STEP-NC Solutions

1. STEP-NC Solutions Martin Hardwick David Loffredo info@steptools.com STEP-NC Manufacturing Center Watervliet Arsenal, Building 20 Metal Processing Manufacturing Division Watervliet, New York 12189 (518) 687-2848 / (518) 687-4420 fax http://www.steptools.com

2. Introduction “4 CAM’s – 2 Controls – 0 Postprocessors” AP-238 BC Table Tilt AB Tool Tilt

3. AP-238 Functionality Benefit Other Models Turning (in AP-238 ed1) EDM Contouring Inspection Robotics Tested during research phase Parametric Operations Today Feature parameters Probing Workingsteps Feature tolerances Toleranced Splines Toleranced Surfacing TCP Lines & Arcs Drilling Cycles Product Geometry Conditional Operations Better Process Control Better Process Monitoring Flexible Manufacturing Functionality

4. New components CNC Vendor components bi-directional Subs Control HMI AP-238 File Converter dll Writer dll CAM TCP Motion Codes Motion Controller Expresso Data check STEP-NC Simulator Smart Process Control • Base level configuration • Eliminates post • Enables faster operator prove-out • Creates pathway for on-machine optimization

5. bi-directional Subs AP-238 File Writer dll CAM Expresso Data check STEP-NC Simulator Smart Process Monitoring New components CNC Vendor components Control HMI Customer Report Monitor dll Block Number TCP Code CNC Loader Motion Controller • Process Monitor configuration • Allows customer to verify correct operation of the control • Timings, operational parameters • Feature, operation and tool id for each workingstep

6. Subs AP-238 File Writer dll CAM Expresso Data check STEP-NC Simulator Smart Manufacturing System Integrator component Control HMI Customer Report Executive Run WS1-N Program Status Sensor value Interpreter dll Sensor value Block Number TCP Code CNC Loader Motion Controller • STEP-NC Interpreter configuration • Execution flow depends on sensor values • Sensor values are connected to NC Variables of the program • Executive tells Interpreter when to start and stop

7. Applications • Smart Process Control • CNC Operator needs to change a speed for all pocketing operations • Converter identifies all workingsteps that use this feed. • CAM operator guided to operations that need to be edited • Smart Process Monitoring • Motion control records maximum Z tool tip position • Monitor dll adds data about workingstep and feature id • OEM checks hole feature has required depth. • Smart Manufacturing • CAM creates program including probing operations • Executive relates probe value to STEP-NC Variable • Interpretation of program decides how to adjust finish allowance

8. The Dynamic “Here are dll’s to read and write STEP-NC data” “Accept jobs defined by AP-238 so I will know how they are machined” OEM ISO Standard Shop “Put the AP-238 dll’s on my TCP controls” “I need AP-238 so I need to upgrade my controls to include the TCP option.” CNC Vendor

9. Current Status • Can machine NAS 979 CDS part with 5 axis cone • 3 and 5 axis tool paths, lines and arcs • Machine functions and technology • Draft International Standard in review • A few EXPRESS errors being found • Some scope for data compression • Enhancements for process monitoring • Writer and Converter dlls ready for Beta use • Stage 1 – replace RS274D but keep same procedures • Stage 2 – optimize procedures using new intelligent data

10. Conclusion • AP-238 delivers rich data to the control • The benefits are well known • Design anywhere, build anywhere • Cross enterprise re-use of CNC programs • Fewer operational errors • Faster machining • The post was always in the way • Delivering low level machine codes • No connection between a feed and the reason for the feed • The combination of Open Controls, TCP Programming and AP-238 eliminates the barrier.