Products of CNC (numerical Control), drives and robots in the advanced processing of metal

The alpha and the omega of the modern manufacturing at Germany are the automation and optimization of machines and processes. Begin in the CNC control system, include the environment of the machine tool and range, depending on the type and size of production, all the way to the articulation of the totality of the means of production.

Modern and effective tool machines require CNC control system functions complex and extremely fast, capacity of multiple channels and simultaneous control of several axes. Images: GE Fanuc

Industrial manufacturing can be structured in different levels of automation: the first level is the machine tool, CNC (numeric Control computer) is responsible for which automatic control. The second level is integrated in the CNC control system, it's the PMC (of English Programmable Machine Control) or programmable automaton, which allows for the smooth functioning of the peripheral equipment of the machine tool. The third level includes all the automated environment machine, loading and unloading thereof, as well as adjacent tasks, such as the deburring, polishing or cleaning of components. In the fourth level of automation, machine tools, measurement devices and other equipment are coordinated and monitored in centralized way. Production data are collected and analyzed, allowing the production optimization.

The essential components in the metal processing industry are machine tools and processing centres which, today, are virtually in its entirety controlled by CNC. A classic lathe in which the forward movement continues through driving already has certain nostalgic character. This type of machines is occasionally used for didactic purposes, so that the future operator develops a "sensitivity" for machining. Moreover, even the simplest machines are equipped with CNC products to facilitate its management and achieve a high-precision constant.

Specifically for this type of basic applications, GE Fanuc Automation has developed products of CNC's basic level of the series 0i. These CNC control systems are suitable for a particularly effective use of lathes, drills, milling machines and grinders of small size, as well as up to three or four axes machining centers. Leopold Schenk, managing director of GE Fanuc CNC Germany, knows the needs of end users: "German producers should be adjusted extremely costs." For many tasks, you can only use machine tools with an advantageous price per hour. However, the user demands precision, reliability and ease of use. "These features are typical of products of GE Fanuc, including the CNCs of series 0i."

Of course, "reliability, quality and productivity" are the qualities leading in most modern systems of control of the upper range of GE Fanuc Series 30i/31i/32i. These CNC products have been designed to meet the requirements of high-performance, such as the transfer machines, rotating machines and complex turning/milling centers and multifunctional machines, which require extremely fast and complex functions capacity of multiple channels and numerous axis simultaneous control. Without effective CNC products would not be possible the operation of such machines, used for example for the manufacture of moulds and tools, as well as in the automotive and aerospace industries. These high-tech CNC control systems contain an ultra high-speed processor, as well as an internal high speed bus. They are also integrated a very fast current controller and an encoder with 16 000 000 pulses per revolution, with interpolation in nanometers, which applies to all the convoluted.

A unique signature automation packages: due to its high quality and reliability, the GE Fanuc servo and CNC control systems are highly regarded.

The PMC is also essential to maintain reduced production times and therefore the high productivity. This PLC integrated in the CNC control unit handles control the peripheral equipment on the machine tool such as, for example, change of tools, supply of lubricant of cooling, etc. GE Fanuc control systems have a PMC integrated in order to not load to the CNC with additional tasks. Also increases the speed: to execute PLC programs, the PMC only requires 25 nanoseconds for instruction, thereby reducing the auxiliary process times and accelerates the manufacturing cycle. Up to three completely separate PLC programs can be run simultaneously. And they are available to 4096 entries and digital outputs.

The increasingly rapid and complex machining operations represent at the same time conditions of growing demand for operators. Also aspects relating to security become more important. The integrated "Safety with double checking" function is responsible for "monitor" the protective doors, defenses, decks and other peripheral mechanisms that contribute to the security. This integrated and programmable safety function monitors access to the machine and all the movements that it runs. Compare rates and current positions of the components in motion of the machine (shafts and heads) with the data of speed and position saved in the security settings, which are protected against unauthorized access. If necessary, and in situations of emergency, the CNC machine.

During the EMO exhibition in Hanover 2005 saw a clear trend towards the automation of the environment of the machine. In many areas, visitors could see the advances in automation by means of handling systems and robots. Special interest caused the new "Robot Cell" of Fanuc, an innovative system of production, consisting of intelligent robots, various machine tools and automated storage of parts. A robot, equipped with a system of vision and motor driven by a servo motor, takes parts provided by the store and puts them on pallets which are then loaded in the machine tool. After processing, the robot removes the finished parts and makes them to deposit in the store. The entire operation takes place completely automatically.

In recent times have been developed consisting of machines processing systems projects tool and robots, other companies have participated in to Fanuc. It's already used solutions for a time in the production and that they have been developed in collaboration with different manufacturers of machines such as, for example, DMG, Chiron, and companies of the Schleifring group.

For Klaus Wagner, managing director of Fanuc Robotics Germany technology, the trend towards the automation of machines using robots is due to different factors: "the extreme importance of high availability and usage of the machine, along with a quality as uniform as possible"When the machine tools are used in countries where wages are high. In addition, manufacturing without human intervention is essential to sustain production for prolonged periods, for example, during the weekends. The use of robots is a big step forward for the achievement of these goals, especially if one takes into account that the cost of the robots is decreasing year on year. "Like the CNC control systems, they will become progressively standard components of automation in the production process."

The great advantage of the robots is their flexibility. They can be used for the loading and unloading of machines and, in addition, for tasks such as deburring, polishing or cleaning of components. Sensors and vision systems, which can be integrated into the robot, 'eyes', provide you with so that you can grab parts with precision and even to eliminate those which are defective.

In contrast to solutions of automation using gantry designs or other linear systems, a robot with articulated arms can start the movement from any position in space. This reduces the amount of engineering and installation required, it is not necessary to align each other with precision machine and automation system. The programming is done, taking into consideration the corresponding position, by the procedure of learning.

According to Klaus Wagner, the programming of the robot and its interaction with the machine are very simple, at least with complementary components of Fanuc GE / Fanuc: "the robot has its own system of control, but communicates with CNC processing machine via a simple field bus connection." Using a cable and enabling the software, the user can build a direct connection, which can also be implemented after the commissioning of the machine. "In addition, it is not necessary to make extensive changes in the software, the machine or for the robot."

High availability and usage of the machine, along with a quality as uniform as possible, are of particular importance when machines tool used in countries where wages are high. In addition, an integrated robot can carry out a good service.

The systems of control of the upper range of the Series 30i/31i/32i of GE Fanuc have been designed to meet the requirements of the rotating machines of high-performance, such as the transfer machines, complex turning/milling centers and multifunctional machines, and enable its automated operation.

The robots are not only used to automatically operate machine tools, but also to take charge of wide variety of tasks such as, for example, in the different departments of production of the car manufacturers and their suppliers. The employment sections of Assembly and painting is well known. But robots are also suitable for connecting machine tool measurement devices and other machines.

In the production facilities where complete assemblies are manufactured, are necessary effective systems of control, as well as different machines and transport equipment. Due to its extensive line of products and its reliability and innovative strength, Fanuc /GE Fanuc is long time collaborator of different car manufacturers for the area of automated production equipment.

With its recent concept for the automation of transfer lines and cell processing, based on the standard CNC Fanuc CNC technology and that it minimizes the PC-based technology, GE Fanuc is intended to primarily provide maximum reliability, simple maintenance, fast service and operation more cost-effective. You can equip the individual machines of a transfer line or a cell processing with a modern system of CNC control and a simple color 10.4-inch LCD display. A PC is used as HMI/SCADA system (line transfer or PC cell) in order to record production data, verify them and evaluate them. In addition, it's interface with higher-level information (IT) systems. The separation of the CNC and PC makes it possible to transfer line or cell processing remain fully operational, although problems may occur in the PC. The main advantage of this concept, which is already being used by some automobile manufacturers and component suppliers, is the increased availability and ease of maintenance of the system of control, which is not exposed to the risks of the technology of the PC, or of other auxiliary components.

Another trend on the rise: users want to get all the components of automation on a single source: control system, the drive and, if possible, the robots. Fanuc GE and FANUC Robotics responded to this demand, all Fanuc products have been designed as a system since its inception and are optimally coordinated among themselves, offering a package of automation. This avoids problems of interconnection, accelerates the implementation underway and ensures a reliable production process.