Presentation date: 2017-10-25 Jasper Sanders Room name ... · PDF fileücomplete 840D...

Unrestricted © Siemens AG 2017

Presentation date: 2017-10-25Presenter Name: Manfred Moritz

Jasper SandersRoom name: Estrel HallPresentation Title: Added value of a Digital Twin - realized for Georg Ultraturn 4000MC by

leveraging NX-VNCK and Sinumerik


Added value of a Digital TwinSeamless process safety realized for a Georg UT4000MCleveraged by a machine simulation with NX VirtualMachine based on Sinumerik VNCK


• Dynamowerk Berlin

• Georg Mill-Turn machining center

• NX-CAM NC-Simulation

• Sinumerik VNCK

• NX-VNCK (development, implementation, engineering)

• About the Project

• VNCK – HMI & other benefits

• Open topics

• Future business model

Agenda

Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)23.10.2017


Founded 1906Employees ca. 750Production area 49.000 m²Office area 5.200 m²Production ca. 200 Machines/YearExport quote 96%

Siemens Dynamowerk Berlin

Business assignment:Custom-built Machines in big and biggestpower range in the complete engine-speedrange, up to 100 MW and up to 15.000 rpm.

23.10.2017 Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)


We develop custom-built engines for different industrybranches

Oil & Gas Energy

MetalIndustry

ShipbuildingMining



Part manufacturing processes of Mill-Turn parts in theDynamowerk

Lathe roughing Setup 1

Lathe rouhging Setup 2

Milling Setup 3

Milling Setup 4

Milling Setup n

Lathe finish Setup n+1

Lathe finish Setup n+2

Lathe grinding Setup

Setup 1: lathe roughing, milling, lathe finish Setup 2: lathe finish, milling, grinding






• Sinumerik VNCK




• Open topics


Agenda



Realization:

• Procurement of a combined Mill-Turn CNC machining center:ü technologically uniqueü maximum effectivenessü maximum flexibilityü complete housingà max. health & safetystandard / Zero Harm

• Manufacturing of a rotor in „one“Setup using all technologies

• Turning / Lathe• Milling• Grinding• Measuringà Reduction of manufacturing time

6 axis heavy duty machining center that combines milling,turning, grinding and measuring in one setup: „GEORG“



Maximum component load

§ Peak width ca. 11.000mm§ Peak height ca. 2.100mm§ Max. outer diameter 4.000mm§ Max. comp. weight in face plate 10t§ Max. comp. weight in center peaks 75t§ Max. comp. weight in two steady rests 180t

Georg ultraturn 4000 MC

Ø Programmed in Siemens NX-CAMØ Simulation with Siemens NX-VCNKØ Usage of Simotion, Sinumerik and Sinamics

componentsØ Connected via Sinumerik Integrate






• Sinumerik VNCK




• Open topics


Agenda



Simulation technologies in NX-CAM




• Toolpath verification • Toolpath verificationwith material removal

• Toolpath verificationwith machine kinematic

Toolpath movements




§ Simulation of the on-the-fly created NC-Codes§ Interpretation of the NC-Codes by

- Controller Emulation (CSE) or by- original Controller Kernel (VNCK)

§ Movement of the machine kinematics

NC-Code ofPostprocessor



Comparison of Simulation-Technologies

Simulation“before Postprozessor“

Simulation based oncontroller emulation

Simulation based onvirtual machine

+ available at an early point

+ no machine definition needed

- kinematic conditions can not be

simulated

- errors from the postprocessor can

not be evaluated

- no simulation of free NC-Code

+ one platform for many different

machines

+ controller types that do not

provide a virtual controller can be

simulated

- emulated controller are very

often insufficent to simulate

complex machining center

+ contains the full functionality of

the controller

+ handling and look&feel are

identical to the real machine

- performance is usually lower

than with controller emulation

(Cf. Volkwein G., 2006, Konzept zur effizienten Bereitstellung von Steuerungsfunktionalität für die NC-Simulation, page 16)






• Sinumerik VNCK




• Open topics


Agenda



SINUMERIK VNCK

ü NCU Linkü multichannelü technology/special functions ascompilecycleü Siemens-, OEM- and User-Cycles

ü complete 840D languageü all movements (spline, polygone)ü all kinematic transformationsü original transformation algorithmsü measuring, travel to fixed stop

VNCK ApplicationAPI

SINUMERIKOperate

orHMI Advanced

HM

ISer

vice

Digital Twin of Sinumerik 840D CNCController



NX Virtual Machine

NX Machinekit (machine specific dataset)

RunMyVNCK NX CAM

Inte

rfac

e(N

X324

07)SINUMERIK

Operateor

HMI Advanced

HM

ISer

vice

Create MyVNCK






• Sinumerik VNCK




• Open topics


Agenda



Setting up the NX Virtual Machine

Import and prepare 3D Model

Create Kinematic Model(MTB)

Create VNCK Driver (SRAM-File)

Subsitute non-NCK functions(ACL Programs & MCF File)



Creating a VNCK Driver

SINUMERIKNC Archive

CreateMyVNCK

VNCKDataset

(SRAM-File)



How to get it?

SiemensPLM

Software

VNCKSupportCenter

MachineUser

OEM Channel







• VNCK – HMI & other Benefits

• Sinumerik VNCK


• RobX

• Open Topics

• NX Virtual Machine Business Model

Agenda



Georg VNCK project goals


• NC Simulation that is topmost precise and as close to reality as possible to ensure processsafety by collision free NC-Programs

• Development of a NC machine simulation in NX, based on Sinumerik VNCK

• Pilot project to evaluate the engineering effort of a NX-VNCK for a complex machining center

• Cooperative development together with Siemens PLM and the VNCK Support Center,supported by the machine manufacturer Heinrich Georg GmbH and the Dynamowerk

• Completion of the CAM-CNC process chain from programming to the machine

• Support of the lighthouse project for Siemens Large Drives division to fit out this high endmachine with the most advanced Siemens products on the market


Work packages in the Georg VNCK Project

• Work package 1: Simplify machine geometries for simulation purposes• Work package 2: Creation of the machine kinematics and additional adjustments of the

machine geometry assembly• Work package 3: Implementation of the new machine and its devices in NX-CAM and

installation of NX-VNCK in NX 10.0.3• Work package 4: Development of PLC replacement programs in ACL and in the machine archive• Work package 5: Adjustments of the “simulation_ini.tcl“• Work package 6: Creation of the first tool load into NX native library• Work package 7: Manufacturing time – evaluation of PLC auxillary process times• Work package 8: Problems/Workarounds:

• C-Axis & SPM-Axis• Spindel SPM2 in different head devices• VNCK bug in the drive assignments• Idleness survey (Stillstandsüberwachung)



NX-VNCK – Georg UltraTurn 4000 MC






• Sinumerik VNCK




• Open topics


Agenda



• HMI with the original look and feel of the real machine

• Exact simulation of all available manufacturingtechnologies of the machining center (e.g. grinding,measurement cycles, measurement equipment, etc.)

• Same program errors as on the machine (e.g. syntaxerrors, missing tool correction, circle endpoint errors,wrong cycle parameters, etc.)

VNCK – HMI & other Benefits



• Block search with calculation (equal to the originalmachine!)

• Simulation in Dry Run possibleà meanssimulation in rapid movement speed = fastsimulation with same error detection but no timecalculation

• Calculation of machining time at a quality of >98%à except of PLC times, they are missing!




• Postprocessor development and bugfixing in the Simulation without on machine time / secondarytimes

• NC-Code is editable in the HMI (e.g. development and test purposes, placement of stop points (M0))

• Retranslation of cycles like on the real machine

• Development and testing of NC user functions







• Sinumerik VNCK




• Open topics


Agenda



Real Machine Virtual Machine

Open Topics – Head-Spindle Issue

Several spindles+ Spindle coupling

inside VNCK

One Spindle +mechanical

coupling with tool



Open Topics – Turning Toolpath issue

Toolpath is fixed to workpiece(needed for milling)

NX CAM is gettingactual values for

angle of theturning spindle

Updating the Toolpathbetween operations results

in shifting it out of theturning plane.



Open topics – VNCK and ROBX

VNCKCompile Cycle Support

Full support of robotscontrolled by 840D

Controllers, includingrobotic machining.



Further Open Topics


• Performance- Unattended Simulation- 3D quality (applying to the Workpiece dimensions of the Dynamowerk)- PLC auxiliary process times

• Collision detection of NX-CAM turning module (fixed with NX12?)

• VNCK Drive Configuration Issue

• Since NX11 the Driver-File is copied to the Part-Folder


Future Topics


• Physical influence on the workpiece

- Calculate the deflection by workpiece weight

- Calculate the right pressure to compensate deflection (e.g. with steady rests andtailstock)

- Calculate thermic influence due to material removal

- Calculate effect of thermal energy on tool (e.g. tool wear)





• Sinumerik VNCK




• Open topics


Agenda



NX Virtual Machine Business Model

SiemensPLM

Software

VNCKSupportCenter

MachineUser

… as proven in 15 otherpilot projects!

OEM Channel

Direct Channel



Manfred MoritzSiemens AGPD LD AP DW FP IE NC

Nonnendammallee 7213629 Berlin

E-Mail:[email protected]

siemens.com

Jasper SandersSiemens AGRC-DE PD CSO 1 SD3 1

Franz-Geuer-Straße 1050823 Köln

E-Mail:[email protected]

Presentation date: 2017-10-25 Jasper Sanders Room name ... · PDF fileücomplete 840D...

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