Advanced management and monitoring functions at the TMA 550AL manufacturing centre, used for ATR

Recen Inno a ions in Mecha onics (RIiM) Vol. 2. (2015). No. 1-2. DOI: 10.17667/ iim.2015.1-2/1. 1 Ad anced managemen and moni o ing unc ions a he TMA 550AL manu ac u ing cen e, used o ATR Moldo an O idiu PhD Uni e si y o O adea, Facul y o IMT, Depa men o Mecha onics, O adea, Romania o [email protected] Moga Ioan PhD Uni e si y o O adea, Facul y o IMT, Depa men o Mecha onics, O adea, Romania imoga@uo adea. o Géza Husi PhD Uni e si y o Deb ecen, Facul y o Enginee ing, Dp . o Elec ical Enginee ing and Mecha onics Deb ecen, Hunga y [email protected] Abs ac —This pape amiss o make an o e iew o he managemen and moni o ing unc ions implemen ed a he TMA 550 AL lexible manu ac u ing sys em, unc ions ha a e used o implemen he au oma ic ool eadjus men unc ion Keywo ds— lexible cells, ool managemen unc ions, ool moni o ing unc ion, mo o load moni o ing. I. INTRODUCTION The au oma ic ool eadjus men unc ion is abb e ia ed ATR. This unc ion is speci ic he Flexible Manu ac u ing Cell le els and Flexible Manu ac u ing Sys em le el and is ask is o p epa e a new se o ools in he s o age sys em o he machine o he nex i em o be manu ac u ed while he cu en i em is being manu ac u ed [1]. F om he poin o iew o he equipmen needed o pe o m he unc ion ATC he e is a g ea a ie y o solu ions acco ding o ealiza ion o ATR unc ion. The usual solu ions depend on he ype o ATC and is based on he le el o machine used. The TMA 55AL (Fig. 1) has been upg aded o include an ATR unc ion. The solu ion used is based on a ool s o age uni accessible o he ool change o he wo k cen e. Fig 1. The TMA 55 Al lexible manu ac u ing cell The ool s o age uni accessible o he ATC is loaded in he machine using he sys ems APC unc ion, and is based on a ombs one de ice. The s eps necessa y o implemen he ATR unc ion a e:  De e mining he lis o necessa y ools o he nex piece o be manu ac u ed.  Making he equipmen and de ices necessa y o implemen  Making and in eg a ing he speci ic so wa e necessa y o he ATR unc ion II. THE TOOL SELECTION The ATR unc ion mus ealize he physical ans e o he ools be ween he cen al s o age uni and he ATC s o age and also make he necessa y upg ade in he ool lis s (ATC ool lis and in he lis o ools a ailable a FMS le el). In o de o be able o ope a e changes in he ool lis o he ATC which is managed by he Fanuc so wa e on he 310i CNC he codi ica ion o he ools and all o he in o ma ion ha a e necessa y o be “deli e ed” wi h he ool mus be known. Fanuc 310i CNC equipmen machine allows he ool selec ion by calling he T add ess. The o m o ool add ess can be se so ha i includes in o ma ion on he numbe o he ool and he posi ion o he o se o each ool in he o se able. The pe mi ed al e na i es a e p esen ed in able 1. TABLE I. T CODE STRUCTURE ALLOWED BY THE CNC[2] T code T code s uc u e T_ _ _ _ _ _ _ _ Fi s 7 by es indica e he ool numbe ; he las digi indica es he numbe o he ool's o se . Recen Inno a ions in Mecha onics (RIiM) Vol. 2. (2015). No. 1-2. DOI: 10.17667/ iim.2015.1-2/1. 2 T_ _ _ _ _ _ _ _ Fi s 6 by es indica e he ool numbe , he las digi s indica es he numbe o he ool's o se . T_ _ _ _ _ _ _ _ Fi s 5 by es indica e he ool numbe , he las digi s indica es he numbe o he ool's o se . The maximum numbe o by es o add ess o T ools iden i ie s managed by he equipmen can be se using pa ame e s (be ween 1 and 8 by es). The e is he possibili y o au oma ically se ing he numbe by es acco ding o he a ailable ool o se s. Thus, in he case whe e he numbe o o se posi ions is be ween 1 and 9 will ha e se en by es o he T add esses, whe e i he numbe o o se add esses is om 10-99 T add ess will ha e 6 by es and i he numbe o posi ions o he o se -s is be ween 100 o 999 he numbe o by es o add ess T will be 5. Gi en he maximum numbe o ools ha can be s o ed in he ATC we ha e op ed o a T code wi h 2 by e wi hou including o he o se . The TMA 55AL machining cen e using as add esses in o m o TXX be ween T01 and T99. The Fanuc equipmen can use he T00 add ess, bu his is no p esen in he ool lis , he T00 add ess is ese ed o he ool in he spindle. Tool managemen unc ion manages he in o ma ion ega ding ools, including in o ma ion abou he ool o se ha li e ime o exis ing ools in he ATC. The ATR unc ion mus upg ade his in o ma ion in o de o ensu e he op imal use o he ools. Iden ical ools a ailable in he ATC magazine can be g ouped in o g oups o ools. Fo each ool is s o ed a numbe o pa ame e s such as ool numbe , pe mi ed ime o use, s a us (e.g. ool b eakage condi ions), he cha ac e is ics o he ool compensa ion (H-leng h, D-diame e , W-wea ), maximum spindle speed o each ool. These da a a e gene ically called ool managemen da a. When a ool numbe is in oked using a code such as T01, he CNC will look o a ool in he same g oup ha has he lowes usage ime. Tool managemen da a s o ed using hese unc ions a e [2]:  Numbe o ool, T code, da a leng h 4 by es;  The coun e o he li e ime o ool and he numbe o uses, 4 by es da a leng h, alues allowed o he li e o up o 3,599,999 and 0 (999 hou s 59 minu es 59 seconds);  The maximum use o ools, da a leng h 4 by es, he maximum alue allowed o use 0 o 3,599,999 s (999 hou s 59 minu es 59 seconds).  Tool s a us, da a leng h one by e, possible alues: 0- managemen unc ion is no ac i e ool, 1 ool was no used, he emaining se ice li e 2, 3 se ice li e used, 4 b oken ool. III. ATC FUNCTION The ATC unc ion s o es he ools in a s o age uni (Fig. 2) and also changes he ool in he spindle wi h he eques ed ool om he magazine using a hyd aulic manipula o (Fig 3). Fig 2. Tool s o age uni o he machining cen e [3] A he TMA 55 AL he ATR unc ion is ealized by using he ATC unc ion o he ans e o he ools om he s o age uni o he ATC s o age. Fig 2. Hyd aulic ATC manipula o o he machining cen e [3] Recen Inno a ions in Mecha onics (RIiM) Vol. 2. (2015). No. 1-2. DOI: 10.17667/ iim.2015.1-2/1. 3 Fig. 3 Gan cha o he ATC unc ion a he lexible manu ac u ing cen e in he TMA 55AL lexible manu ac u ing cell Fig. 4 Resou ce usage o he ATC unc ion a he lexible manu ac u ing cen e in he TMA 55AL lexible manu ac u ing cell Fig. 3 p esen s he 3 Gan cha o he ATC unc ion a he lexible manu ac u ing cen e in he TMA 55AL lexible manu ac u ing cell and in Fig. 4 is p esen ed he esou ce usage o he ATC unc ion a he lexible manu ac u ing cen e IV. FUNCTIONING PARAMETERS MONITORING SYSTEM AT THE FANUC 310 I CNC EQUIPMENT. The FANUC 310i CNC sys em has an in eg a ed pa ame e s moni o ing unc ion which among o he op ions including he spindle mo o pa ame e s moni o ing unc ion. Using his unc ion a numbe o pa ame e s ela ed o he spindle mo o can be measu ed ha may con ibu e o he ools managemen and such be in eg a ing he ATR unc ion in a concep o ool managemen . In igu e 5 is shown he sc een o moni o he pa ame e s o he mo o on he machine. Fig. 5 Sc een o moni o he pa ame e s o he se o-mo o s (X,Y,Z, B and C axis and spindle mo o ) [4] Using his unc ion a da a acquisi ion was ealized o he pa ame e s ela ed o he spindle mo o . In Fig.6 is p esen ed he menu o pa ame e se ings o he da a acquisi ion. Recen Inno a ions in Mecha onics (RIiM) Vol. 2. (2015). No. 1-2. DOI: 10.17667/ iim.2015.1-2/1. 4 Fig. 6 Sc een pa ame e se ings (pa ame e s o be acqui ed) and pa ame e s o he DAQ The da a collec ed using he FANUC CNC was sa ed in a x ile using a s uc u e speci ic o he equipmen . The ile was p ocessed using Ma lab o ob ain he da a o he spindle mo o . In able 2 a e p esen ed he alues base alues o he spindle load when wi h no wo k load. TABLE II. BASE VALUES FOR THE SPINDLE LOAD WHEN WITH NO WORK LOAD 500 pm 600 pm 700 pm 800 pm 900 pm 1000 pm 1100 pm 1200 pm 2% 4% 5% 7% 8% 9% 10% 12% Fig. 7 E olu ion o he spindle load (wi h no wo k load)[4] Al hough hese alues a e low, he e use in moni o ing he ool wa e ough he moni o ing o he ool wa e is no easible due o he ansi o y egime o he mo o when he numbe o o a ion is changed. In o de o highligh he ansi o y egime a se ies o es whe e ealized using he same p ocedu e, bu he alues o he mo o load du ing he change o he o a ion whe e acqui ed. The ansi ion om one speed o ano he in ol es loading he engine. The g aph ob ained o a ia ions in speed om 500 pm o 1100 pm wi h inc emen s o 10% is shown in he igu e 7. Fig. 7 The g aph ob ained o a ia ions in speed om 500 pm o 1100 pm wi h inc emen s o 10%[4] V. CONCLUSION A new goal o he TMA 55Al is he in eg a ion o he ATR unc ion wi h he ool managemen unc ion, including he o ac i a ing he ATR based on da a collec ed ough means o ool moni o ing echniques. These echniques can o e in o ma ion ela ed o he ool wa e. The mos accessible in o ma ion would be he da a collec ed ough he wa e o m diagnosis unc ion. In e ms o wo kload moni o ing he d i e mo o o he spindle is obse ed ha a cons an speeds wo kload is ela i ely small (max.12%), howe e ansi o y egimes a speed change mus be conside ed because he load can each 40 %. In his con ex an algo i hm o moni o engine load condi ion and moni o ing ool spindle mus ake in o accoun hese ansien s. [4] Acknowledgmen “This wo k was pa ially suppo ed by he s a egic g an POSDRU 107/1.5/S/77265, inside POSDRU Romania 2007- 2013 co- inanced by he Eu opean Social Fund – In es ing in People.” Re e ences [1] Macedon Ganea, Masini unele e si Echipamen e ehnologice pen u p eluc a ea pieselo p isma ice.I- Module si echipamen e speci ice celulelo si sis emelo lexibile. Cali a ea si ecep ia masinilo unel e CNC.: Edi u a Uni e si ății din O adea, 2010. [2] Fanuc, GE, Ope a ion and main enance handbook B-63947EN/01. [3] TMA 55 manu ac u ing cen e-Use manual [4] O idiu Moldo an, "Tool wa e moni o ing echniques and in eg a ion possibili ies wi h he au oma ic ool eadjus emen unc ion," Annals o he O adea Uni e si y Fascicle o Managemen and Technological Enginee ing, ol. XXII, no. 1, pp. 199-202, 2013.