Adaptive Control & Monitoring (ACM) System for CNC Metal Cutting Optimization

Technical Specification

TSGen 100617

June 2010

Technical Specification OMATIVE ACM Systems

Contents
1 2
2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14

ADAPTIVE CONTROL & MONITORING (ACM) TECHNOLOGY.................................. 1 PRODUCT FEATURES ......................................................................................................... 1

Real-time Feed Optimization..........................................................................................................1 Tool Breakage Protection ...............................................................................................................1 Spindle Drive Protection .................................................................................................................1 Automatic Feed Adjustment for Tool Wear Compensation........................................................1 Tool Wear Monitoring ....................................................................................................................1 Tool Breakage Detection .................................................................................................................2 Tool Overload Detection .................................................................................................................2 Tool Life Extension..........................................................................................................................2 Coolant Flow Monitoring................................................................................................................2 Tool Performance Statistics............................................................................................................2 Process Monitoring..........................................................................................................................2 GE P11TF12 Conformance.............................................................................................................2 Advanced Holemaking ....................................................................................................................3 Shopfloor Network Connectivity....................................................................................................3

3
3.1 3.2 3.3

OPERATING MODES ........................................................................................................... 3

Adaptive Control .............................................................................................................................3 Monitoring........................................................................................................................................4 Event Logging ..................................................................................................................................4

4 5 6

SETUP & OPERATION......................................................................................................... 5 APPLICATIONS..................................................................................................................... 6 ACM CONFIGURATIONS .................................................................................................... 8

6.1 6.1.1 6.1.2 6.2 6.3 6.4 6.5 6.6 6.6.1 6.6.2 6.7 6.8 6.8.1 6.8.2 ACM for SINUMERIK ...................................................................................................................8 ACM All-Software Configuration for SINUMERIK 840D ..........................................................8 ACM Hardware/Software Configuration for SINUMERIK ......................................................11 ACM for Heidenhain iTNC530 ....................................................................................................13 ACM for FANUC i-Series.............................................................................................................14 ACM for Okuma OSP-P200 .........................................................................................................16 ACM for DMG MillPlus ...............................................................................................................18 ACM for Fidia................................................................................................................................19 ACM All-Software Configuration for Fidia X-Power ................................................................19 ACM Hardware/Software Configuration for Fidia X-Power.....................................................20 ACM for Bosch-Rexroth MTX.....................................................................................................21 ACM for Other CNCs ...................................................................................................................23 Add-on PC-Based ACM Configuration......................................................................................23 Universal ACM Add-on Hardware Configuration......................................................................24

7 8

ACM INTEGRATION INTO THE MACHINE SHOP NETWORK.................................. 25 TECHNICAL CHARACTERISTICS................................................................................... 26

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Technical Specification OMATIVE ACM Systems

Adaptive Control & Monitoring (ACM) Technology

CNC machines operate at constant pre-programmed feed rates for each operation, even though cutting conditions may vary considerably during machining for the following reasons: Cutting depths and widths may vary especially in roughing operations Tool sharpness decreases during machining due to tool wear Material hardness varies within each workpiece Workpiece surface is often not even, whether the blank is a bar stock, forging, or casting Material hardness and blank dimensions vary from piece to piece and even more so from batch to batch Chip accumulation may occur especially in drilling Cooling qualities vary during machining Fixture stability may be adversely affected by dynamically varying forces CNC machines do not have the flexibility to adapt to the dynamic changes that occur during cutting. OMATIVE Adaptive Control & Monitoring (ACM) technology provides the solution to this limitation. OMATIVE ACM systems monitor actual cutting conditions in real-time and automatically adjust the feed rate to its highest feasible level during each operation, and if necessary, they stop the machine in case of overload conditions or tool breakage.

2
2.1

Product Features
Real-time Feed Optimization
In turning operations, OMATIVE ACM senses when the cutting load reaches the main drives maximum permissible load and reduces the feed rate until the cutting load falls within the acceptable load range. When cutting conditions permit, OMATIVE ACM increases the feed rate according to the maximum acceptable load.

OMATIVE ACMs unique expert systems continuously measure actual spindle loads, calculate optimal feed rates for each cutting tool and specific workpiece material, and adjust cutting feeds in real time. Smaller spindle loads activate higher feeds, while greater spindle loads trigger lower feeds in a controlled and scientifically calculated manner. The results are a significant cycle time reduction, and the prevention of damage to the spindle, cutting tools, and parts especially in critical roughing and semi-finishing applications where load variations are considerable.

2.4

Automatic Feed Adjustment for Tool Wear Compensation

2.2

Tool Breakage Protection

Since spindle loads increase gradually as tools wear, OMATIVE ACMs automatic and real-time feed adjustment ensures that the applied feed rate is continuously adjusted to compensate for gradual tool wear. When using OMATIVE ACM, NC programmers do not need to be conservative in programming feed rates for worn tools. Feeds may be programmed as though the tools were new and sharp. During actual cutting, the Adaptive Controller compensates for tool wear automatically throughout the process. Cycle time minimization is not compromised by tool wear.

During tool overload conditions, OMATIVE ACM automatically reduces the feed rate to an acceptable level as determined by ACMs internal expert system, and if necessary, even stops axis movements. After the extreme condition passes, the system increases the feed rate to the maximum feasible level again. Alternatively, users may customize the system to stop the machine automatically in selected tool overload conditions.

2.5

Tool Wear Monitoring

2.3

Spindle Drive Protection

In milling, drilling, grinding and gear hobbing, OMATIVE ACM detects when the maximum permissible spindle load is approached, stops the machine to prevent spindle and machine damage, and issues an alarm to alert the operator.

OMATIVE ACM can learn to monitor tool wear in a production run based on cutting the first workpiece. During the machining of subsequent workpieces, OMATIVE ACM continuously monitors cutting tool status and displays the extent of the tool wear as a percentage of the maximum permissible wear. When a tool is worn, the system outputs information to indicate this condition. 1

Technical Specification OMATIVE ACM Systems

The system issues an alarm, alerting operators to the need to change worn tools. Alternatively, machine tool manufacturers may use the output information to activate the Alternate Tool Station function in the CNC.

2.11 Process Monitoring

OMATIVE ACM includes a Windows-based graphics software component for monitoring the cutting process. This software performs the following: Real-time graphic display of load and feed variations, enabling analysis of machine and tool conditions. Display of production information for each job, including: job & operation start and end times, time spent in the workpiece, spindle rotation, and overload. In addition, this software enables the user to set up OMATIVE ACM systems for any job, even while other jobs are being run on the machine. A database can be created for all tool types, eliminating the need for repeated setup of tool types for different jobs on different machines.

2.6

Tool Breakage Detection

When activated for the cutting of the first part, this feature learns to detect tool breakage for subsequent parts. If a tool breaks while machining subsequent parts, OMATIVE ACM responds instantly with a Tool Breakage alarm and stops the machine movement.

2.7

Tool Overload Detection

During cutting, as the actual tool load reaches the Warning overload limit for any particular cutting tool, the OMATIVE ACM responds with a warning. This enables corrective actions such as timely tool replacement, feed and speed corrections, etc.

2.8

Tool Life Extension

OMATIVE ACM decreases the feed rate under extreme load conditions, and in doing so, eliminates excessive tool wear, thus extending tool life in many applications.

2.9

Coolant Flow Monitoring

If the machine is fitted with an appropriate coolant flow sensor (which is readily available from many vendors), OMATIVE ACM may be set to monitor the coolant flow rate continuously. Users can set a desired threshold flow rate to be maintained during the cutting operation. If the coolant flow ceases for a period of time longer than a preset value, the system will stop the machine.

Process Monitoring Screen

2.10 Tool Performance Statistics

OMATIVE ACM records tool performance data for all tools used. This data includes cutting time both with and without optimization, tool wear, and the minimum feed rate override that was measured during cutting operations. This data may be displayed on the screen for all completed operations at any time without interrupting the current operation. In the versions with PC-based user interface, this data (except for tool wear) is all displayed in real-time including for the currently running operation. More detailed performance statistics may be obtained by using the optional PC-based OMATIVE-PRO software.

2.12 GE P11TF12 Conformance

The following monitoring features are specifically included to conform to GE P11TF12 Specification: Additional hardware enabling the spindle load and coolant flow to be measured by an external device independent of the machine. Spindle load monitoring and its display in mV Display of load warning level (YELLOW) Display of load stop level (RED) Spindle speed monitoring Monitoring of external coolant flow Warning and machine stoppage when any of the monitored parameters reach their limits

Technical Specification OMATIVE ACM Systems

2.13 Advanced Holemaking

The following monitoring features are specifically included when Advanced Holemaking mode is selected: Spindle load monitoring and its display in mV Display of load warning level (YELLOW) Display of load stop level (RED) Spindle speed monitoring Monitoring of external coolant flow Monitoring of internal coolant flow and display of its rate Recording of actual values of parameters as specified in the NC program Warning and machine stoppage when any of the monitored parameters reach their limits

2.14 Shopfloor Network Connectivity

All OMATIVE ACM systems configurations can be integrated into a PC network running the optional OMATIVE-PRO Productivity Management software. As a management tool, OMATIVE-PRO assists shopfloor managers to effectively monitor and control the productivity of their machine tools. OMATIVE-PRO receives event data from OMATIVE ACM systems during cutting and provides Production event logging, Status Monitoring, production performance monitoring, and statistical reporting. In addition, OMATIVE-PRO assists users to support their ACM systems from a location remote from their machines; including ACM setup, NC program editing, and data exchange with ACM systems.

3
3.1

Operating Modes
Adaptive Control

For each operation, ACM may be set to operate in the Adaptive Control, Monitoring, or Event Logging mode. Adaptive Control

In the Adaptive Control mode, OMATIVE ACM systems continuously monitor actual spindle loads, calculate optimal feed rates for each cutting tool and specific workpiece material, and then adjust cutting feeds in real time. Smaller spindle loads trigger higher feed rates, while greater spindle loads trigger lower feed rates in a scientifically calculated manner. Thus, in this mode, cycle times can be reduced, especially in roughing and semi-finishing applications where load variations are considerable. In this mode, Event Logging is also performed (see section 3.3 below).

Technical Specification OMATIVE ACM Systems

3.2

Monitoring

In Monitoring mode, the system performs spindle load monitoring and tool condition monitoring to provide protection for the tools, spindle, and parts. In this mode, Event Logging is also performed (see below). Two monitoring mechanisms may be applied: 1. Maximum Load Monitoring OMATIVE ACM continuously compares the actual spindle load against a previously recorded maximum spindle load for the current cutting operation. Two levels are recognized: a. Warning Level If only the Warning Level is reached, OMATIVE ACM issues a warning message, and either continues without stopping, or stops the axis movement at the next air cutting, or at the end of the operation. b. Alarm Level If the spindle load reaches a predefined Alarm Level, OMATIVE ACM issues an alarm and immediately stops the machine if set to do so. 2. Load Band Monitoring OMATIVE ACM continuously compares the actual spindle load with a previously recorded spindle load variation pattern for the current specific cutting operation. Two bands are recognized, corresponding to two thresholds: a. Warning Boundary If only the Warning Boundary is reached, OMATIVE ACM issues a warning message, and either continues without stopping, or stops the axis movement at the next air cutting, or at the end of the operation. b. Alarm Boundary If the actual spindle load reaches the Alarm Boundary, OMATIVE ACM issues an alarm and immediately stops the machine. The Load Band Monitoring mechanism allows detection of: Tool overload condition Tool breakage Missing tool or part Erroneous second run of the same part that has already been machined The Load Band Monitoring mechanism is based on recording the load variation pattern for the entire cutting operation, and is therefore applicable to relatively short cycle jobs.

3.3

Event Logging
Alarms In-cut and air cutting times

In Event Logging mode, OMATIVE ACM records machining information for all the operations in the part such as: Start and End times of parts and operations Spindle ON/OFF status Tool and spindle overload Recorded machining information may be displayed on the ACM screen or uploaded to a PC to enable relevant statistical analysis. The selection of Adaptive Control or Monitoring modes for any operation does not eliminate the Event Logging features, which remain active.

Technical Specification OMATIVE ACM Systems

Setup & Operation

For proper performance, OMATIVE ACM systems need to be setup for each specific tool and part. For this setup, the following options are available, depending on the ACM configuration: 1. Automatic Setup ACM creates the required setup data automatically during a sample cut. ACM automatically defines a job in its database and assigns default values to the operation parameters. During subsequent runs of the NC program, ACM performs feed control or monitoring functions based on the job data recorded in its database. There is no need for any modification of the original NC program. 2. Network-based Setup OMATIVE-Pro Productivity Management software package may be used for preparing job and operation data on a remote PC. This prepared data may then be used in either of the following ways: The prepared data is inserted into the NC program. The first time that the NC program is run, ACM automatically reads its required setup data and saves the data into its database for subsequent runs of the program. The job and operation data is transferred to the ACM. This data tells the ACM everything it needs to know to run this job or operation, such as reference numbers, tool details, impact and exit protection, operating mode, etc. 3. Manual Setup Data is entered manually into ACM for each tool and part, and simple instructions are inserted into the NC program that inform the ACM system of each tool change during machining. Depending on the setup method, simple NC instructions may have to be inserted into the NC program. For its operation, OMATIVE ACM does not require the operator to set any load limits, since the system learns the appropriate limits automatically by self-teaching during a sample cut. OMATIVE ACM's operation is entirely automatic not requiring operator attendance. OMATIVE ACM performs stable and continuous control, as well as dynamic tool protection, for the entire range of the cutting area and for all surface condition variations. During machining, the system automatically applies a specific algorithm derived from the operation setup data. During machining, OMATIVE ACM automatically receives tool-change information from the NC program. Based on the current tool information and ACM's continuous spindle load monitoring, it executes adaptive control, monitoring, overload detection, and alarms.

OMATIVE ACM Integration into a CNC

Technical Specification OMATIVE ACM Systems

Applications

OMATIVE ACM systems are applicable to virtually any machining application. By selecting each operation to perform Adaptive Control, Monitoring, or Event Logging only, users can enhance every machining application as follows: Cycle-time reduction, especially in roughing and semi-finishing operations Process monitoring and protection of tools, parts and machine spindles in all machining operations Tool wear monitoring in roughing and semi-finishing operations involved in batch production when material hardness and blank dimensions do not vary significantly Tool life extension and tool breakage detection in milling, drilling, grinding and gear hobbing in batch production Event logging in all machining operations OMATIVE ACM systems are applicable to all milling, drilling, turning, grinding, boring, and gear hobbing applications involving: Cutting area variations Material hardness variations Significant surface variations Coolant variations Fixture instability Tool breakage Tool breakage upon entering and exiting material

OMATIVE ACM in CNC Milling

OMATIVE ACM in CNC Deep Hole & Gun Drilling

OMATIVE ACM in CNC Turning

OMATIVE ACM in CNC Grinding

Technical Specification OMATIVE ACM Systems

OMATIVE ACM in CNC Gear Hobbing In addition, OMATIVE ACM systems are also particularly beneficial for the following specific applications: Drilling, involving issues such as: Drill breakage Peck-drilling With ACMs unique Loaddependent peck-drilling strategy, pecking begins only when the maximum permissible load is reached. This ensures shorter cycle times, less pecking passes and drill protection Deep hole and gun drilling Breakage in cross-holes Chip accumulation Tapping If the maximum permissible tool load is approached, ACM can stop the machine after completing the current tapping operation in order to prevent breakage during the subsequent tapping operation. In the unlikely event of tap breakage, ACM will detect this breakage.

Special Grinding applications such as: In Creep feed grinding, real-time feed adjustments achieve cycle time reduction. In grinding applications using cyclic dressing, ACM continuously monitors the wheel condition through its load monitoring, and triggers the need for dressing of worn wheels at the optimally right time.

Technical Specification OMATIVE ACM Systems

ACM Configurations

OMATIVE ACM systems are available in various configurations depending on the CNC type, model, and version. In each configuration, OMATIVE ACM systems consist of two main components: ACM control component, which automatically executes the controlling and monitoring functions in real time. ACM user interface component, which is used to initialize, configure, and monitor the ACM functions Depending on the specific CNC, each ACM component may be a either an All-Software component that is fully integrated into the CNC, or alternatively, firmware built into an add-on hardware package. The All-Software solutions are generally available for all later model CNC versions. For older versions of CNCs, some hardware component may be required. On some machines, in addition to the standard ACM configurations, there is also an all-software, Windows based Real-Time Application (RTA) configuration. This configuration has limited functionality, providing real-time monitoring and reporting, but not supporting the adaptive control function. All CNC systems have the option of using the Add-On Hardware configuration. The following table outlines available ACM configurations, with cross-references to descriptions of CNC requirements. Available OMATIVE ACM Configurations ACM User Interface: ACM Real-Time Control: Siemens SINUMERIK Heidenhain iTNC 530 FANUC i-Series Okuma OSP-P200 (THINC) DMG MillPlus Fidia X-Power Bosch-Rexroth MTX Other CNCs Integrated into CNC-HMI Integrated into CNC See 6.1.1 See 6.2 See 6.3 N/A See 6.5 See 6.6.1 N/A N/A Integrated into CNC-HMI Windows Application See 6.1.1.2 N/A N/A N/A N/A N/A N/A N/A Integrated into CNC-HMI Add-On Hardware See 6.1.2 N/A N/A See 6.4 N/A See 6.6.2 See 6.7 N/A Add-On Hardware Add-On Hardware See 6.8.2 See 6.8.2 See 6.8.2 See 6.8.2 See 6.8.2 See 6.8.2 See 6.8.2 See 6.8.1 & 6.8.2

6.1

ACM for SINUMERIK

For machines using a Sinumerik CNC, OMATIVE ACM is available in either All-Software or Hardware/Software configurations.

6.1.1

ACM All-Software Configuration for SINUMERIK 840D

For machines with the Sinumerik 840D CNC, OMATIVE ACM is available in two All-Software configurations: ACM with Real-Time control integrated into the NCK ACM with Windows-based Real-Time control

6.1.1.1

ACM Configured with Real-Time Control Integrated into the NCK

The Windows based graphic User Interface in this configuration is a software component integrated into the SINUMERIK HMI. This component is used to initialize, configure, and monitor the Adaptive Control and Monitoring function.

Technical Specification OMATIVE ACM Systems

The real-time control component, which is also all software, is integrated into the NCK and consists of: Real-time ACM software in the form of an ELF-file SINUMERIK 840D base system. Siemens Compile Cycle IACT (for SINUMERIK Power Line), or IMD-Base (for Power Line or Solution Line)

An ACM Screen Displayed on the SINUMERIK 840D Each ACM product package is supplied by OMATIVE Systems with a unique product key that matches the CNC MAC Address. Alternatively, a Software Protection Plug (Dongle) may be supplied. CNC Requirements for Installing ACM [All-Software Configuration] on SINUMERIK 840D Solution Line Component Drive Hardware Requirements SINAMICS S120 Drive system Comments Digital drive provides digital current, power and torque information.

PC Hardware PC Operating System CNC Hardware Control Software HMI Software Additional Software

SINUMERIK PCU50.3 Windows XP NCU 710.x/720.x/730.x SINUMERIK 840D SL NCU software version 01.03.00 or higher with CC Interface version 007.001 or higher SINUMERIK 840DI/840D/SL HMI-Advanced software version 7.3 (or higher) SINUMERIK Compile Cycle: Integrated Monitoring and Diagnostic "IMD-Base" version 02.02.00 or higher.

Technical Specification OMATIVE ACM Systems

CNC Requirements for Installing ACM [All-Software Configuration] on SINUMERIK 840D Power Line Component Drive Hardware PC Hardware PC Operating System CNC Hardware Requirements Drive system based on SIMODRIVE 611D SINUMERIK 840D PCU50 or PCU70 Windows NT, XP NCU572.x or NCU573.x The NCU acts as an interface between the drive system and the OMATIVE ACM and provides access to the current, torque and active power information of the digital drive system An upgrade from the previous versions of NCU software may be ordered from Siemens. Comments Digital drive provides digital current, power and torque information.

Control Software or

SINUMERIK 840D NCU software version 06.05.11 or higher with CC Interface version 003.003 or higher, NCU software version 07.02.05 or higher with CC interface version 007.001 or higher.

HMI Software Additional Software

SINUMERIK 840D HMI software version 06.03.15 or higher The Siemens Compile Cycle: Integrated Adaptive Control Technology (IACT) or Integrated Monitoring and Diagnostic "IMD-Base" version 02.02.00 (or higher) Supplied with OMATIVE ACM System IMD may be used with Power Line version P7.. only

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Technical Specification OMATIVE ACM Systems 6.1.1.2 ACM Configured with Windows-Based Real-Time Application (Limited Version For basic Monitoring)

On some machines, in addition to the standard ACM configurations, there is also an all-software, Windows based Real-Time Application (RTA) configuration. This configuration is similar to the configuration of ACM with Real-Time Control integrated into NCK. However, in this configuration the OMATIVE ACM Windows RTA obtains the required real-time data directly from the NCK without accessing the Siemens Interface CC. This configuration has limited functionality. It still provides real-time monitoring and reporting, but does not support the adaptive control function. To carry out this integration, the following requirements must be met: Component Drive Hardware PC Hardware PC Operating System CNC Hardware Requirements Drive system based on SIMODRIVE 611D SINUMERIK PCU50 Windows NT / XP NCU572.x or NCU573.x The NCU acts as an interface between the drive system and the OMATIVE ACM and provides access to the current, torque and active power information of the digital drive system Comments Digital drive provides digital current, power and torque information.

Control Software HMI Software

SINUMERIK 810D/840D NCK software version 06.04 or higher SINUMERIK 810D/840D HMI software version 06.02 or higher

6.1.2

ACM Hardware/Software Configuration for SINUMERIK

This configuration of ACM is compatible with SINUMERIK 810D/840D/840Di/840DE. In this configuration, the OMATIVE ACM real-time control component includes hardware that is connected to the CNC, while its user interface is a software component integrated into the SINUMERIK HMI. Hardware/Software Integration of ACM for SINUMERIK

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Technical Specification OMATIVE ACM Systems

The real-time control component in this configuration consists of: ACM Control Unit Connects from its digital outputs to the NCU, and from its analog inputs to the OMATIVE Power Transducer Module (PTM). The ACM Control Unit measures the spindle power, and communicates with SINUMERIKs PC through the SINUMERIK RS232 port. ACM real-time software Integrated into a microcontroller on the ACM Control unit. ACM user interface A Windows Graphic User Interface application that is used to configure and monitor the Adaptive Control and Monitoring functionality. CNC Requirements for Installing ACM [Hardware/Software Configuration] on SINUMERIK Component Drive Hardware PC Hardware COM Port PC Operating System CNC Hardware Control Software Requirements Any drive system (digital or analog) SINUMERIK 810D/840D PCU50/70 or MMC103 A spare RS232 port on the PCU/MMC Windows 95, NT, XP Any SINUMERIK NCU Any SINUMERIK 810D/840D/840Di/840DE NCU System Software There are no special requirements for the NCU hardware version. There are no CNC software requirements since the Compile Cycle Technological Function is not used. To receive feed rate override control from ACM and to trigger ACM alarms, some PLC modification may be required. Versions: 3.7, 4.3, 4.4, 5.1, 5.2, 5.3 or higher Comments There are no drive system requirements since OMATIVE PTM provides the spindle power data.

PLC Software

HMI Software

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Technical Specification OMATIVE ACM Systems

6.2

ACM for Heidenhain iTNC530

For machines with the Heidenhain iTNC530 CNC, OMATIVE ACM is available as All-Software requiring no additional hardware. ACM software for Heidenhain iTNC530 is available in two configurations: ACM for dual-processor iTNC530 In this configuration, a Windows graphic user interface enables all ACM functions to be initiated on the CNC and displays performance results. These include the ACM setup functions, monitoring of actual cutting conditions, production event logging, production performance monitoring, and statistical reporting. ACM for single-processor iTNC530 In this configuration, ACM uses Heidenhains native Cycle Design function to create ACM cycles that are then transparently called during NC program execution. However, if full performance monitoring and reporting is required, a graphic user interface is separately available to run on an external PC connected to the CNC via Ethernet. The Real-Time Control component in both configurations is a software application integrated into the CNC Real-Time software. Note: The ACM for single-processor iTNC530 may also be run on a dual-processor iTNC530. An ACM Screen Displayed on the Heidenhain iTNC530

CNC Requirements for Installing ACM on Heidenhain iTNC Component CNC Hardware CNC Operating System CNC Option Requirements Heidenhain iTNC530 Single or Dual Processor Software ID number 340480, 34049x, or 340422, but NOT export versions 340481 and 340423 Adaptive Control option (option #12) must be enabled. Heidenhain's DNC option (option #18) must be enabled

Each product package requires a unique OMATIVE product key that matches the CNC SIK number. 13

Technical Specification OMATIVE ACM Systems

6.3

ACM for FANUC i-Series

For machines with the Fanuc i-series CNC, the OMATIVE ACM option is available as All-Software requiring no additional hardware. Both the User Interface and the real-time control components are software applications integrated into the FANUC CNC. An ACM Screen Displayed on the FANUC i-Series

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Technical Specification OMATIVE ACM Systems

CNC Requirements for Installing ACM [All-Software] on FANUC Series 16i/18i/21i/30i/31i/32i and FANUC Series 160i/180i/210i/300i/310i/320i Requirements C Executor Function Comments Part number A02B-XXXX-J734 (XXXX represents CNC type). Note 1: C executor can execute only one user application at a time. OMATIVE ACM can be installed as long as no other application is running on the C executor. Note 2: The Multi C executor option (part number A02B-028x-S770) will be required if one of the following FANUC C executor functions resides on a FANUC Series 16i/18i/21i: Manual Guide i (part number A02B-028x-S780) Tool Management Expansion (part number A02B-028x-S852) Servo Guide Mate (part number A02B-028x-S840) If the CNC is equipped with the C executor library BY01 version 3.0M (or a later version), the multi-C executor will enable two MEM files to be loaded and executed at the same time. This function is supported only by FANUC Series 16i/18i/21i model B. Note 3: If the CNC already has Macro Executor function (part number A02BXXXX-J888), the upgrade to C executor function has to be purchased. This upgrade always comes with the Macro executor function. Screen Display Function This function is required when installing this version of OMATIVE ACM software on Open CNC FS160i/FS180i/FS210i etc., connected via HSSB or Ethernet. The part numbers for the CNC Screen Display Function on FS160i/ FS180i/FS210i is: A02B-0207-J850. On FANUC 3x0i series, the part number for the CNC Screen Display Function is: A02B-0207-J858. Main CPU Custom Software DRAM size of 5MB Part number A02B-XXXX-J738#5M. A separate area of this 5MB is used and must be specified optionally. Therefore, an upgrade for CPU CARD may be required. E.g., from a CPU CARD with 16MB of DRAM (A02B-0281-H001) to a CPU CARD with 32MB of DRAM (A02B-0281H002). For FANUC 3Xi Series, a CPU card with 128 MB of DRAM is required. FROM memory is used to store OMATIVE ACM software. SRAM memory is used to store Job and Operation data. 59KB is enough for 10 jobs with up to 30 operations per job. In order to allocate 192KB additional non-volatile memory for the C executor application, the following option is required: A02B-XXXX-J736-C executor additional SRAM. The Part numbers for FROM and SRAM are: A02B-XXXX-H043 FROM/SRAM memory (16MB/2MB) or A02B-XXXX-H048 FROM/SRAM memory (32MB/2MB) Two Physical PMC Addresses of 24VDC Digital I/O: 1 Type-X input 1 Type-Y output PMC Modifications PMC must be modified to enable it to read and implement OMATIVE ACM Feed Rate Override Code and its Alarm information. The digital input/output will be connected to OMATIVE PLM modules digital input/output.

Flash ROM Area of 5MB 59KB of SRAM Standard 251KB of SRAM Optional.

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Technical Specification OMATIVE ACM Systems

6.4

ACM for Okuma OSP-P200 (THINC)

This configuration of OMATIVE ACM is available for the Okuma OSP-P200 CNCs, and consists of a combination of software and hardware components: ACM hardware An ACM Control unit connected via its digital outputs to the CNC digital inputs, via its analog input to the OMATIVE Power Transducer Module, providing information about current spindle motor power, and communicating with the CNC's PC through its RS232 port. ACM Real Time Application (ACM RTA) software Integrated into a microcontroller on the OMATIVE Control Units PCB. In this configuration, the ACM RTA runs independently of the CNC in a microcontroller located in the ACM Control Unit. The microcontroller performs all the calculation and control operations. It sends the Feed Rate Override signals to the CNCs digital inputs for an external feed rate override control. The ACM Real Time software, running in the OMATIVE Control Unit, communicates with the ACM Windows application (ACM HMI), running on the OSP-P200M PC, through the serial interface. ACM HMI Integrated into the CNCs Front-end software. The ACM HMI runs under Windows, and is used to initialize, configure, and monitor the ACM functions. Okuma OSP-200 Base System OSP-200M Generic Adaptive Control Assembly This OSP add-on hardware interface provides the necessary additional functionality in the existing PLC (feed rate override control from the ACM, triggering of ACM alarms etc). An ACM screen displayed on the Okuma OSP-P200

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Technical Specification OMATIVE ACM Systems

Hardware/Software Integration of ACM for Okuma OSP-P200

CNC Requirements for Installing OMATIVE ACM on Okuma OSP-P200CNC Component Drive Hardware Requirements Any drive system. There are no special requirements for the drive system because the spindle power information is provided by OMATIVE ACMs PTM. A spare RS232 port on the OSP-P200M Windows XP OSP-P200M hardware OSP-P200M software OSP-200M Generic Adaptive Control Assembly SE911-0919-001-00 API version 1.6 or higher

COM port PC Operating System CNC Hardware CNC Software Additional OSP Hardware Interface Additional OSP Software

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Technical Specification OMATIVE ACM Systems

6.5

ACM for DMG MillPlus

For DMG machines with the MillPlus CNC, OMATIVE ACM is an All-Software product, requiring no additional hardware. Both the User Interface and the real-time control components are software applications integrated into the MillPlus CNC. ACM for DMG MillPlus consists of: Real-time software that is loaded into the MillPlus IT. A Windows Graphic User Interface application. An ACM Screen Displayed on the DMG MillPlus

CNC Requirements for Installing ACM on DMG MillPlus Component CNC Hardware CNC Software Version CNC Option Requirements MillPlus IT-Double Processor (DP) MillPlus-IT V5.10 and up Adaptive Feed Control option (defined by Machine Control #340) must be enabled.

Each product package requires a unique OMATIVE product key that matches the CNC SIK number.

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Technical Specification OMATIVE ACM Systems

6.6

ACM for Fidia

For machines using a Fidia CNC, OMATIVE ACM is available in either All-Software or Hardware/Software configurations.

6.6.1

ACM All-Software Configuration for Fidia X-Power

The OMATIVE ACM system in this configuration is a fully integrated software product that consists of: Real-time software component, which is linked to the CNC software The user interface software component, integrated into the Fidia HMI An ACM screen displayed on the Fidia X-Power:

CNC Requirements for Installing ACM All-Software Version on Fidia Component Drive Hardware PC Operating System CNC Hardware Control Software Requirements Fidia digital drives Windows XP Fidia X-Power, CPU5 Fidia CNC Software version V3R6.0 or higher

Each ACM product package is supplied by OMATIVE Systems with a unique product key that matches the CNC MAC Address.

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Technical Specification OMATIVE ACM Systems

6.6.2

ACM Hardware/Software Configuration for Fidia X-Power

This configuration of OMATIVE ACM is available for the Fidia X-Power CNCs that do not meet the CNC requirements of the ACM All-Software configuration. The real-time control component of this configuration consists of: ACM Control Hardware An OMATIVE Control unit connected via its analog and digital outputs to the NCU, via its analog inputs to the OMATIVE Power Transducer Module, measuring spindle motor power, and communicating with the Fidia PC through its RS232 port. ACM Real-Time Software Integrated into a microcontroller and provided on the OMATIVE ACM Control unit. The ACMs User Interface in this configuration is a software component that is integrated into the Fidia HMI. CNC requirements for installing ACM [Hardware/Software Configuration] on Fidia XPower Component Drive Hardware CNC Operating System CNC Hardware COM Port Control Software Requirements Any drive (digital or analog) Windows XP Fidia X-Power A spare RS232 port on the Fidia PC Fidia CNC Software version V3R3.0 or higher

Each ACM product package is supplied by OMATIVE Systems with a unique product key that matches the CNC MAC Address.

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Technical Specification OMATIVE ACM Systems

6.7

ACM for Bosch-Rexroth MTX

OMATIVE ACM for the Bosch-Rexroth IndraMotion MTX CNC consists of a combination of software and hardware components: ACM hardware Containing the OMATIVE ACM Control unit connected via its digital outputs (ACM feed rate override) to the CNC and via its analog inputs to the Power Transducer Module. The ACM Control unit communicates with the OMATIVE ACM windows application (ACM HMI), running on the IndraControl V PC through its RS232 serial interface. ACM real-time software Integrated into a microcontroller on the OMATIVE ACM Control unit, which performs all calculation and control operations. It sends the Feed Rate Override signal to the PLC for external feed rate override control. ACM User Interface (ACM HMI) A WIN32 application that runs on the IndraControl V industrial PC and is used to initialize, configure, and monitor the ACM functions. ACM PLC software Provides the necessary additional functionality in the existing PLC (feed rate override control from OMATIVE ACM, triggering of OMATIVE ACM alarms, etc.). Upon installation, the ACM PLC software will be adjusted to integrate with the CNC machine's PLC software. An ACM screen displayed on the Bosch-Rexroth MTX

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Technical Specification OMATIVE ACM Systems

Hardware/Software Integration of ACM for Bosch-Rexroth MTX

CNC Requirements for Installing OMATIVE ACM on Bosch-Rexroth MTX CNC Component Drive Hardware Any drive system. Since OMATIVE ACMs Power Transducer Module (PTM) will be installed to measure the actual spindle power in real-time, there are no special requirements for the spindle drive system. PC Hardware COM Port PC Operating System Control Software CNC Hardware PLC Software IndraControl V Industrial PC A spare RS232 port on the IndraControl V PC Windows XP IndraWorks version 5.7.64 and higher IndraControl P To receive feed rate override control from ACM and to trigger ACM alarms, some PLC modification is required. Requirements

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Technical Specification OMATIVE ACM Systems

6.8

ACM for Other CNCs

Add-on PC-Based ACM Configuration

6.8.1

Another alternative for integrating OMATIVE ACM into a CNC can be accomplished by using an OMATIVE ACM Control Unit and a PC. This unit is electrically connected to the CNC as a black box (not usually accessible to the end user) and the user interface is integrated into a PC. Depending on the CNC's software configuration, the User Interface may be integrated into the CNCs PC. ACM Integration Using the ACM Control Unit and a PC

Requirements for Installation of the Add-On PC-Based ACM Component PC CNC Feed Rate Override CNC Output Mechanism for Tool Referencing Requirements Windows 98/ME/2000/NT/XP Switch, potentiometer or pushbutton A minimum of one unassigned M-function hardware output or The ability to output ASCII characters from the NC program through the RS-232 serial port during NC program execution Availability of a spindle drive Speed Monitoring analog output signal For turning machines only Comments A PC must be used next to the machine The upper limit of the feed override should be greater than 100%

Lathe Spindle Drive

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Technical Specification OMATIVE ACM Systems

6.8.2

Universal ACM Add-on Hardware Configuration

The universal add-on hardware configuration of ACM is a separate microprocessor-based unit (referred to as an ACM Unit) with its own LCD and Keypad. The ACM Unit can connect to virtually any existing CNC machine. The system is attached to the CNC operating console and connected to the CNC machine through the following signals: Spindle load/power signal from the machine spindle drive. OMATIVE proprietary Power Transducer may be installed to ensure that the signal is a true representative of the active spindle power. Feed Override signal to the CNC in order to control the feed rate. Start/Cancel signals from the CNC (initiated by the NC program) in order to reference the indexed tool in real time. Spindle speed monitoring signal (required only from lathes) to enable a true representation of actual power as the cutting diameter varies. The installation is carried out by OMATIVE qualified representatives and does not require any machine modifications. Subsequent to the installation, a one-time calibration procedure is carried out to adapt the system to its specific machine environment. Universal Hardware Add-on ACM Connection to Machine

CNC Requirements for Installing a Universal Add-On ACM System Component Feed Rate Override Output Mechanism for Tool Referencing Requirements Switch, potentiometer or pushbutton A minimum of one unassigned M-function hardware output or The ability to output ASCII characters from the NC program through the RS-232 serial port during NC program execution Availability of a spindle drive Speed Monitoring analog output signal For turning machines only Comments The feed override upper limit should be greater than 100%

Lathe Spindle Drive

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Technical Specification OMATIVE ACM Systems

ACM Integration into the Machine Shop Network

OMATIVE ACM systems in all their configurations can be integrated into a PC network running OMATIVE-Pro Productivity Management system. Since the communication with OMATIVE-Pro is via Ethernet, depending on the specific ACM configuration, one of the following techniques may be used to communicate with ACM: If ACM is integrated into a CNC or a PC-based platform that has an Ethernet interface available, the communication will be directly via Ethernet. If ACM is integrated into a CNC where no Ethernet is available, or if the Universal add-on Hardware ACM system is installed, one of the following methods will be used to convert the CNCs RS232 protocol to Ethernet: Using an Ethernet/RS232 converter Using an additional PC on which OMATIVEs Opti-Pilot software is run Note: Opti-Pilot is a utility application included along with OMATIVE-Pro, and is installed by the OMATIVE Technical Representative.

Configuration of OMATIVE-Pro and ACMs in the Machine Shop

OMATIVE-Pro Software OMATIVE-Pro Server Software

OMATIVE-Pro Software

OMATIVE-Pro Software

Ethernet

Ethernet

Ethernet/RS232 Converter
RS232

Opti-Pilot

Ethernet/RS232 Converter
RS232

Opti-Pilot

RS232

RS232

CNC Machine

Add-on ACM

CNC Machine

Add-on ACM

ACM Integrated into non PC-based CNC Machine

ACM Integrated into PC-based CNC Machine

ACM Integrated into PC-based CNC Machine

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Technical Specification OMATIVE ACM Systems

Technical Characteristics
Feature Characteristics Up to 6 spindles (Milling & Drilling) 100 ms 0 200% depending on CNC specification 8 12 ms When a pre-programmed load limit is exceeded Programmable 0.3 3.0 s 1. Operator Warning Lamp 2. Immediate Machine Stop 3. Stop in air 4. Stop at end of Operation

Number of Spindles on CNC machine Override Switching Cycle Time Override Range Response Time on Impact Tool Overload Display Tool Overload Checking Time before Reacting Reaction on Tool Overload

Reaction on Tool Wear

1. Tool Wear Value Display on the screen 2. Operator Warning Lamp at the end of operation 3. Stop at end of program

Reaction on Tool Breakage Parameters displayed at the end of each operation

Immediate Machine Stop 1. Total Cutting Time for the Operation 2. Total Regular Cutting Time without adaptive control 3. Minimum Feed Rate Override 4. Extent of Tool Wear as a % of Max. Permissible Tool Wear 5. Number of times the operation has been repeated 6. The maximum power, measured during the operation

Feed Rate Override is based on:

1. Monitored Load or Power 2. Workpiece Material (selected from the material library or learned with Teaching Method) 3. Tool Type (selected from the tool library or learned with Teaching Method) 4. Programmed Feed Rate 5. Programmed Spindle Speed 6. Tool Diameter (N/A to turning) 7. Number of Teeth on the tool (N/A to turning) 8. Workpiece diameter (turning only) 9. Cutting angle (turning only)

Operating Modes

1. Feed Control 2. Monitoring 3. Event Logging

Methods of Operation

1. Preset: Based on selected parameter values on setup 2. Teaching: Based on parameter values automatically learned during a sample job

Conformance (for ACMs hardware components)

CE & FCC regulations, UL recognized

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