integration of information technology in machine tools

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ABSTRACT
Today s buzzword IT has revolutionized every aspects of our day today working lives.
Automation of industries is one of its main contributions. Automation can be de
fined as technology concerned with the application mechanical, electronic and co
mputer-based systems to operate and control production. . The main advantage of
automation is increased labor productivity at reduced labor cost. The heart of m
achine tool is a CNC (Computerized Numerical Control) system, which coordinates
with the displays, PLC, drives system, and feed back systems. This paper deals w
ith the data acquisition, program management and remote diagnosis of the system
Numerical control is for of programmable automation in which the mechanical acti
ons of a mechanical tool or other equipment are controlled by a program containi
ng coded alphanumeric data. Computerized numerical control (CNC) is defined as a
n NC system who s MCU is based on a dedicated microcomputer rather than a hardwire
d controller.
Remote diagnosis or Tele service offers remote support for CNC systems, making i
t a cost-effective alternative to service calls. Lot of time can be saved by thi
s.
INTRODUCTION
Today s buzzword IT has revolutionized every aspects of our day today working lives.
Automation of industries is one of its main contributions. Automation can be de
fined as technology concerned with the application mechanical, electronic and co
mputer-based systems to operate and control production. Automated manufacturing
systems operate in the factory on the physical product. They perform operations
such as processing, assembly, inspection or material handling, in some cases acc
omplishing more than one of these operations in the same system. They are called
automated because they perform their operations with a reduced level of human i
ntervention. The main advantage ofautomation is increased labor productivity at
reduced labor cost.
An automated system consists of three basic elements:
1. Power to accomplish the process and operate the system
2. A program of instructions to direct the process and
3. A control system to actuate the instructions.
Here we are discussing about the developments in the software part, which contro
ls the entire process in machine tools.
The heart of machine tool is a CNC (Computerized Numerical Control) system, whic
h coordinates with the displays, PLC, drives system, and feed back systems. This
paper deals with thedata acquisition, program management and remote diagnosis o
f the system.
NC & CNC
Numerical control is for of programmable automation in which the mechanical acti
ons of a mechanical tool or other equipment are controlled by a program containi
ng coded alphanumeric data. The alphanumerical data represent the relative posit
ion between the work head and the work part as well as other instructions needed
to operate the machine. The concept for NC dates from the late 1940s and the fi
rst machine was developed in 1952 by US airforce.
Computerized numerical control (CNC) is defined as an NC system who s MCU is based
on a dedicated microcomputer rather than a hardwired controller. It includes ad
ditional features beyond what is feasible with conventional hardwired NC. It inc
ludes
Storage of more than one part program
Various forms of program input
Program editing at the machine tool
Fixed cycles and programming subroutines
 Positioning features for setup and cutter length and size compensation
Communication interface and
Diagnostics
The CNC systems have processors for specific applications as the speed requireme
nts for the system is far greater here. The processors available in a CNC used t
o perform various tasks like communication, trigger, display, interpolation & ca
lculation functions, diagnosis, data exchange with PLC and other peripheries. Th
e new technology based personal computers has also made rapid development of new
manufacturing processes that enable achieving higher productivity and improved
job finish. Today several solutions are available for IT- integration from proce
ssing of job orders on as machine tool to vertical integration oat factory level
onto ERP systems like SAP and so on. The data available as a result may be used
in various activities vary ranging fromproduction planning to management inform
ation system.
Enterprise wide integration of factory data: The most recent progression in PC b
ased distributed control is enterprise wide integration of factory operations da
ta as depicted in the figure. It is according to the new philosophies of worker
empowerment, which assume fewer levels of company management and greater respons
ibilities for front line workers in sales, order scheduling andproduction.

fig.1. Enterprise Wide Management

Let us look at the different modules of information technology that can be integ
rated into machine tools. The very base of various modules is of handling a host
of data and a wide range of diagnostic functions.
MODULES IN MACHINE TOOLS
MODULE FOR PRODUCTION DATA MANAGEMENT
The module is available in two different variants i.e., WinBDE for machine data
management to carryout machine data acquisition and local evaluation and WinPDA
for central machine and production management to carry out central production ar
chiving and evaluation. WinPDA server is used as a data administrative unit for
the machine information, which is acquired and passed on by the WinBDE systems.
WinPDA server is responsible for all upload and download functions to SAP and Wi
nBDE. The WinPDA clients are the user interfaces for the WinPDA server. These cl
ients can be run on a standard Windows PC (Windows NT or Windows 2000) and are c
onnected to the server over Ethernet. Plant supervisors andproduction engineers
are the main users of WinPDA client. WinBDE is designed for the acquisition and
evaluation of machine data. The system acquires process information automaticall
y from a PLC s memory.
What WinBDE can do
Determination of the machine performance
Detailed disturbance analysis and diagnostics
Transparency at the machine due to graphical error diagnoses
Analysis of weak points
Function overview
A pilot study was conducted to assess Siemens MES solution s capabilities that incl
uded nine machines at one of their US facilities. The pilot included nine marria
ge machines in their assembly area. Three WinBDE terminals were used for data co
llection. The system automatically collects machine status conditions. Each marr
iage machine communicates digital process data via digital outputs to a Simatic
S7-ET200M. The Simatic S7-ET200M then communicates that information to a Simatic
S7 PLC (CPU 315-2DP) through a Profibus DP network connection. A WinCC station
was used to gather the process data from the PLC and pass the information to the
Open ShopFloor data acquisition program WinBDE through an OPC connection. Figur
e shows the system architecture.
Fig.2 WinBDE network
According to the result of the experiment, the customer could optimize their wor
k schedule by using the paperless order dispatching system. Work orders can now
be quickly assigned to a particular machine. The operators at the specified mach
ine can easily confirm the parts produced for the work order and when the order
is completed, it is automatically closed and the machine state is automatically
set to free. At this point area supervisor can assign a new work order to that m
achine. All this information is automatically sent to SAP. The customer has also
been able to track very precisely their machine utilization. Using the data, th
e customer can optimize their work schedules and improve machine utilization. Hi
storical data has proved to be extremely useful. While analyzing machine utiliza
tion and disturbance codes, the customer noticed some interesting patterns. Thes
e patterns showed some very regular disturbances. After further analysis, they d
iscovered that a small change in their maintenance schedule reduced and in some
cases eliminated the problem. This increased the machine utilization and reduced
maintenance costs.
What WinPDA can do
The main area of application for which WinPDA is de-signed is the dispatch and e
valuation of production and machine data (MDA/PDA). Using production data that i
s acquired either manually or automatically by means of PLCs, you always have an
up-to-date overview of the status of production orders, machine assignments, pe
rsonnel deployment, etc. This allows you to intervene appropriately to balance r
ates of utilization, to speed up order throughput and to significantly reduce in
ventory. Higher planning quality is achieved in a manufacturing requirements pla
nning system (MRP) due to the up-to-date data that is reported back by the onlin
e WinPDA system. If no information is reported back from the manufacturing proce
ss, planning options are very limited.
Function Overview
Fig3. WinPDA network
The core functions are production data acquisition and processing. This comprise
s all the interactive functions for processing order, workstation and personnel
data. Automatic machine data acquisition in addition to manual input dialogs ens
ures that process information is always up-to-date. WinPDA an Open System Enviro
nment User Interface. WinPDA is a client-server system that uses open internatio
nal standards based on Microsoft Windows with PC clients and network communicati
ons via a LAN to the data server running the Oracle relational database. WinPDA
is based on the Toolbox, which is a high-level development platform. The modular
open system structure ensures that you can integrate adaptations. Multi-stage s
ystem expansion options and the distribution of functions to different computers
allow the system to grow with your needs.
Main Data Acquisition Areas
Order or operation data (runtimes, piece counts, scrap,...)
Personnel data (working hours, reasons for absence, )
Machine and workstation data (utilization, availability, disturbances,...)
Acquiring Manual Production Events
Manual production events are entered at machines by the operators using the WinB
DE acquisition component. The system supports simple PDA terminals with displays
or user-friendly Windows terminals. The interactive functions available on the
WinBDE terminals include:
Dialogs for processing orders including quantity acquisition and reasons for int
erruptions or rejects
Dialogs for workstations with status acquisition (disturbance, maintenance)
Dialogs for personnel data
Acquiring Automatic Production Events
You can acquire and process events online via the PDA terminal's digital inputs:
Piece counts (good, scrap)
Down-time monitoring
Disturbances
WinPDA's user interface is designed with the same look and feel as Microsoft Win
dows. Users can modify overview tables, dialog windows, labels and even the lang
uage used. This makes possible easy adaptation to specific operating conditions
and individual requirements.
Dialogs for Production and Order Dispatch
The dialogs for production and order control are available on Windows clients. T
his allows you to use the PCs that are integrated in the WinPDA network as multi
functional operator control and monitoring stations. Dialogs for order control a
re available in the following form:
Order and operation overview
Maintain single order
Workstation overview
Maintain workstation
Display logbook
Personnel overview
Maintain personnel data
Maintain master data evaluations under Windows
The evaluations below are available as standard as stand-alone Windows programs:
Plant diagram Graphic display of the current workstation status (e.g. red = dist
urbed; green = production; etc.)
Representation in table form of currently pending reasons for disturbances/statu
s conditions
Shift profile Representation as a bar chart of the events of a completed shift f
or a selected workstation
Day profile- Representation as a bar chart of the events of the day for a select
ed workstation
Status profile Representation of the duration and frequency of individual status
conditions of a shift listed chronologically per workstation
Rate of utilization/availability
Representation of the rate of utilization/availability of a workstation over a s
electable period.
Works Calendar under Windows
The variations in working time models demand a flexible and convenient maintenan
ce function. WinPDA provides dialogs for setting up shift types and working time
models with appropriate works calendar structures.
Security Concept
To ensure a consistent data stock and to prevent unauthorized access to data, Wi
nPDA has available a comprehensive security concept. This includes:
Access and authorization functions
Disk mirroring (hardware option)
Transaction security
Un-interruptible power supplies
Interface to SAP R/3 Release 3.0
Today's MDA/PDA systems are only economically viable if you can integrate them a
t a low cost to other processes. A certified interface to SAP R/3 Release 3.0 is
available for this. The link modules offer functions for :
Accepting target data from the higher level system (E.g., order data).
Accepting master data from the higher level sys-tem (E.g. workstation data)
Processing the acquired actual data and reporting
It back the shopfloor controller or the MRP system
MODULE FOR NC PROGRAM MANAGEMENT
The important part of job shop manufacturing on machine tool is part program man
agement. The transfer of part programs was initially carried on punched tape by
a reader and further by floppy disks in recent years. Today the programs can be
transferred at a speed thousand times that of punched tape on industrial Etherne
t. Apart from transfer, the organization of part programs and handling plays an
important role in enhancing productivity and ensuring availability of desired pa
rt programs.
Functions of NC program management module
Scalable expansion system from small local DNC systems to DNC center archives wi
th DNC-NT 2000 server for entire plant.
NC program handling by means of DNC explorer.
Shop floor oriented NC program storage structure.
Data can be displayed, edited, printed, copied and pasted & deleted.
 Functions and filters tailored to the requirements of the user.
Fast and simple analysis of optimized programs with the original programs.
Program transfer through operator action and direct loading of NC programs into
the CNC enabling fast transmission on Internet.
Simple and flexible interface through any NC program systems and data archives.
Online help system to assist the system operator.
Log book to record system messages.
ADVANTAGES
Cost reduction in NC data organization through simple handling of NC programs, t
ime-consuming process of handling punched tapes and floppy disks is eliminated.
Cost effective and safe electronic data acquiring.
Increased machine-operating time through short set up time by safe and fast NC d
ata transfer and provision of several NC programs.
Brings in transparency and convenience in handling and storage of part programs
even if several programs are available in the system.
No DNS terminals are required in latest CNC systems on one hand and conventional
CNC systems can be hooked on by dialog functions.
COMMUNICATION SOFTWARE- COMPUTER LINK
The software module provides for establishment of link between a master computer
to CNC system via ethernet network. The offers defined, open communication inte
rface to transfer the essential data of CNC control.
USER BENEFITS
Simple integration: The control can be simply integrated in a simple manner in u
ser s projects/ applications, using defined interfaces like ethernet/ TCP-IP.
Simple configuration: Data to be transferred to the PLC can be simply configured
.
Improved productivity: The module can be used as a tool to implement measures fo
r increased productivity.
Reduced cost: The use of standard hardware and software components reduces the c
ost of implementation, training, and maintenance.
DATA TRANSFER THAT CAN BE CARRIED OUT WITH COMPUTER LINK
NC programs
Tool data
Machine and operating data like operating modes, machine status and actual NC pr
ograms.
Machine messages like operator messages, operator interventions/ interruptions,
operating and fault messages.
Production dialog, configurable data transfer.
Data transfer with open architecture applications.
REMOTE DIAGNOSIS
Remote diagnosis or Tele service offers remote support for CNC systems, making i
t a cost-effective alternative to service calls.
HOW IT WORKS
The module consists of two subsets namely, Host and the Viewer , the host being instal
ed at the machine user end and the viewer at the machine manufacturers end (or on
the side of the service provider for the CNC system). The two, i.e. the host and t
he viewer are installed on the control at the machine end connected via a modem, w
hich in turn is linked to a telephone line through a modem. The host is installe
d on a PC at the other side and equipped with a modem to hook on a telephone lin
e.
The service or support requests are triggered by the Host and authorize the View
er with login password permitting access for exploration and support activities
on the CNC system remotely. The service provider on the viewer end confirms the
service request and initiates the remote diagnosis by calling the telephone numb
er.
The components of the remote diagnosis system are
TEAMS: Testability assessment and improvement (DFT), reliability analysis, Failu
re Modes, Effects and Criticality Analysis (FMECA) and pre-computed diagnostic t
est strategy generation in a variety of forms (e.g., SGML-based Interactive Elec
tronic Technical Manual);
TEAMS-RT: on-board diagnostics, health and usage monitoring systems;
TEAMATE: Portable Intelligent Maintenance Aids (PIMAs) with interactive electron
ic technical manuals and multi-media animation, dynamic TPSs for ATEs.
TEAMS-KB: Scheduled and unscheduled maintenance and diagnostics data collection,
Statistical data analysis and data mining for trend and anomaly detection/isola
tion.
FUNCTIONS OFFERED
Chat mode to enable the Host and the Viewer to understand the status of the machin
e via mail or voice call
Remote control mode to analyze the operator acti9ons and direct the operator actio
ns file transfer mode to automatically read out the important control files, to
transfer the corrected file or new software releases to the control side. This c
ompletes the process of diagnosis.
APPLICATION AREAS
With the machine tool manufacturer: useful for configuring and engineering, mach
ine testing and integration, start- up.
With the end users: setting up and controlling the machine tool, generating NC p
rograms, process visualization and monitoring, diagnostics and service, performa
nce enhancement and optimization.
ADVANTAGES FOR END USERS AND SERVICE PROVIDERS
Time advantage when service is required:
Help instead of travelling.
Better information transfer via chat mode.
Reduced machine down time.
Remote update/upgrade of software by file transfer mode.
Telephone/internet cost instead of travel cost.
Global support: wide applicability world wide, start up support, service support
and when machine re-equipping is required.
IN FUTURE,
Service providers can be reached around the clock via internet, by email or SMS
worldwide
Messages can be sent immediately after the fault occurs
At the service provider end , this information enables in faster in selection of
appropriate expert
CONCLUSION
The availability of PC technology and the control system architecture adapted fo
r the new changes has opened more and more opportunities for convergence of manu
facturing technology and information technology. With the advent of information
technology the entire process of running an entire plant, from generating and st
arting with the job orders, through production planning up and up to strategic p
lanning can be integrated. A new trend that has recently been put in is the web-
based support system. The users can post their needs and queries on the relevant
designated site to obtain the possible solutions and FAQ s and user documentation
. Several of the global automobile giants such as BMW AG, the Boeing company USA
etc and their likes are incorporating information technology into their plants
BIBLIOGRAPHY
1. Integration of information technology in machine tools ,
Mr. Virupakshappa HK, Industrial Automation, July 2003
2. Automation, Production Systems and Computer integrated Manufacturing, Mikell
p Groover, second edition, Pearson Education Asia.
3. http://www.siemens.it
4. http://www.sea.siemens.com
ACKNOWLEDGEMENT
I extend my sincere gratitude towards Prof . P.Sukumaran Head of Department for
giving us his invaluable knowledge and wonderful technical guidance
I express my thanks to Mr. Muhammed kutty our group tutor and also to our staff
advisor Ms. Biji Paul for their kind co-operation and guidance for preparing and
 presenting this seminar.
I also thank all the other faculty members of AEI department and my friends for
their help and support.

CONTENTS
1. Introduction . . .... . 01
2. NC & CNC . .. . 02
3. Modules in machine tools . . .. .. 04
3.a. Module for production data management . . .. . 04
3.a.i. What Win BDE can do . . 04
3.a.ii. What Win PDA can do... . 06
3.b. Module for NC program management . .. . 11
3.c. Communication software-computer link . .. . 12
4. Remote diagnosis .. . .. 14
5. Conclusion ... . 17
6. Bibliography ... .. 18
Reference: http://www.seminarprojects.com/Thread-integration-of-information-tech
nology-in-machine-tools#ixzz0v5YABYUd