Workshop on Integrated Machine Tool Simulation Verification April

Workshop on Integrated Machine Tool Simulation & Verification April 9 -10, 2002 Cypress, California

Workshop on Integrated Machine Tool Simulation & Verification Agenda First Day – April 9 th: 08: 30 – 09: 30 Introduction to IS&V and its architecture 09: 30 – 10: 00 IS&V demonstration 10: 00 – 12: 00 Machine tool builder application 12: 00 – 13: 00 Setting for machine tool simulation 13: 00 – 14: 00 Lunch 14: 00 – 17: 00 Workshop - building your machine tool model Second Day – April 10 th: 08: 30 – 09: 00 Review & Discussion 09: 00 – 09: 45 Machine tool driver philosophy 09: 45 – 10: 30 Using S&V Commands 10: 30 - 11: 30 Walkthrough driver examples 11: 30 - 13: 00 Workshop - building your machine tool driver 13: 00 - 14: 00 Lunch 14: 00 - 16: 45 Continue workshop 16: 45 - 17: 00 Summary

Workshop Objective Our Objective: To teach you the tools you need to model the machine tool kinematics and its virtual controller. At the end of the workshop we hope you could simulate a machine tool you built during the workshop. Your Objective: To give us your feedback, any feedback, about the system during the workshop and after… good or bad.

IS&V Highlights § § § Fully integrated machine tool simulator. New machine tool builder application. In process machine tool and controller considerations: • • § Close loop control From Postprocessor to Machine Tool Driver. ‘Close to Reality’ simulation: • • Controller plug-in option. Accurate simulation for controller dependent events. § Customizable Virtual NC controller based on Manufacturing Output Manager (MOM). § Utilization of UG technologies: Assembly modeling and d. Cade toolkit library (e. g. collision library). § Library managed machine tool, fixtures and devices.

Current Architecture Events Mfg. Output Manager Events Cutting Tools Cutting Methods Part Materials UG CAM Process Data Event Handler Machine Tool Statements External Simulators CL File G 01 X 3. 4 G 03 Y 3. 1 I 3. 3 Tool Materials Feed & Speeds Toolpaths Machine Tools Tool Simulator Material Removal Mfg. Setup Machining Filters Graphical. Feedback Graphical Vericut Unisim

IS&V Architecture Mfg. Output Manager Events Machine Tool Driver Machine Driver Cutting Tools Process Data Process Event Handler Cutting Methods Part Materials Tool Materials Feed & Speeds UG CAM S&V Commands NC code Virtual NC Controller Machine Tools Fixtures S&V Events Machine Devices Feedback S&V Engine S&V Events Graphical Feedback Mfg. Setup External System CL File G 01 X 3. 4 G 03 Y 3. 1 I 3. 3

S&V Control Loop Event Generator Toolpath Events CEvents G 01 X 3. 4 G 03 Y 3. 1 I 3. 3 Design Parts Machine Tool Driver NC-Post UG CAM S&V Commands t c e s s Mfg. Resources Feedback ‘G Code’ a o P r S&V Control Loop D a Virtual NC Controller Plugin S&V Engine S&V Events

IS&V Building Blocks Machine tool builder (MTB) Machine tool configurator (MTC) Machine tool simulation Machine tool driver (MTD) Virtual NC Controller (VNC)

Machine Tool Builder §New application to build a machine tool or machine device. §Geometric model by Assembly. §Build Kinematics model. §Define Mounting model. §Animate axes for testing. §Edit model by Kinematics Tree manipulations.

Machine Tool Configurator § Has similar functionality as machine tool builder. § Active in Manufacturing application only § Used for mounting workpiece and fixtures on machine tool. § Other future uses like defining machine state.

Machine Tool Driver (MTD) § § § Generates NC-Program and emulates the NC controller. Motion control - accurate path based on machine configuration. Events Machine Tool Driver Process Data Handles specific machine tool features such as macros, cycles, subroutine call. Key role in machine tool simulation. Fully customizable as TCL program. Textual, graphical and audio feedback triggered by events. Post Event Handler CL File G 01 X 3. 4 G 03 Y 3. 1 I 3. 3 NCcode NC Virtual NC Controller S&V Commands S&V Events S&V Engine NC Controller Plug-IN

Machine Tool Simulation §Customizable user interface §Step through events in three different modes. §Continuos position and parameters display. §Step through NC program (G codes) §Flexible collision control §More. . . Collision Customizable Simulation Control Panel Configuration Simulation Configuration

Current IS&V v 19 Scope and Status Focus: System architecture and Simulation Machine tool simulation for milling, turning and millturn. New application to build the machine tool model. Collision detection between all machine components. Close loop control architecture Machine tool driver architecture Library managed machine tool, machine devices and fixtures. TCL based customizable virtual NC controller. Plugin interface to machine tool driver. Customizable simulation dialog Closer Integration with CAM processor Status: done partially done

IS&V v 20+ Proposed Features Focus: CAM Processor Integration w Closer integration: w w w 4 -axis lathe programming and simulation. w w Consolidate machine tool kinematics and data(e. g. used in post). w w CME integration Machine state for each operation. Consider machine tool for collision and accessibility (e. g. variable axis machining and hole making). Processor can be enhanced to take advantage of it. Show machine state while programming. (e. g. show part moving when applicable). Analysis tools for: material removal rate to adjust cutting parameters, loads on cutting tools, forces on fixtures.

IS&V v 20+ Proposed Features (Cont. ) u Consolidate Visualize and Machine Tool Simulation. u IPW and gouge detection in machine tool simulation context. u Material removal during machine tool simulation. u Machine tool simulation directly from ‘G’ codes. u Interface to commercial plugin (open controllers). u Special turning support (e. g. , millturn and 4 -axis lathe) u Generic inverse kinematics engine based on machine tool kinematics. u Enhance post builder to build machine tool drivers.

More on IS&V More information on IS&V can be found in: § Visual requirement specifications (camsav 200 project) § Function specifications (camsav 200 project) § § Machine tool for Simulation functional spec S&V Engine functional spec Machine tool driver functional spec d. Cade toolkit functional spec § IS&V Help § Examples of machine tool models and drivers.

Demonstration Build it… Configure it… and Simulate… Unisign Machine Tool Sinumerik 840 Controller

Demonstration (cont. )