control (CNC) machine. The XML (eXtensible Markup Language) code used to extend the MTConnect schema to include the data obtained from the probing routines is also presented. The statistical analysis was developed as a Graphical User Interface (GUI) in LabVIEW. The statistical analysis was carried out as a case study by producing a widget. Real machining was carried out to produce 48 of these widgets using a combination of end mills and face mills. The data obtained during the subsequent quality testing was used to carry out the statistical analysis. The limitations of conventional SPC techniques during the developmental and analytical phases of the study are discussed. The presence of a chip during an on machine probing routine, the variations due to disparities in tool macro geometry, and the demand for conformance to requirements are studied in the view of a statistical process monitoring standpoint. Various alternatives are also discussed that aim to correct and improve the quality of machined parts in these scenarios.

Characteristics and Technologies of Advanced CNC Systems

2011 ◽  
pp. 519-526 ◽  
Author(s):  
M. Minhat ◽  
X.W. Xu
Keyword(s):  
Computer Aided Design ◽  
Manufacturing Industry ◽  
Numerical Control ◽  
Monitoring And Control ◽  
Cnc Machine ◽  
Computer Aided ◽  
Process Monitoring And Control ◽  
Key Issues ◽  
Aided Design ◽  
And Control

Computer Numerical Control (CNC) systems are the “backbones” of modern manufacturing industry for over the last 50 years and the machine tools have evolved from simple machines with controllers that had no memory and were driven by punched tape, to today’s highly sophisticated, multiprocess workstations. These CNC systems are still being worked and improved on. The key issues center on autonomous planning, decision making, process monitoring and control systems that can adjust automatically to the changeable requirements. Introduction of CNC systems has made it possible to produce goods with consistent qualities, apart from enabling the industry to enhance productivity with a high degree of flexibility in a manufacturing system. CNC systems sit at the end of the process starting from product design using Computer Aided Design (CAD) tools to the generation of machining instructions that instruct a CNC machine to produce the final product. This process chain also includes Computer Aided Process Planning (CAPP) and Computer Aided Manufacturing (CAM).

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