integration of information

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INTRODUCTION

Todays buzzword IT has revolutionized every aspects of our day

today working lives. Automation of industries is one of its main contributions.

Automation can be defined as technology concerned with the application

mechanical, electronic and computer-based systems to operate and control

production. Automated manufacturing systems operate in the factory on the

physical product. They perform operations such as processing, assembly,

inspection or material handling, in some cases accomplishing more than one of

these operations in the same system. They are called automated because they

perform their operations with a reduced level of human intervention. The main

advantage of automation is increased labor productivity at reduced labor cost.

An automated system consists of three basic elements:

1. Power to accomplish the process and operate the system

2. A program of instructions to direct the process and

3. A control systemto actuate the instructions.

Here we are discussing about the developments in the software part,

which controls the entire process in machine tools.

The heart of machine tool is a CNC (Computerized Numerical

Control) system, which coordinates with the displays, PLC, drives system, and

feed back systems. This paper deals with the data acquisition, programmanagement and remote diagnosis of the system.


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NC & CNC

Numerical control is for of programmable automation in which the

mechanical actions of a mechanical tool or other equipment are controlled by a

program containing coded alphanumeric data. The alphanumerical data represent

the relative position between the work head and the work part as well as other

instructions needed to operate the machine. The concept for NC dates from the

late 1940s and the first machine was developed in 1952 by US airforce.

Computerized numerical control (CNC) is defined as an NC system

whos MCU is based on a dedicated microcomputer rather than a hardwired

controller. It includes additional features beyond what is feasible with

conventional hardwired NC. It includes

Storage of more than one part program

Various forms of program input

Program editing at the machine tool

Fixed cycles and programming subroutines

Positioning features for setup and cutter length and size compensation

Communication interface and

Diagnostics

The CNC systems have processors for specific applications as the

speed requirements for the system is far greater here. The processors available in

a CNC used to perform various tasks like communication, trigger, display,

interpolation & calculation functions, diagnosis, data exchange with PLC and

other peripheries. The new technology based personal computers has also made

rapid development of new manufacturing processes that enable achieving higher

productivity and improved job finish. Today several solutions are available for


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IT- integration from processing of job orders on as machine tool to vertical

integration oat factory level onto ERP systems like SAP and so on. The data

available as a result may be used in various activities vary ranging from

production planning to management information system.Enterprise wide integration of factory data:The most recent progression in PC

based distributed control is enterprise wide integration of factory operations data

as depicted in the figure. It is according to the new philosophies of worker

empowerment, which assume fewer levels of company management and greater

responsibilities for front line workers in sales, order scheduling and production.

fig.1. Enterprise Wide Management

Let us look at the different modules of information technology that can be

integrated into machine tools. The very base of various modules is of handling a

host of data and a wide range of diagnostic functions.

EngineeringWorkstation

QualityControl

PurchasingProductionPlannin

Finance

Local operatorstation

Local operatorstation

Central control room

Process stationProcess stationProcess stationProcess station

Process


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MODULES IN MACHINE TOOLS

MODULE FOR PRODUCTION DATA MANAGEMENT

The module is available in two different variants i.e., WinBDE for

machine data management to carryout machine data acquisition and local

evaluation and WinPDA for central machine and production management to

carry out central production archiving and evaluation. WinPDA server is used as

a data administrative unit for the machine information, which is acquired and

passed on by the WinBDE systems. WinPDA server is responsible for all uploadand download functions to SAP and WinBDE. The WinPDA clients are the user

interfaces for the WinPDA server. These clients can be run on a standard

Windows PC (Windows NT or Windows 2000) and are connected to the server

over Ethernet. Plant supervisors and production engineers are the main users of

WinPDA client. WinBDE is designed for the acquisition and evaluation of

machine data. The system acquires process information automatically from a

PLCs memory.

What WinBDE can do?

Determination of the machine performance

Detailed disturbance analysis and diagnostics

Transparency at the machine due to graphical error diagnoses

Analysis of weak points

Function overview

A pilot study was conducted to assess Siemens MES solutions

capabilities that included nine machines at one of their US facilities. The pilot


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included nine marriage machines in their assembly area. Three WinBDE

terminals were used for data collection. The system automatically collects

machine status conditions. Each marriage machine communicates digital process

data via digital outputs to a Simatic S7-ET200M. The Simatic S7-ET200M thencommunicates that information to a Simatic S7 PLC (CPU 315-2DP) through a

Profibus DP network connection. A WinCC station was used to gather the

process data from the PLC and pass the information to the Open ShopFloor data

acquisition program WinBDE through an OPC connection. Figure shows the

system architecture.

Fig.2 WinBDE network

According to the result of the experiment, the customer could

optimize their work schedule by using the paperless order dispatching system.

Work orders can now be quickly assigned to a particular machine. The operators

at the specified machine can easily confirm the parts produced for the work order

and when the order is completed, it is automatically closed and the machine state


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is automatically set to free. At this point area supervisor can assign a new work

order to that machine. All this information is automatically sent to SAP. The

customer has also been able to track very precisely their machine utilization.

Using the data, the customer can optimize their work schedules and improvemachine utilization. Historical data has proved to be extremely useful. While

analyzing machine utilization and disturbance codes, the customer noticed some

interesting patterns. These patterns showed some very regular disturbances. After

further analysis, they discovered that a small change in their maintenance

schedule reduced and in some cases eliminated the problem. This increased the

machine utilization and reduced maintenance costs.

What WinPDA can do?

The main area of application for which WinPDA is de-signed is the

dispatch and evaluation of production and machine data (MDA/PDA). Using

production data that is acquired either manually or automatically by means of

PLCs, you always have an up-to-date overview of the status of production

orders, machine assignments, personnel deployment, etc. This allows you to

intervene appropriately to balance rates of utilization, to speed up order

throughput and to significantly reduce inventory. Higher planning quality is

achieved in a manufacturing requirements planning system (MRP) due to the up-

to-date data that is reported back by the online WinPDA system. If no

information is reported back from the manufacturing process, planning options

are very limited.


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Function Overview

Fig3. WinPDA network

The core functions are production data acquisition and processing.

This comprises all the interactive functions for processing order, workstation and

personnel data. Automatic machine data acquisition in addition to manual input

dialogs ensures that process information is always up-to-date. WinPDA an Open

System Environment User Interface. WinPDA is aclient-server system that uses

open international standards based on Microsoft Windows with PC clients and

network communications via a LAN to the data server running the Oracle

relational database. WinPDA is based on the Toolbox, which is a high-level

development platform. The modular open system structure ensures that you can

integrate adaptations. Multi-stage system expansion options and the distributionof functions to different computers allow the system to grow with your needs.


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Main Data Acquisition Areas

Order or operation data (runtimes, piece counts, scrap,...)

Personnel data (working hours, reasons for absence,)

Machine and workstation data (utilization, availability,

disturbances,...)

Acquiring Manual Production Events

Manual production events are entered at machines by the operatorsusing the WinBDE acquisition component. The system supports simple PDA

terminals with displays or user-friendly Windows terminals. The interactive

functions available on the WinBDE terminals include:

Dialogs for processing orders including quantity acquisition and

reasons for interruptions or rejects

Dialogs for workstations with status acquisition (disturbance,

maintenance)

Dialogs for personnel data

Acquiring Automatic Production Events

You can acquire and process events online via the PDA terminal's

digital inputs:

Piece counts (good, scrap) Down-time monitoring

Disturbances


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WinPDA's user interface is designed with the same look and feel as

Microsoft Windows. Users can modify overview tables, dialog windows, labels

and even the language used. This makes possible easy adaptation to specificoperating conditions and individual requirements.

Dialogs for Production and Order Dispatch

The dialogs for production and order control are available on

Windows clients. This allows you to use the PCs that are integrated in the

WinPDA network as multifunctional operator control and monitoring stations.

Dialogs for order control are available in the following form:

Order and operation overview

Maintain single order

Workstation overview

Maintain workstation

Display logbook

Personnel overview

Maintain personnel data

Maintain master data evaluations under Windows

The evaluations below are available as standard as stand-alone

Windows programs:

Plant diagram Graphic display of the current workstation status (e.g.

red =disturbed; green =production; etc.)

Representation in table form of currently pending reasons for

disturbances/status conditions

Shift profile Representation as a bar chart of the events of a completed

shift for a selected workstation


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Day profile- Representation as a bar chart of the events of the day for a

selected workstation

Status profile Representation of the duration and frequency of

individual status conditions of a shift listed chronologically per

workstation

Rate of utilization/availability

Representation of the rate of utilization/availability of a workstation

over a selectable period.

Works Calendar under Windows

The variations in working time models demand a flexible and

convenient maintenance function. WinPDA provides dialogs for setting up shift

types and working time models with appropriate works calendar structures.

Security Concept

To ensure a consistent data stock and to prevent unauthorized access

to data, WinPDA has available a comprehensive security concept. This includes:

Access and authorization functions

Disk mirroring (hardware option)

Transaction security

Un-interruptible power supplies

Interface to SAP R/3 Release 3.0

Today's MDA/PDA systems are only economically viable if you can

integrate them at a low cost to other processes. A certified interface to SAP R/3

Release 3.0 is available for this. The link modules offer functions for :


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Accepting target data from the higher level system(E.g., order data).

Accepting master data from the higher level sys-tem(E.g. workstation data)

Processing the acquired actual data and reporting

It back the shopfloor controller or the MRP system

MODULE FOR NC PROGRAM MANAGEMENT

The important part of job shop manufacturing on machine tool is part

program management. The transfer of part programs was initially carried on

punched tape by a reader and further by floppy disks in recent years. Today theprograms can be transferred at a speed thousand times that of punched tape on

industrial Ethernet. Apart from transfer, the organization of part programs and

handling plays an important role in enhancing productivity and ensuring

availability of desired part programs.

Functions of NC program management module

Scalable expansion system from small local DNC systems to DNC center

archives with DNC-NT 2000 server for entire plant.

NC program handling by means of DNC explorer.

Shop floor oriented NC program storage structure.

Data can be displayed, edited, printed, copied and pasted & deleted.

Functions and filters tailored to the requirements of the user.

Fast and simple analysis of optimized programs with the original

programs.

Program transfer through operator action and direct loading of NC

programs into the CNC enabling fast transmission on Internet.


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Simple and flexible interface through any NC program systems and data

archives.

Online help system to assist the system operator.

Log book to record system messages.

ADVANTAGES

Cost reduction in NC data organization through simple handling of NC

programs, time-consuming process of handling punched tapes and floppy

disks is eliminated.

Cost effective and safe electronic data acquiring.

Increased machine-operating time through short set up time by safe and

fast NC data transfer and provision of several NC programs.

Brings in transparency and convenience in handling and storage of part

programs even if several programs are available in the system.

No DNS terminals are required in latest CNC systems on one hand and

conventional CNC systems can be hooked on by dialog functions.

COMMUNICATION SOFTWARE- COMPUTER L INK

The software module provides for establishment of link between a

master computer to CNC system via ethernet network. The offers defined, open

communication interface to transfer the essential data of CNC control.

USER BENEFITS

Simple integration:The control can be simply integrated in a simple

manner in users projects/ applications, using defined interfaces like

ethernet/ TCP-IP.


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Simple configuration: Data to be transferred to the PLC can be

simply configured.

Improved productivity: The module can be used as a tool to

implement measures for increased productivity.

Reduced cost: The use of standard hardware and software

components reduces the cost of implementation, training, and

maintenance.

DATA TRANSFER THAT CAN BE CARRIED OUT WITH COMPUTER

LINK

NC programs

Tool data

Machine and operating data like operating modes, machine status and

actual NC programs.

Machine messages like operator messages, operator interventions/

interruptions, operating and fault messages.

Production dialog, configurable data transfer. Data transfer with open architecture applications.


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REMOTE DIAGNOSIS

Remote diagnosis or Tele service offers remote support for CNC

systems, making it a cost-effective alternative to service calls.

HOW IT WORKS?

The module consists of two subsets namely, Host and the Viewer,

the host being installed at the machine user end and the viewer at the

machine manufacturers end (or on the side of the service provider for the CNCsystem). The two, i.e. the host and the viewer are installed on the control at

the machine end connected via a modem, which in turn is linked to a telephone

line through a modem. The host is installed on a PC at the other side and

equipped with a modem to hook on a telephone line.

The service or support requests are triggered by the Host and

authorize the Viewer with login password permitting access for exploration and

support activities on the CNC system remotely. The service provider on the

viewer end confirms the service request and initiates the remote diagnosis by

calling the telephone number.

The components of the remote diagnosis system are

TEAMS: Testability assessment and improvement (DFT), reliability

analysis, Failure Modes, Effects and Criticality Analysis (FMECA) and

pre-computed diagnostic test strategy generation in a variety of forms

(e.g., SGML-based Interactive Electronic Technical Manual);

TEAMS-RT: on-board diagnostics, health and usage monitoring systems;


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TEAMATE: Portable Intelligent Maintenance Aids (PIMAs) with

interactive electronic technical manuals and multi-media animation,

dynamic TPSs for ATEs.

TEAMS-KB: Scheduled and unscheduled maintenance and diagnostics

data collection, Statistical data analysis and data mining for trend and

anomaly detection/isolation.

FUNCTIONS OFFERED

Chat mode to enable the Host and the Viewer to understand the status of

the machine via mail or voice call Remote control mode to analyze the operator acti9ons and direct the

operator actions file transfer mode to automatically read out the important

control files, to transfer the corrected file or new software releases to the

control side. This completes the process of diagnosis.

APPLICATION AREAS

With the machine tool manufacturer: useful for configuring and engineering,

machine testing and integration, start- up.

With the end users: setting up and controlling the machine tool, generating NC

programs, process visualization and monitoring, diagnostics and service,

performance enhancement and optimization.


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ADVANTAGES FOR END USERS AND SERVICE PROVIDERS

Time advantage when service is required: Help instead of travelling.

Better information transfer via chat mode.

Reduced machine down time.

Remote update/upgrade of software by file transfer mode.

Telephone/internet cost instead of travel cost.

Global support: wide applicability world wide, start up support, service

support and when machine re-equipping is required.

IN FUTURE,

Service providers can be reached around the clock via internet, by

email or SMS worldwide

Messages can be sent immediately after the fault occurs

At the service provider end , this information enables in faster inselection of appropriate expert


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CONCLUSION

The availability of PC technology and the control system architecture

adapted for the new changes has opened more and more opportunities for

convergence of manufacturing technology and information technology. With the

advent of information technology the entire process of running an entire plant,

from generating and starting with the job orders, through production planning up

and up to strategic planning can be integrated. A new trend that has recently been

put in is the web-based support system. The users can post their needs and

queries on therelevant designated site to obtain the possible solutions and FAQsand user documentation. Several of the global automobile giants such as BMW

AG, the Boeing company USA etc and their likes are incorporating information

technology into their plants


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BIBLIOGRAPHY

1. Integration of information technology in machine tools,

Mr. Virupakshappa HK, Industrial Automation, July 2003

2. Automation, Production Systems and Computer integrated

Manufacturing, Mikell p Groover, second edition, Pearson Education

Asia.

3. www.siemens.it

4. www.sea.siemens.com


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ACKNOWLEDGEMENT

I extend my sincere gratitude towardsProf . P.Sukumaran Head of

Department for giving us his invaluable knowledge and wonderful technical

guidance

I express my thanks to Mr. Muhammed kutty our group tutor and

also to our staff advisor Ms. Biji Paul for their kind co-operation and

guidance for preparing and presenting this seminar.

I also thank all the other faculty members of AEI department and my

friends for their help and support.


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ABSTRACT

Todays buzzword IT has revolutionized every aspects of our day

today working lives. Automation of industries is one of its main contributions.

Automation can be defined as technology concerned with the application

mechanical, electronic and computer-based systems to operate and control

production. . The main advantage of automation is increased labor productivity

at reduced labor cost. The heart of machine tool is a CNC (Computerized

Numerical Control) system, which coordinates with the displays, PLC, drives

system, and feed back systems. This paper deals with the data acquisition,program management and remote diagnosis of the system

Numerical control is for of programmable automation in which the

mechanical actions of a mechanical tool or other equipment are controlled by a

program containing coded alphanumeric data. Computerized numerical control

(CNC) is defined as an NC system whos MCU is based on a dedicated

microcomputer rather than a hardwired controller.

Remote diagnosis or Tele service offers remote support for CNC

systems, making it a cost-effective alternative to service calls. Lot of time can be

saved by this.


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CONTENTS

1. Introduction....... 01

2. NC & CNC.... 02

3. Modules in machine tools...... 04

3.a. Module for production data management.....04

3.a.i. What Win BDE can do?.. 04

3.a.ii. What Win PDA can do?.... 06

3.b. Module for NC program management.... 11

3.c. Communication software-computer link.... 12

4. Remote diagnosis..... 14

5. Conclusion.... 17

6. Bibliography..... 18

integration of information

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