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Automation of machine tools programming

Automation of machine tools programming. Ing. Jan Tomíček. Course description. Course is focused fundamental possibilities of automatization of machine tools and automatization of programme preparation for CNC machine tools. 1+2, CA – classified assessment - 3 credits Presentations

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Automation of machine tools programming

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  1. Automationofmachinetoolsprogramming Ing. Jan Tomíček

  2. Coursedescription • Courseisfocused fundamental possibilities of automatizationofmachinetoolsandautomatizationof programme preparation for CNC machine tools. • 1+2, CA – classifiedassessment - 3 credits • Presentations • Exercises • commontasks • individualwork

  3. Presentations 1+2, 1 hourofpresentation, 2 ofexercise => 13 + 13weeks (13+26) => 4 + 9 approx.(12+27) presentationexplainthework on exercise=> presentationwillbetogether on thebeginning andthenyouwillhavetime to makethetaskandindividualwork!

  4. Lesson 1 – Automationoverview longerpresentation no exerciseortask

  5. Introduction Work on conventionalmachinesisreplaced by automatedwork on automaticmachines. These machines are workingwithouthumancontrolwithhigher speed, precision, saferand more productivlythanhumans. Butwheredidit start?

  6. Automation of machining • Is connected with the rising demands of society and industry development. • Is the way to intensification of manufacturing – increasing productivity, improving quality and lowering costs • Is the way to improvements in manufacturing technology, spreading the technological possibilities and way to make the inovation cycle faster.

  7. Whatweneed to automate? • Tool management • Toolchange • Toolmovements • Spindle start, devices start • Materialloading • Finishedpieceremove

  8. AUTOMATION OF MACHINING Machine tools: • general-purpose, manually operated (conventional); - Theleadingpoweristheworker

  9. AUTOMATION OF MACHINING Machine tools: • automated: a) fixed automation – mechanisms: cams, gear wheels, links, levers, arms; mechanical stops, limit switches, etc. b) flexible automation – programcontrol, numerical control

  10. Fixed automation elements

  11. Cam Is a discorcylinderwith a curveshapedpath. A boss in support is in thepathand as thecamturnsthe support moves. Cam are connectedtogether to providecomplexmovementof support, feed, rotationandother.

  12. Cylindrical cam use – automatic lathe carriage

  13. Fixed automation machine tools • automatic general-purpose machine e.g. a semiautomatic or an automatic lathe • single-purpose machine (usually unit-built) workpiece oriented function design • transfer line integrated workpiece transport system

  14. Unit-built machine

  15. Modular units design

  16. Single purposemachine • Just oneoperation, ofop. Step isdone. • Sometimes a batchofoperationsteps • Specialmachinedesigned to maximizetheproduction: • Multiple spindles • Highfeeddrives • Multiple clamping • Automatic part in feed • Specialtoolingusage

  17. Single-purpose machine efficiency

  18. Transfer line – a concept

  19. Transfer line – a schema

  20. Block machining transferline Video – Transfer line

  21. Transfer line station – an example

  22. 2) Flexibleautomation • (soft, programableautomation) isaimedatpieceandsmallbatchproductiondue to easyreprogramming. Two basic forms • Program sequencecontrol • Numericalcontrol

  23. Program sequencecontrol Thesequenceofmotionsandswitchingsiscontrolled by relays, timers, switches, perforatedtape, programablecylinders, plugboardsandothercontrollers. Easierreprogramming, limited program options, almost no adjustments

  24. Perforated tape Each line presents a different movement or switch. It has to be printed correctly, no error control. FYI: 8 line perforated paper tape can contain one byte of information in one column of holes. Normal pitch of columns is 2,54 mm. That means you need 2,6 m of tape to store 1kB of data. A dual-layer DVD is then approx. 22100 km of perforated tape.

  25. Numericalcontrol • The most important type ofautomation. Almostallofnewmachines are numericallycontrolled. Priciple: Machineandallofitsmovements are controlled by a program. Program is a list ofinstructionswrittenisspecific syntax andhavingspecificformat.

  26. Mechanical vs. numerical • Limitations – speed, lengthof program, possiblemotions on cams.

  27. FLEXIBLE AUTOMATION • Conventional machine tool

  28. FLEXIBLE AUTOMATION 2. NC machine tool (stand-alone)

  29. FLEXIBLE AUTOMATION 3. NC machine tool with tool magazine

  30. FLEXIBLE AUTOMATION 4. CNC machine tool

  31. Mechanization vs. automation • Mechanization – human power is replaced by machines, drives, hydraulic or mechanic devices • Automation – human control is replaced by sequentional machine, cams, computer, PLC controller

  32. Automation degree • Semiautomatic run – tools are changed automatically, blank or finished workpiece is renowed by operator • Automatic run – both the tool and pieces are placed and removed automatically by robot (line, tables)

  33. Whatweneed to automate? Semiautomatic • Tool management • Toolchange • Toolmovements • Spindle start, devices start • Materialloading • Finishedpieceremove Automatic

  34. NC / CNC definition Originalyonly NC controlwasused. Program wasstored on tapeordiscandreadone line afteranother. Influence of rapid developmentofcomputersresulted to CNC control (Computernumericalcontrol). Nowthe program isloadedintocomputersmemoryandexecutedfromhere.

  35. CNC advantages

  36. Basic principlesof CNC machines • NC/CNC machine consist of 3 basic elements. List of instructions – NC code – a mix of alphabecial and numerical information. Contaion information about movements, feed, speed, tool change and other machine functions (cooling, measuring) Control unit - control system – convertsthe program intosignalformachineandsendthem to machine(PLC controller) NC code Machine Control unit (system) Drive motor Sensing device

  37. Basic principlesof CNC machines • NC/CNC machine consist of 3 basic elements. Machinetool – fittedwith drive motor to operateslides, support andspindle. Alsowithswitches to start/stop specificfunctions Sensing device – optional(closedcircuit)- sensing device controlif a specificdemandwasfullfilled. Support feed, Table positionetc. NC code Machine Control unit (system) Drive motor Sensing device

  38. CNC machine tool

  39. Motions Threetypesofmotion • point-to-point motion – toolismoved to specificlocation, pathor speed ofmovebetweenlocationis not controlled. (drilling) • Linearcontrol – movementalongoneoftheaxesofthemachine. • Contouringcontrol – movementcanbemade in twoor more axessimultaneously.

  40. Motions Point-to-point controlLinearcontrolContouringcontrol (continual) drillingmillingmachines, lathesmachiningc.(milling, turning)

  41. CNC machining centre(MC) • MC combine a number of different machining processes in one operation

  42. Modular tool set

  43. Modulartool set – toolingsystem Allmanufacturersaroundtheworld Basic concept: • Holderwithstandadizedconecting part – ISO, BSK cone, CAPTO systemetc. • Extension bar – active (vibrationelimination) adujstableandbalanced • Quickchangetooltip/insert

  44. SECO - Combimaster

  45. Tool exchange

  46. Tool exchange

  47. Flexible cell – a concept

  48. Flexible manufacturing system

  49. Conveyors Device usedfortransportationofblankandsemiproduct in production Types: Beltconveyor Pulley(rolls) conveyor Cradleconveyor

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