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CIM Notes Typed
CIM Notes Typed
The
control
cannot
turn
handwheels,
so
all
the
axis
slides
are
equipped
with
feed
mototrs.
The
control
provides
signals
to
moe
the
tool
or
workpiece.
These
signals
are
amplified
in
amplifier
and
passed
onto
feed
motors
in
the
axis
concerned
to
move
the
axis
slide
as
per
the
speed
and
duration
already
programmed.
It
becomes
more
clear
from
the
figure
on
Position
Control
Loop.
To
control
the
feed
rate,
each
feed
motor
is
equipped
with
a
tachogenerator
which
signals
the
actual
motor
speed
to
the
amplifier.
The
latter
uses
this
signal
to
calculate
the
actual
feed
rate
and
compares
it
with
the
programmed
feed
rate
and
in
case
of
a
deviation,
an
electric
signal
is
supplied
to
the
amplifier
to
accelerate
or
decelerate
the
feed
motor.
This
process
is
referred
to
as
Feed
Control
Loop
and
is
related
to
a
Closed
Loop
System.
Advantages
of
NC/CNC:
1. The
design
and
construction
of
NC/CNC
Machine
tools,
together
with
the
fact
that
these
machines
are
controlled
by
numerical
values,
ensure
positioning
accuracy
and
repeatability.
In
other
words,
if
the
same
program
is
employed
to
produce
a
number
of
parts,
they
would
have
exactly
identical
dimensions.
2. Complex
shaped
components
can
be
machined
automatically
with
closer
tolerances
and
high
degree
of
reliability.
3. Since
these
machines
can
operate
without
involving
operator
all
the
time,
it
is
useful
for
hostile
environments.
4. NC
Systems
transfer
a
substantial
portion
of
planning
for
the
processing
operation
from
the
shop
floor
to
offices,
where
a
specialist
prepares
the
NC
part
program
in
a
comfortable
environment.
Consequently,
production
can
be
directly
monitored
and
controlled
by
the
management.
5. A
sequence
of
machining
operations
can
be
performed
in
a
single
set
up
on
a
single
machine
In
fact,
this
is
considered
to
be
one
of
the
major
advantages
of
NC
machine
tools,
,
since
the
unproductive
time
used
in
setups
and
workpiece
transfer
amounts
to
a
high
percentage
of
total
production
time.
6. Since
Idle
Time
is
minimum,
employing
NC
Machine
Tools
is
always
accompanied
by
increased
productivity.
7. NC
Machine
Tools
are
highly
advantageous
when
i.
Number
of
operations
Many
ii.
Number
of
dimensions
to
be
maintained
High
iii.
Complexity
of
operations
High
iv.
Repeatability
of
batches
Often
v.
Size
of
Batch
Small/Medium
vi.
Labour
Cost
High
vii. Ratio
of
Cutting
to
Non-cutting
Time
Low
viii. Variety
of
Components
More
ix. Cost
of
specialized
tooling
High
x.
Setup
Time,
Inspection
Time
High
xi.
Accuracy
High
xii.
Space
on
the
Shop
Floor
Less
xiii.
Budget
Sufficient
PART
PROGRAMMING-
Geometric
fundamentals
the
programmer
informs
the
control
in
advance
what
to
do
and
then
the
machine
operates
independently
without
human
interference.
However
this
will
only
work
if
the
control
is
fed
with
necessary
geometry
data
and
technological
parameters
for
work
piece
concerned.
For
our
discussion
we
consider
CNC
universal
milling
boring
machine
(
or
CNC
jig
boring
machine)
on
which
following
slide
motion
are
obtainable
:
Table
to
the
right
or
left
(
x
axis
motion)
Spindle
head
forward
or
back
(
called
y
axis
motion)
Table
up
or
down
called
(z
axis
motion)
There
is
an
essential
difference
between
table
slide
machine
and
bed
machine.
In
table
slide
machine,
it
is
the
table
(and
thus
the
workpiece)
that
form
the
moving
part.
To
simplify
the
matter
and
to
avoid
confusion
in
CNC
technology,
we
program
all
machine
motions
as
if
it
were
the
tools
that
move.
This
process
is
referred
to
as
programming
the
relative
toll
motion.
PROGRAMMING
FUNDAMENTALS-
Having
programmed
the
geometric
data
(part
description
)
of
the
component,
we
move
to
tool
programming.
CNC
control
can
move
a
tool
along
any
straight
and/or
circular
path.
To
do
so,
it
requires
certain
data:
-Where
the
target
point
is
located
(x,y,z
coordinates)
-Along
what
path
(
straight
or
circular)
the
tool
is
to
be
moved
to
the
target
TOOL
COMPENSATION:
-
It
is
a
built
in
feature
of
todays
CNC
controls.
To
perform
this
displacement
the
control
needs
following
data:
1. Cutter
Diameter
2. Direction
in
which
the
displacement
is
to
be
effected
From
this
data
the
control
calculates
the
cutter
path
actually
required
for
the
cut
to
be
taken(
on
CNC
machine
tool);
the
compensated
path
of
the
cutter
axis
as
shown
in
figure(page
7)
THE
APT
(Automated
Programmed
tool)
CNC
language:-
The
development
of
this
CNC
language
started
in
Electronic
System
Laboratory
of
Massachusetts
Institute
of
Technology
in
collaboration
with
US
aircraft
industry.
It
is
accepted
by
all
CNC
machines
and
has
become
world
wide
standard
of
CNC
machines.
This
language
controls:
1. Geometrical
statements
(or
geometry
statements)
2. Tool
motion
statements
3. Miscellaneous
statements
viz.
a) Post
processor
statements(COOLANT/ON
i.e.
turn
coolant
on;
FEDRAT/200
i.e.
tool
federate
200mm/min;
SPINDL/1250,CLW)
b) Cutter
specifications
c) Tolerance
specifications
(OUT
TOL/0.001;
IN
TOL/0.001)
d) Initial
and
Termination
statements:
The
first
statement
in
an
APT
program
begins
with
the
word
PART
NO.
(for
eg.
PART
NO
CAM
PLATE);
The
last
statement
will
be
FINI.
It
defines
no
successor
and
has
the
effect
of
terminating
the
program.
A
copy
of
the
APT-CNC
Program
prepared
by
myself
at
M/S
GEC
Limited,
UK(
Biggest
private
organization
of
UK)
for
a
component
to
be
machined
on
CNC
Lathe
is
enclosed
herewith.
ADVANTAGES
OF
FMS:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
ELEMENTS
OF
FMS:
i.
CNC
machine
tools
or
machining
centers
are
the
basic
constituents
of
FMS
and
have
been
discussed
in
detail
along
with
their
programming
procedures.
Work
handling
systems
(conveyors,
AGVs,
robots
etc.)
Pallets,
fixtures
etc.
Buffer
storage,
warehouses.
Tooling
and
handling
systems
Sensing
devices
ii.
iii.
iv.
v.
vi.
FMS
LAYOUT
SYSTEM
MANAGEMANT
IN
FMS:
1) Control
of
FMS:
prime
element
in
the
integration
of
the
system
(input
and
work
handling
equipment)
is
a
computer.
BLOCK
DIAGRAM
OF
ADVANCED
FMS
CONTROL:
TOOL
CRIB
IS
THE
AREA
WHERE
TOOLING
MAINTENANCE,
PREPARATION
AND
ORGANISATION
OF
THE
TOOLINGS
IS
CARRIED
OUT.
2) TOOL
MANAGEMANT:
it
is
achieved
by
auto
tool
handling.
3) THE
MANNINF
OF
FMS:
it
is
achieved
with
the
help
of
system
operator.
4) CONTROLLING
PRECISION:
to
ensure
the
required
close
tolerance
accuracies
etc.
CMM
are
used.
FMS IN THE SHEET METAL INDUSTRIES
Sheet metal parts have traditionally been produced by a range of conventional machining
tools. With the advent of NC/CNC technology it has been possible to produce CNC Press
Brake, CNC Turret Punch Press and high speed sheet metal machining centers (SMMC).
Hence among processes other than machining sheet metal work has the most immediate
potential for FMS and good amount of research work can be undertaken (carried out) in this
field.
In a typical CNC punch press, there are about 60-72 tools to punch holes of different sizes
and shapes. The table can usually carry a sheet up to 1.3x2.5 m in size and to move it in the x
and y planes so that the required area is underneath the punch. The tools are usually
incorporated in rotary heads so that they can be brought into action quickly at lightning speed
compared with the operation of an ATC-on machine tool.
Peripheral FMS equipment manufactured by M/s AMADA, JAPAN includes auto
warehouse, unmanned carriage, auto storage, an automatic labeler, single sheet pick up unit,
loader, unloader, sorting cart, lifting table, lifter table, handling robot, turning and turnover
unit etc.
1. Automatic Warehouse and Automatic Storage: Auto warehouse is a system of steel
frame racks arranged in rows.
A mobile crane (which lifts or lowers materials) can travel between the rows of racks.
Crane stops in the position specified in the program and either inserts or removes the
material, the partially finished product on the pallets or empty pallets from the array
of racks.
2. Unmanned Carriage: Provides the link between auto warehouse & each of production
machines. Carriage is controlled by the cable buried in the floor. The destination of
unmanned carriage is determined by AMACOM through the information transmitted
from each process station requiring loading/unloading
3. Material feed station & single sheet pick up unit: MFS is defined as a station at the
loading side of each processing machine where material (with pallet) is changed from
unmanned carriage & fractional material (with pallet) is returned to the unmanned
carriage.
Single sheet pick up unit uses powerful suction cups to lift sheet metal loaded on the
pallets. Lifted material is released on the slot conveyor (which is at elevated position)
and is next fed to the machine. A magnetic floater accurately separates the sheets.
The machine loader: It positions the workpiece via roller conveyor.