The manufacturing industry faces two significant challenges: declining added value due to industrial restructuring and an aging workforce stemming from demographic shifts. In the machining sector, leveraging big data from machine tools has become increasingly critical for enhancing productivity and implementing intelligent manufacturing systems. However, varying data formats and communication methods across different equipment hinder efficient integration, posing a major barrier to the digital transformation of manufacturing. This study develops an integrated server system to facilitate the digital transformation of the machining industry by enabling effective collection, storage, processing, and analysis of data from machine tools. The system features a standardized protocol-based interface for consistent data collection and control across heterogeneous CNC machine tools. By leveraging IEC 62541 OPC UA (Open Platform Communication Unified Architecture) and OPC 40501-1 UMATI (Universal Machine Technology Interface), it ensures interoperability with upper-level applications through standardized information models. The proposed approach addresses inefficiencies in vendor-dependent CNC data systems, providing consistent data management for diverse equipment. By enhancing real-time data handling and eliminating integration challenges, the system contributes to the digital transformation of the manufacturing sector and the creation of an efficient production environment.
In CNC machining, NC data created by CAM software is usually linearly interpolated. This linearly interpolated tool path, however, may degrade the dynamic motion performance of the machine tool and the geometric accuracy in comparison with the reference CAD data. Tool path smoothing can be an effective way to address these problems. In this paper, a five-axis tool path smoothing method is proposed based on dual cubic B-spline curves. The proposed smoothing method includes two steps. First, the tool orientation is adjusted to reduce drastic changes in tool orientation movement. Then, dual B-spline curves are generated for smooth interpolation of tool position and orientation, wherein their control points are created by using modified internal division points between the top and bottom points of the tool defined by given tool position and orientation vectors. The B-spline curves pass through the junctions of straight line segments comprising the top and bottom points, respectively. Smooth tool position and orientation vectors are finally obtained by simultaneous interpolation of the B-spline curves. The proposed method is implemented in a PC-based five-axis control system and experimentally demonstrated to show improvements in the dynamic motion performance and the geometric accuracy compared with the conventional linear interpolation.
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The Human Machine Interface (HMI) is dependent on the Computerized Numerical Control (CNC). As a result, the HMI software is developed according to the interface method of each CNC in duplicate. Even though the same function of HMI software module is developed using the same data item, it must be implemented separately in different development environments. This is because each CNC has a different address system and provides unique data interface method. In this study, we proposed a unified interface system that can standardize and integrate data interface method to support the development of HMI software module applicable to machine tools adopting multi-vendors’ CNCs. To clearly define this work, we developed new parameters, methods, and address system based on the machine state model, composed of data elements of machine tool structure, process, and status, provides the same interface by capsulizing existing CNC interfaces. The proposed interface system is designed to provide an API (Application Programming Interface) in the form of a library. The implementation architecture is designed and details of the operating logic within the detailed components and interfaces are elaborated. The implementation and test results are illustrated to verify an application example of the proposed unified interface system.
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In CAD/CAM, NURBS (Non-Uniform Rational B-Spline) is used to represent a wide variety of free-form curves. NURBS interpolation is advantageous in the processing of smooth curves and is capable of high-speed and high-precision CNC machining. In this paper, a real-time 5-axis NURBS curve interpolator is proposed. The proposed interpolator is based on tool center point control and can produce smooth tool orientations as well as accurate tool paths, thereby realizing high precision and efficient 5-axis machining. Using newly defined G codes, tool orientations are described by vectors and the proposed interpolator can be applied to any 5-axis machines regardless of their rotary axis configurations. In addition, the proposed interpolator calculates both tool positions and orientations simultaneously using a shared interpolation routine and we can reduce the computation load. The proposed NURBS interpolator is implemented on a PC-based 5-axis CNC testbed. The performance of the proposed interpolator is compared with the conventional linear interpolator in terms of smoothness of feedrate, contour errors, and tool orientation errors.
This paper describes the design of the beam of a gantry robot for Computer numerical control (CNC) lathe that can automatically attach and detach a workpiece. The gantry robot takes the unprocessed workpiece from the stoker and mounts it on the chuck of a CNC lathe. The robot then removes the processed workpiece fixed to the chuck and places it in the processed workpiece stoker. The workpiece consists of a body, x-axis beam, x-axis driving device, y-axis beam, yaxis driving device, z-axis beam and z-axis driving device. Finite element analysis was performed to design the x-axis beam, the y-axis beam, and the z-axis beam. Based on the results, the optimal size of the x-axis beam was designed to have a size of 150 mm × 150 mm × 4681 mm with a thickness of 9 mm. The x-axis beam is less eccentric in the position of the chuck of the CNC lathe.
We used a construction method using a CNC milling machine, where free-formed molds were made by cutting EPS (Expanded PolyStyrene) foam with the CNC machine, to build free-formed buildings. CNC milling is off-the-shelf technology that can easily cut EPS foam; however its production cost is too high and the time to manufacture an EPS mold is too long. This paper proposes a novel cutting machine with a fast and cost effective mechanism to manufacture EPS concrete molds. Our machine comprises a cutter and Cartesian coordinate type moving mechanism, where the cutter cuts EPS foam using a hotwire in the shape of ‘Π’ and is capable of adjusting its cutting angle in real-time while keeping its cutting width. We proved through cutting experiments on the CNC machine that cutting time was greatly shortened compared to the conventional method and that the resulting concrete mold satisfied manufacturing precision.
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