OpenCNCAt a Glance

• Servo loop entirely closedin software running on astandard computer

• Over a half-million hoursin production. Runningsuccessfully at customersites since 1993

• Soft CNC, soft PLC andHMI in one application

• No proprietary hardwareor motion control cardsrequired

• Microsoft® Windows NT®

operating system

• Runs on a wide variety oflathes, machining centers,and gear hobs

• Collects, updates andshares real-time dataautomatically, withoutoperator intervention,without specialtyhardware

• Features open ApplicationProgramming Interface(API) for integration ofthird-party software

OpenCNC® software is a production-proven, unbundled,software CNC control built on an open architecture thatenables manufacturers to integrate off-the-shelf hardwareand software technologies to achieve flexible and agileworld-class manufacturing. Unlike proprietary CNCcontrols, OpenCNC requires no proprietary hardware ormotion control cards. Combining a soft CNC and soft PLCin a single application, OpenCNC is well suited for newequipment as well as machine control replacements.

OpenCNC®

SOFTWARE CNC

The value of software-based control

OpenCNC software utilizes a minimalamount of off-the-shelf hardware tomaximize your flexibility and manufac-turing process creativity. An unbundledsoftware CNC approach provides theend user and machine tool builder max-imum choice. OpenCNC provideschoice in hardware, software, dataaccess/distribution and integration. Thisenables you to optimize the CNC con-trol configuration for your uniquemanufacturing and machine tool appli-cation.

Only a robust, production-proven CNCcontrol can meet the rigorous demandsof manufacturing. OpenCNC hasproven its reliability on the plant floorsince 1993. OpenCNC offers severalsignificant benefits including:• lower control and life-cycle costs • increased machine tool up-time and

productivity • incremental upgrades of control

systems with technology advances • integrated diagnostic tools • simple and common approach to

communication and networking • reduced operator learning time • increased return on manufacturing

assets

Breadth of machine toolcontrol applications

OpenCNC software provides the perfor-mance, functionality, reliability andaccuracy for controlling and managinga wide variety of production machinetools, including two- and four-axis lath-es; mills; three-, four-, and five-axismachining centers; millturns; hobs; andgrinders. It can be used to control ‘n’number of spindles, ‘n’ number ofaxes, ‘n’ number of inputs and outputsand ‘n’ number of Independent JobStreams.

OpenCNC applications span virtually everyindustry that utilizes metal cutting ormetal forming machine tools, including:• consumer products• automotive• aerospace• construction and agricultural

equipment• mechanical machinery

Tecumseh ProductsCompany standardizeson OpenCNC

Tecumseh Products Companyfirst put OpenCNC on a three-axis VMC in 1995. Three yearsand a dozen machines later,Tecumseh, a $2 billion globalmanufacturer with 17,000employees and 31 plantsworldwide, chose tostandardize its controltechnologies with OpenCNC.They will replace proprietaryNCs and PLCs on new andexisting machine tools -including lathes, mills, grinders,dial machines, and transferlines, worldwide.

“OpenCNC has run tens ofthousands of hours inTecumseh plants,” said James F.Curley, corporate director, manufacturing engineering,“and has proven to be a reli-able, quality product. BecauseOpenCNC’s open architectureallows us to standardize acrossall types of machines, we’ll cutcosts to a fraction of thoseincurred with traditional controls. MDSI has created asoftware control technologythat will increase the flexibilityand agility of our factories andtake us to the 21st century.”

The functionalitymanufacturers need

OpenCNC provides the breadth anddepth of machine control functionalityrequired by manufacturers. It supportsRS-274D standard part programmingand is fully compatible with all majorNC programming systems. Support forturrets and tool changers is standard.

OpenCNC incorporates a soft CNC andsoft PLC in one application. It includesthe following modules:• human-machine interface (HMI) • machine diagnostics tools • soft PLC • software motion control • real-time data collection and

distribution

It performs all of the real-time taskssuch as linear, circular and helical inter-polation, cutter radius compensation,velocity feed forward and ‘S’ curvevelocity profiling in software.

Standards reduce machine control costs

There are several benefits to an openarchitecture approach based on the PCplatform. Because so many applicationsare developed for or interface to the PC,you can mix and match hardware andsoftware options from different vendors.This gives you the flexibility to adjust yourcontrol platform incrementally.

OpenCNC on Microsoft® Windows NT®

with real-time extensions allows users toaccess the thousands of Windows-basedsoftware applications and link themdirectly to the machine tool, providingthe data and tools necessary to improvemanufacturing processes and produc-tivity. And, unlike other CNC controls, itdoes this all on a single operating system— Windows NT — running with a singleIntel® processor, in a single PC.

The use of commercially available computer technology enables MDSI toreduce machine control system and lifecycle costs and increase reliability andexpandability. As the performance of PCscontinues to increase, so will yourmachine tool — without any changes tothe software.

OpenCNC®

SOFTWARE CNC

From backlash and leadscrew compensationto cutter radius compensation, OpenCNChas the tools to get the job done.

Programming standards IEC-1131-3 and RS-274Dare supported by OpenCNC.

Easy for any operator to learn or use

OpenCNC software supports a range ofoperator control interfaces: color touchscreen, keyboard, machine buttons, orpendant. The machine can run com-pletely from the touch screen, or it canbe supplemented by additional hard-ware buttons or pendants.

Optimized for ease of learning and use,the interface lets users customize or addfunctions to the software without addinghardware. The interface can also be tai-lored for the type of operator: production,set up, machinist, or maintenance.

You can use the standard machine controluser interface provided with OpenCNC, oryou can modify it to meet your needs. Inaddition, you can decide the presentationof machine control functionality. You canalso select which functions are availableto individual users.

Maintenance and diagnosticstools keep machine tools in operation

With today’s pressures to reduce costs,increase quality and reduce time to market, the time required to design,integrate, and maintain machine toolcontrol systems has a significant impacton a company’s ability to compete.Manufacturers can’t wait days or weeksfor an outside service organization toget their machine tool control opera-tional. They need to solve the problemimmediately and get the machine backinto production.

With OpenCNC, hardware componentsconform to industry-standard PC inter-faces. As a result, control hardwareamong machine tools is interchange-able; there’s no machine-specificfirmware on any component.

OpenCNC also provides software tools toperform system integration, maintenanceand diagnostics. The ability to use thesetools while running a part program helpsyou find and solve problems that occuronly when the machine tool is cutting apart. This allows you to get the optimalmachine tuning and thereby improvepart quality and reduce cycle times.

NUCON chose OpenCNCfor complicated parts

NUCON Corporation, a specialtymanufacturer of parts for theaerospace industry, is one ofthe few manufacturers in theworld capable of machiningcomplex impellers and turbines.Machining times are typicallymeasured in weeks. OpenCNCwas installed on a Sundstrandfive-axis Omnimill in 1996.Thanks to OpenCNC’s robust-ness and reliability, there havebeen no control-related down-times during the longmachining cycles.

“We have very specific require-ments for our manufacturingprocess,” said David L.Stormont, NUCON’s president.“OpenCNC was able to meetthose requirements. By virtue ofits openness and design, wherefunctions are in software ratherthan hardware, OpenCNC pro-vides the flexibility we need togrow and to integrate ourother unique technologies. You can change a software program easier than hardware.OpenCNC is a technology doorto the future.”

The touch screen operator interface leverages theconcept of soft control buttons versus hardwarebuttons.

OpenCNC’s diagnostic tools can be used duringstart-up or while the machine tool is running todebug or troubleshoot electrical and mechanicalproblems.

Network distributed machine control

OpenCNC can be implemented as anetwork or stand-alone control system.You can start with a stand-alone config-uration and later create an OpenCNCnetwork configuration via a standardEthernet network. OpenCNC comesready to support standard networkingprotocols right out of the box. Thenetwork system provides bi-directional

communication between themachine tool and manufacturing

engineering.

OpenCNC can makeeach machine tool an

on-line peripheraldevice of a PC

or workstation. This can be networkedto a server PC, other engineering andmanufacturing management PCs, andother machine tools, to enable flexibleand agile manufacturing.

An integrated DNC capability givesyour operators the ability to downloadpart programs and associated tool and fixture offsets. No longer will theyhave to wait to be given the next partprogram.

In a network implementation, eachmachine tool can communicate to aserver, providing feedback related tomachine tool performance. By integrat-ing machine tools in an open networkenvironment, real-time manufacturingprocess improvements can be achieved.

OpenCNC®

SOFTWARE CNC

Network users can download part programsor CAD drawings or upload machine statusinformation.

ProductionControl

Front Office

Factory Floor OpenCNC®OpenCNC® OpenCNC®

Engineering Accounting CustomerService

Manufacturing Enterprise Network

Real-time machine event reporting

Only with timely and accurate informa-tion can manufacturers take correctiveaction to improve production processesand increase productivity. If you cannotmeasure it, you cannot manage it.

With OpenCNC, manufacturing management, engineers and machineoperators can collect and distributemachine tool manufacturing processinformation in real time — automatically,without human intervention, withoutspecialty hardware — and make it available across a company network.

With its patented real-time databasetechnology, OpenCNC collects anunlimited range of data types orSignificant Events™ from the machinetool during its operation. This includesproduction, quality and maintenancedata, which can be transferred automatically to product planning andscheduling or computerized mainte-nance management systems.

Flexibility to add newfunctionality

With OpenCNC’s modular architecture,MDSI can rapidly add new capabilitiesand deliver regular functionalityupdates to all supported machines. The open architecture also allows usersto easily add or upgrade controllerfunctionality. As a result, all OpenCNCcontrols will work the same regardlessof when they were installed — unlikeproprietary “black-box” CNC controls.

Through the OpenCNC ApplicationProgramming Interface (API), users caneasily add new functionality or customizeOpenCNC for your specific machine toolapplication. In addition, the user can

tailor or build a new graphical user inter-face with Microsoft® Visual Basic®.

The control logic can be developed ormodified with an integrated off-the-shelf PLC logic editor. The control PLCcan be programmed with any or all ofthe IEC-1131-3 standard languages.This includes:• ladder logic • sequential function charts • instruction list • function block diagram • structured text

On the cutting edge oftechnology

Dana Corporation’s SpicerClark-Hurth Off-HighwayComponents Division installedMDSI’s OpenCNC on a WarnerSwasey 2SC two-axis lathe as aresult of persistent problemswith the machine tool’s formerproprietary black box CNC control. Satisfaction with performance after OpenCNC is100%. Dana Corporation hassince started a multi-year program to upgrade numerousmachines in the Statesville, NCplant to OpenCNC.

“With OpenCNC, I can manipu-late the machine any way Iwant,” said Thomas N. Payne,CNC electronics technician. “Ican add value and function. I’mnot closed out as I was before.It gives me a chance to be righton the cutting edge of wheretechnology is. When they talkabout Bill Gates, Java, Internet,I know I’m there. And so aremy operators. This is where itstarts.”

With OpenCNC‘s API, you can automate manufac-turing processes, integrate third-party applicationsor develop new machine tool applications.

OpenCNC includes robust real-time event reporting.

OpenCNC®

SOFTWARE CNCService, support and training

MDSI is dedicated to meeting yourapplication support needs and is constantly upgrading the OpenCNCsoftware and documentation to betterserve you. With more than a quartercentury of experience in CNC technology,nobody understands the needs of man-ufacturing better. We want to be yoursupplier today and tomorrow—and youcan be assured that the quality of ourservice will reflect this commitment to along-term business relationship.

MDSI provides a variety of trainingoptions, including classroom trainingor user-paced multi-media trainingtools to build customer independenceand confidence. The training includesinstallation, soft logic development,software configuration, diagnosticsand networking.

For more information on OpenCNC, contact Manufacturing Data Systems, Inc.Or, visit our Web site at www.mdsi2.com.

220 East Huron Street, Suite 600Ann Arbor, MI 48104Tel 888.OpenCNC (U.S.A. only)Tel 734.769.9000Fax 734.769.9112marketing@mdsi2.comwww.mdsi2.com

MDSI, the MDSI logo, and OpenCNC are registered trademarks of Manufacturing Data Systems, Inc.Significant Events and OpenEvents are trademarks of Manufacturing Data Systems, Inc.Microsoft, Windows, Windows NT, Visual Basic, and Visual C++ are either registered trademarks or trademarks of Microsoft Corporation in the U.S. and/or other countries. All other brand or productnames are trademarks or registered trademarks of their respective owners.

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