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Model-Driven e-Manufacturing Using STEP-NC

Explore the benefits and capabilities of STEP-NC technology for direct control of machine tools from 3D data, transforming manufacturing processes with increased efficiency and reduced operational costs.

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Model-Driven e-Manufacturing Using STEP-NC

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  1. STEP-NC: E-ManufacturingUsing STEP David Loffredo loffredo@steptools.com STEP Tools, Inc. 216 River Street, Troy, NY 12180 (518) 687-2848 / (518) 687-4420 fax http://www.steptools.com

  2. Model Driven e-Manufacturing • Direct control of machine tools from 3D data • Using STEP-NC specification under development in Europe and Far East for 3 years • Milling, Turning, EDM, Grinding, Bending • Extensions for Robotics and Assembly anticipated • Benefits • 35% reduction in time for job shop to set up machining job • 75% reduction in time for OEM to prepare data for job shop • 50% reduction in computer infrastructure costs • Faster, safer, more adaptable machine tools

  3. Current NC programming using ISO 6983 machine-specific part program with axis data generated by a postprocessor % N05 G54 N10 G00 Z10.000 N15 G91 G0 Z200 N20 T5 D1 WW N30 G90 M5 N35 G00 X0.000 Y-150.000 N40 G00 Z5.000 N45 M08 N50 S3183.000 N55 M03 N60 F1477.000 N65 G00 X60.000 Y-150.000 N70 G00 Z5.000 N75 G00 X60.000 Y-150.000 N80 G01 Z-0.500 ... vendor-specific extensions of the original standard only primitive motion and switch commands no standardized data format for spline processing and sophisticated NC technology STEP-NC replaces this with a rich, integrated data format Courtesy WZL RWTH Aachen

  4. STEP-NC Is Integrated workpiece workplan geometry S[0:?] L[0:?] machining_feature machining_workingstep geometry 1 S[0:?] pocket plane hole region machining_operation 1 L[0:?] plane_milling side_milling drilling tool technology toolpath geometry 1 strategy cutter_contact_trajectory cutter_location_trajectory parameterised_path Courtesy WZL RWTH Aachen

  5. Use Cases for STEP-NC (ISO 14649) STEP-NC enables direct control of NC machine tools from 3D data. Courtesy WZL RWTH Aachen

  6. Model Driven Intelligent Control of Manufacturing Function Design AP-203 AP-214 “Super Model” STEP-NC Database . . Intelligent Controller Mfg Design Intelligent Interface AP-224 AP-xxx Process Capture AP-213, PSL ISO 14649 ISO 13399 STEP Tools, Inc. 216 River Street Troy, NY 12180 info@steptools.com Electro-Mechanical Integrators Honeywell Liberty Consulting RPI

  7. GE Fanuc CNC Data (MASTERCAM) CADKEY Alibre Boeing General Electric General Motors Gibbs and Associates Hurco Companies Inc. Lockheed Martin IBM Monarch Machine Tools NASA (GSFC) NASA (JPL) NCMS Unigraphics Solutions NIST Intelligent Systems Lawrence Livermore Chrysler Watervliet Arsenal (Benet) General Dynamics The Design Edge RMC Associates Fala Technologies Cambridge Valley Maching Allied Signal Bridgeport Controls Liberty Consulting RPI MDICM Industrial Review Board

  8. Software tools to make implementing and using the STEP ISO standard easy. Forerunners in STEP technology since 1991 Founders working on product data since 1978 First commercial software tool kit First solid model data exchange using STEP First STEP Repository Contributors to STEP and STEP-NC meetings Owner of Parts 14, 21, and 24 of STEP Owner of Parts 3 and 51 of STEP-NC 300+ customers use our tools to define and implement STEP and STEP-NC Who We Are

  9. End User Benefits The supplier creates the production process from a 3D product model instead of paper drawings Measured by Lockheed Martin

  10. End User Benefits STEP is used to automatically prepare visuals for process plans. GOAL: Reduce manufacturing costs • 50% of total process plan effort is composing visuals. • STEP-based system using to produce process plan visuals. • Projected 75% reduction in man hours spent in visuals preparation (25 hours vs. 100 hours). Measured by Raytheon

  11. The Super Model Solution Ford GM Boeing Lockheed CAD System 2 STEP Interface CAD System 1 STEP Interface CAD System 3 STEP Interface CAD System 4 STEP Interface “Super Model” = STEP +++ database on the Internet STEP Interface Supplier 1 STEP Interface Supplier 2 STEP Interface Supplier 3 STEP Interface Supplier 4 STEP Interface Supplier A STEP Interface Supplier B STEP Interface Supplier C STEP Interface Supplier D CAM CAPP NC Milling NC Turning One database replaces hundreds of PDM files

  12. MDICM Year One Pilot Project CADKEY CAD AP-203 STEP-NC AIM has not yet been given an AP number by ISO STEP Process Planning FBMACH STEP-NC AIM Work Plan STEP-NC Database XML ISO 14649-11 Work plan Bridgeport Controller Bridgeport Controller Tool Path Generation Virtual Gibbs EASYMILL Milling Machine Benet Laboratories Watervliet Arsenal Demonstration General Dynamics Land Systems Demonstration

  13. Year One Pilot in Detail (1 of 3) CADKEY • Enhanced FB Mach CAM system to write STEP-NC data for holes, pockets and slots • Developed the STEP-NC AIM model • Reviewed by ISO STEP • New Work Item being submitted to get an AP number • ST-DeveloperTM and ST-ACISTM are STEP programming tools developed by STEP Tools ST-ACIS AP-203 FBMACH STEP-NC AIM ST-Developer Work Plan

  14. Year One Pilot in Detail (2 of 3) STEP-NC AIM Database • Work Plan generator • Bridge between STEP and XML • Feeds XML data to EASYMILL shop floor programming system • An application of the STEP Tools database product ST-RepositoryTM Work Plan Generator ST-Repository XML Work Plan Bridgeport Controller EASYMILL

  15. Year One Pilot in Detail (3 of 3) • STEP-NC Controller • Modified EASYMILL to read XML Work plan • Put Controller and EASYMILL onto PC • Working with General Dynamics Land Systems for second demonstration ST-Repository+ XML Work plan ST-Developer Bridgeport Controller EASYMILL

  16. Consequences of STEP-NC • No more post processors! • Every tool reads the same instructions • New market for CAM software! • Every controller needs tool path generation software • More efficient CAD! • Less tedious process planning • Self correcting manufacturing! • Every work plan includes the nominal geometry of the part • Faster, safer, more intelligent machine tools! • Verify set up • Dynamic optimization

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