Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
CHICAGO, April 5, 2011 — At this year’s AERODEF show in Anaheim, California, Siemens will demonstrate new solutions and services for machine tool end-users and manufacturers. Under the theme, “Productivity in motion,” the presentation will focus on turnkey solutions for the aerospace manufacturing industry.
For machine tool end-users and OEMs, Siemens will exhibit new value-added services ranging from condition monitoring and manufacturing IT to innovative solutions for CNC training and machine tool retrofit, as well as the newest innovations in CNC (computer numerical control), motor and drive technology.
SOLUTIONS FOR MANUFACTURING EXCELLENCE
Condition Monitoring and Manufacturing IT are two value-added services that are continuing their introduction to the U.S. machine tool market.
Condition Monitoring is an internet-based service from Siemens that supports maintenance processes while simultaneously forming a platform for cross-company service and support between OEMs and machine operators. Services can be configured over secure Internet connections from anywhere in the world via a standard PC, an internet connection and a web browser.
Manufacturing IT solutions from Siemens provide software tools for fast, easy integration of machines in a production network, while ensuring that production planning, scheduling and execution
is always problem-free and based on the very latest data.
An entire line of powerful software modules for production machines ensures optimum integration of the machines in the IT-environment and supports a wide range of different functionalities including:
SOLUTIONS FOR AEROSPACE
For the aerospace market, the new Sinumerik 840D solution line is the latest in CNC technology that increases performance and user productivity. The Sinumerik 840D sl is a universal and flexible CNC system featuring the innovative Sinamics S120 drives that can be used for up to 31 axes. It is a distributed, scalable, open and inter-connecting system offering a wide range of specialized functions for milling, drilling, turning, grinding and handling technologies.
The Sinumerik 840D offers users innovative features that increase productivity on the manufacturing floor, especially the challenging segments of high-speed and five-axis aerospace machining.
SOLUTIONS FOR THE JOB SHOP
For the job shop, the new Sinumerik 828D numerical control will be presented. Perfect for
mid-range machine tools, the Sinumerik 828D is designed to address the needs of complex milling and turning machines in the job shop segment. It combines CNC, PLC, operator panel and axis control for six CNC measurement circuits in a single, robust operator panel.
The Sinumerik 828D is capable of full graphical, high-level language command and supports ISO programming that is customary in the United States. Programming time can be further reduced for small-batch production with the use of the ShopMill and ShopTurn graphical workstep programming system, while high-level language programming can be used in conjunction with programGuide to significantly reduce programming times for large-scale serial production.
With the introduction of the Sinumerik 828D, modern PC and mobile phone technology is now available to the mid-range machine tool. Extensive online help animations and a new type of input prompting system with moving picture sequences provide the basis for exceptional user convenience. USB, Compact Flash (CF) card and Ethernet ports enable high-speed data transfers onto storage media or integration of the control system into corporate networks. Through the use of its Easy Message functionality, the Sinumerik 828D offers production status monitoring by text messaging (SMS). Depending on the recipient’s profile setting, the machine will transmit information about workpiece machining status, report on the tool condition currently in use and send machine maintenance bulletins to a mobile phone, anytime and anywhere. These combined functions are designed to help keep machine downtime to a minimum.
SOLUTIONS FOR CNC TRAINING
Newly introduced to the American machine tool industry, and based upon the new Sinumerik Operate user interface, SinuTrain is the ideal solution for control-identical CNC training.
With SinuTrain, actual NC programs are developed and simulated, to speed the program generation protocol. In this way, machine tool operators not only learn the control language commands, but they also visualize part programs on a PC screen that are identical to the machine tool’s screen. As a further benefit, programs generated through SinuTrain can then be used on actual machines.
SinuTrain is available for different needs and budgets including a trial version, a study version, a single-user license and an educational license. It is available in English, Spanish, French, German, Italian and Simplified Chinese, and requires Windows® XP (32-bit). Support for Windows 7 (32- / 64-bit) coming in 2011.
For more information about CNC solutions and services from Siemens, point your web browser to www.usa.siemens.com/cnc.
For specific product information and inquiries:
SIEMENS INDUSTRY, INC.
DRIVE TECHNOLOGIES
MOTION CONTROL
MACHINE TOOL BUSINESS
390 Kent Avenue
Elk Grove Village, IL 60007
Phone: 847-640-1595
Fax: 847-437-0784
Web: www.usa.siemens.com/cnc
Email: SiemensMTBUMarCom.sea@siemens.com
Attention: John Meyer, Manager, Marketing Communication
Follow us on Facebook: www.facebook.com/SiemensCNC or Twitter: www.twitter.com/siemens_cnc_us.
—
Siemens Industry Sector is the world’s leading supplier of innovative and environmentally friendly products, solutions and services for industrial customers. With end-to-end automation technology and industrial software, solid vertical-market expertise, and technology-based services, the sector enhances its customers’ productivity, efficiency and flexibility. With a global workforce of more than 100,000 employees, the Industry Sector comprises the Industry Automation, Drive Technologies and Customer Services Divisions as well as the Metals Technologies Business Unit. For more information, visit http://www.usa.siemens.com/industry.
The Siemens Drive Technologies Division is the world’s leading supplier of products, systems, applications, solutions and services for the entire drive train, with electrical and mechanical components. Drive Technologies serves all vertical markets in the production and process industries as well as the infrastructure/energy segment. With its products and solutions, the division enables its customers to achieve productivity, energy efficiency and reliability. For more information, visit http://www.usa.siemens.com/drivetechnologies.
Continue readingInternational firm uses robotic ultrasonics and conventional machine tools to supply product, usually with 24-hour turnaround; achieving near 24-7 unattended operation with over 15 percent reduction in scrap material on very expensive substrates.
OpenHealth, one of the world’s leading providers of business and technical solutions to the dental healthcare industries, was formed by the owners of five major international dental lab groups — Aurum, Cordent, DTS, Race and ZMC — who combined to harness the strategic synergies of their respective lab and milling center services. The milling and technology business, under the brand name of Core3D Centres and operating six facilities, brings the OpenHealth group’s expertise and comprehensive service package to labs, dentists and educational institutions in 15 countries on three continents.
We interviewed Tim McKimson, Core3D’s Worldwide Director of Engineering, at OpenHealth’s Las Vegas-based Core3D facility, located near the prestigious Las Vegas Institute for Advanced Dental Studies (LVI), where restorative and cosmetic dental techniques are taught to practicing dentists and lab technicians, Here, Core3D provides a full range of CAD/CAM/CNC machining and finishing services to LVI and dental labs across the United States. Led by technical operators Mark Ferguson, Danny Palomares and Drew Hrubes, the Core3D team prepares CAD files developed from data typically gathered with an iTero oral scanning wand or from CAD files from scans of conventional dental impressions from the patient’s mouth, which are then digitally captured in a dental scanner from companies such as 3shape. CADENT and other software are typically used to image the impression and begin the process of creating the crown, bridge, abutment, coping, implant or even full denture restoration, as required by the individual lab. 3D CADENT files are G-coded at a remote location of the parent company for transfer to the CNC machine tools at the various Core3D facilities worldwide. 
The next step is translation of the digital impression to a RenShape® mold, using conventional machine tools. In most cases, the required structures are designed simultaneously, then the mold with coping is introduced to the DMG Sauer ultrasonic dental machine for preparation of the final structures. This is where the most advanced substrates are processed, ranging from conventional, yet difficult to machine metals such as titanium and cobalt chrome, to the newest advanced materials, including glass ceramics, lithium disilicate and zirconia. These substrates are quite expensive, therefore extreme care is taken in their handling and processing to reduce scrap and conserve operating costs.
As McKimson explained, the decision to cut with ultrasonic technology was relatively easy, given the inherent wear conditions and high cost of conventional tooling. In the ultrasonic process, a combination of electrolysis and fluid lubrication act in concert to create an ionic attraction of particles, removing material in a highly predictable and accurate manner, without the mechanical stress implicit in conventional machining techniques. As a result, the surface of even the hardest materials can be machined with the necessary tactile smoothness required for dental implants.
The DMG Sauer ultrasonic machines located at this Las Vegas facility, fully operated by Siemens Sinumerik 840D sl CNC technology, are loaded with blanks of material into a 66-position feeder station, then delivered into the cutting theater by a Motoman robotic arm with Schunk pressure grippers. The Sinumerik 840D sl recognizes the code on each workpiece pallet and each job is identified by the patient’s name to minimize the risk of error in work product delivery. As McKimson further notes, in detailing the accuracy of the ultrasonic machining technique, each tool used is obtained from the 25-position tool changer and its position is monitored by an integral Renishaw probe. The technicians often load three sets of the tools needed for the 66-piece runs, ensuring virtually 24/7 unattended operation of the machines. Through the capability of the Siemens CNC, a remote alarm can be sent when tool breakage or other off-normal condition occurs during production.
The extremely hard materials being machined are produced with accuracies in the 2-4 micron range, owing to the combination of ultrasonic technology and the high precision of the Sinumerik CNC, according to McKimson, who notes the reliability of this accuracy has been a significant advantage in reducing scrap at Core3D.
In another area of the facility, conventional mills are used to make polyurethane models and Wieland Zeno 4820 and 4030 mini-milling machines are also utilized for the production of various crowns, wax/resin forms and models, veneers, inlays and implant abutments. 
As evidence of the decidedly international nature of this emerging dental giant, all the zirconia and lithium disilicate materials are provided in the IPS e.max System from Ivoclar Vivadent, a company based in Liechtenstein. The company has branches in the United States and Canada, which supply the Core3D Centres in those countries. The templates and cutting tools are closely controlled and validated by the manufacturer to ensure that the preparation of these materials in dental applications is properly executed.
In commenting on the use of the DMG Sauer ultrasonic machines, McKimson notes that it was the machine builder who recommended the Siemens control. “They knew we were dental technicians and engineers, not machinists, by nature. The Siemens control has been extremely easy-to-use and our training time from the builder was minimal. Troubleshooting is mostly done by our operators, with only occasional assistance from Siemens.” Danny Palomares, one of the technical operators, agrees. “My training is in the dental lab world, not on machine tools. It was a great relief to have such a sophisticated control operate with relatively simple language commands and cycle adjustments.”
Palomares is also responsible for the translation of the lab’s incoming data files, so he is involved from start-to-finish with most of the projects done at this Core3D facility. In a single day, for example, he might use Delcam DentCAD, then hyperDENT CAM software, all translating the cutting paths from the dentist’s impression to the Siemens CNC on the DMG ultrasonic machines in this facility. As McKimson adds, “The sub-routines on the Sinumerik CNC make our job much easier to accomplish and faster to complete. Plus, when you add the upside of at least 15 percent reduction in the scrap that we’ve realized with the ultrasonics, it’s a real win-win situation for us.”
While there are substantial differences between the European and American dental labs in terms of the materials and assembly techniques used, and despite the fact that literally all projects are highly customized based on the individual needs of the patients and the preferences of the labs and those of the dentists performing the procedures, in the end, the typical project is being turned in 24 hours or less.
For Core 3d Centres, utilizing the best-in-class equipment is critical. In complement the quality machines here, a key part of the overall efficiency protocol in the Core3D network of companies, McKimson points out, is the “know-how” provided through their CAM-DO committee. This global technical committee conducts regular online meetings to discuss what’s working and what’s not in their various worldwide operations and then optimizes and standardizes the processes. He recalls one unanimous vote of approval was voiced on the performance of the DMG Sauer ultrasonic machines with Siemens controls. Core3D currently has nine such machines in their network, all used to process the most advanced materials.
® RenShape is a registered trademark of Huntsman Corporation.
For more information on this story, please contact:
Core3D Centres
Tim McKimson
Engineering Technology Director
5955-2 Wigwam Avenue
Las Vegas, NV 89139
Toll-Free: 1-888-750-9204
Phone: 702-750-9204
http://www.core3dcenters.com/
tmckimson@core3dcenters.com
OR
Siemens Industry, Inc.
John Meyer
Manager, Marketing Communications
390 Kent Avenue
Elk Grove Village, IL 60007
(800) 879-8079 ext. Marketing Communications
www.usa.siemens.com/cnc
SiemensMTBUMarCom.industry@siemens.com
Follow us on Facebook: www.facebook.com/SiemensCNC or Twitter: www.twitter.com/siemens_cnc_us.
—
Siemens Industry Sector is the world’s leading supplier of innovative and environmentally friendly products, solutions and services for industrial customers. With end-to-end automation technology and industrial software, solid vertical-market expertise, and technology-based services, the sector enhances its customers’ productivity, efficiency and flexibility. With a global workforce of more than 100,000 employees, the Industry Sector comprises the Industry Automation, Drive Technologies and Customer Services Divisions as well as the Metals Technologies Business Unit. For more information, visit http://www.usa.siemens.com/industry.
The Siemens Drive Technologies Division is the world’s leading supplier of products, systems, applications, solutions and services for the entire drive train, with electrical and mechanical components. Drive Technologies serves all vertical markets in the production and process industries as well as the infrastructure/energy segment. With its products and solutions, the division enables its customers to achieve productivity, energy efficiency and reliability. For more information, visit http://www.usa.siemens.com/drivetechnologies.
Continue reading
OP 090/OP 100 in sequence at General Motors Toledo Powertrain plant.
GM realizes “weeks to hours” reduction in line change and transmission build dynamics at Toledo Powertrain, resulting from Flexible Assembly Configuration System (FACS) and Siemens control/communication
A tried and true euphemism nowadays, “thinking outside of the box” usually refers to a pattern of thought or action that results in rapid innovation, enhanced relationships being developed from established concepts as well as new ones, plus a genuine willingness to forego past practices in favor of a better way. Enter the GF6 six-speed, front wheel transmission line at General Motors Powertrain on Alexis Road in Toledo, Ohio.
Here, a new front wheel drive transmission line for smaller, more fuel efficient vehicles such as the popular Chevy Malibu and new Chevy Cruze is currently ramping up to its initial goal of 2200 units per day. Nothing new about such an event, until a closer look reveals the method used to program this line, implement changeover, stage the workpiece flow, perform all machining, secondary operations and assemble the finished transmissions.
Greg Nazareth, GM controls engineer, demonstrates the reconfiguration procedure on the FACS server, part of the overall Flexible Assembly Configuration System, provided by Elite Engineering of Rochester Hills, Michigan.
During the development of this line, several years ago, GM engineering contacted its longtime controls suppliers to investigate ways of significantly reducing the workflow through the line, as well as enable faster changeover, reduce reprogramming and prevent the curse of all automated manufacturing lines, situations where one out-of-spec machine caused complete shutdown. Another key driver in the development of the GF6 line was the need to minimize maintenance time by installing PLCs, drives and component pallet recognition devices outside the conventional cabinetry found on traditional assembly lines. In addition, controllers were distributed throughout the system, which allowed for removal of typical zone controllers and, in turn, substantially increased system flexibility.
Following considerable investigation into the process for the new line, the major obstacle remained changeover and the need for a more flexible yet highly automated system of transmission builds. In consultation with the controls provider on the existing six-speed, rear wheel drive line, Siemens Automotive Center of Competence (Troy, Michigan), as well as third party software package provider, Elite Engineering (Rochester Hills, Michigan), a deterministic study was undertaken and the result was the line now in production. Siemens provided the PLC, CNC, HMI, RFID and its high-level Ethernet protocol, Profinet, to run on the GM network. Overlaying this hardware and communications topology, Elite Engineering delivered its Flexible Assembly Configuration System (FACS), complemented by Siemens to create its SIFACS solution, wherein all the control elements for every assembly operation and test stations would be fully integrated. SIFACS largely focuses on the integration of the core PLC software blocks and functionalities of the individual stations with the RFID tags on each of the workpiece pallets, according Jim Remski, manager of powertrain activities for Siemens.
Siemens CNC and HMI technology combine with its Profinet high-level Ethernet communications and RFID pallet tags to execute the machining, assembly and testing at this transmission plant, currently targeting an output of 2200 units/day.
AN INTEGRATED APPROACH
Within any flexible automated assembly system, the keyword is flexible. All hardware and related software must be designed with a deterministic functionality that is both valuable to the customer’s build strategy and cost-competitive, as well. Working with technical specialists in safety integrated systems and industrial communications alike was the key to the success of this project at GM Toledo. By creating a decentralized control network that was nonetheless in complete harmony with the overall workflow of the plant, GM and Siemens devised the optimum modular yet flexible architecture for the entire system. This totally integrated automation approach not only addressed multiple families of hardware involved, it also coordinates all code development, safety and communications functions into a seamless and interdependent yet highly flexible and adaptive control scheme.
This integration is nowhere more visible than in the modular and open controller and I/O rack assemblies located throughout the facility. A Siemens Simatic® S7 CPU, the Siemens Safety Integrated drives platform and all I/O, including RF antennas for RFID tag reading are configured and reside here.
Diagnostics in the system are similarly integrated, according to Matthew Thornton and Jeremy Bryant, who consulted from Siemens. “We devised pre-made templates and blocks important to the powertrain build process, as our starting point,” commented Thornton, who further noted the importance of placing the critical performance data on all the HMI panels in the system for easy operator access. “With all motion and safety functions integrated into the drives, there was no need to build a separate troubleshooting architecture for what would be a more traditional safety network of relay cabinetry.”
Bryant continued, “Only a few components talk on the Profibus system, all other I/O and automation components communicate over Profinet.
Reinhold Niesing of the Siemens Automotive Center of Competence further explained the contact process between his group and the provider of the FACS. “They provided the configuration and monitoring system, while we (Siemens) provided the automation run time system. Both systems needed to run in sync to provide GM with configurable options, when changes in production or manufacturing enhancements were needed.”
Each RFID tag carries all the information needed to produce the part at each of the machining and assembly stations in the line.
Comau machining centers produce transmission cases and torque converter housings.
The result of this collaboration, coordinated under the Siemens Transline solution, whereby all operational, visualization and diagnostic functions are streamlined in a consistent control scheme, was the Transline HMI Lite CE package. This package provides uniform user interface for operational and diagnostic functions on the vast majority of the various machine tools, transfer lines, robotics, assembly machines, sensing devices and vision systems throughout the entire facility. As Michael Grass, project manager for Siemens, explains, “The best part is that the package can be customized to meet specific user needs and preferences. It provides our SIFACS (see sidebar) system of configurable assembly automation very useful information, as the two systems complement each other quite well.” In the safety communications area, he also noted that GM is currently reviewing another Siemens option for open safety communications technology on distributed automation systems.
RFID GETS THINGS STARTED
As a workpiece proceeds through the line, having been delivered by an AGV in most cases, each pallet is equipped with an RFID tag. Reinhold Niesing, engineering manager on the project for Siemens, explains, “The key here is the data throughput in the system, as it directly impacts the cycle time or takt time (maximum allowable time to produce one finished part or product) of the line. The tags must be able to function in static mode, whereby the data on the part must be read before the process begins. Model number, serial number and build status information are all contained in the tag. The faster we read the information, the faster the process begins.” Niesing also detailed the dynamic mode of operation for this RFID system, in which the information at subsequent line stations must be read “on the fly” without any line stoppage, as is often seen in conventional packaging, shipping or other line applications for RFID. In this case, all data are read as the tag passes by the antenna.
Often, in less sophisticated applications, the signal can degrade over time and number of reads. Here, according to the Siemens technical specialists, two interface protocols are supported, namely, ISO 15693 (open standard) and a proprietary Siemens-developed standard, Simatic RF300. The latter uses a state-of-the-art chip paired with highly optimized communications to achieve the faster data read/write rates. Large amounts of data (64kB) are handled in faster cycle times, while the overall RFID solution is applied in a high-speed, non-stop environment. One of the key drivers in the system is the fact that each RFID tag has both EEPROM and FRAM. The 20-byte EEPROM is actually designed to be a one-time programmable memory chip (OTP), a security feature that was deemed most desirable by GM for this application. Meanwhile, the FRAM can be written and rewritten many times for optimum utilization of the hardware, over time.
Despite this level of sophistication in the RFID hardware, the system easily communicates over the existing Profinet, Profibus and other common protocols.
LOGIC BLOCKS ALL AROUND
Open hardware racks and communications cabling are easily accessible for maintenance personnel.
The overall thrust of the line development, according to George Jewell, the GM engineer responsible for the implementation of the FACS online at the Toledo plant, was to have consistent, even identical logic blocks at every station. This would allow, as is seminal to the FACS architecture, immediate successive modifications to be made in the machine or assembly operations performed, throughout all stages of the line. When rebalancing was needed, when an upturn/downturn in current production was required or when an entirely new model came onto the line, the changeover needed to happen in hours, rather than in weeks, as was the industry norm.
By standardizing on the hardware, software and communication protocols used, engineering costs could be contained and, as a collateral but vital side effect, maintenance on the system could be made much more efficient with much of the system hardware exposed on the line, rather than enclosed in electrical cabinets, again the norm for the industry in the past. Flexible modules would allow more rapid reconfiguration, product changes and a genuine synergy with the ongoing GM commitment to continuous improvement in the line, as the new GF6 transmission ramped up to incremental target levels of production.
Jewell noted that Siemens responded to the challenges, “…with a plug-and-play technology approach, coupled with an understanding of the processes we utilize.”
From the utility perspective, he also noted that the run-time component in the system would function without the full configuration system being online, further complementing a decentralized architecture. Bob Raven, GM controls manager, further commented, “The Siemens commitment to provide this value added functionality geared towards flexibility within our manufacturing principles has substantially supported GM Powertrain’s efforts to standardize processes, controls and continuously improve.”
Reaction carrier sub-assembly.
Currently, GM uses the FACS at various plants in Mexico, China, India, Thailand, Korea and the U.S. — and soon in Canada and Eastern Europe, for the production of transmissions, engines and even the generator on the new Chevy Volt. These products, it should be noted, can be manufactured, assembled and tested, all within the same flexible control architecture, while supporting standardized GM processes.
Rather than textbook product life cycle management, Jewell sees FACS as more of a production line life cycle management tool, as its inherent adaptability means common hardware can be made to do diverse tasks, at varying rates, with on-the-fly changeover, in far less time than previously possible.
TYPICAL STATION DYNAMICS
On one automated assembly station, Hanwha produces the various sub-assemblies of the transmission, as other lines produce the components that go into the sub-assemblies. Adding a station, as Greg Nazareth, GM controls engineer, explained, requires simply adding a PLC with the standard SIFACS logic, desired process devices and downloading an eFACS configuration. In contrast to the traditional zone control, this reconfiguration is not a building block concept; rather, the instructions being given impact the entire line. Nazareth worked with the full GM controls team, headed by Ron Goeckerman, to implement FACS with the host server.
By contrast, all manual workstations on this line have the same download received to a PLC, provided by Siemens in its Simatic lines. While not reliant on the server network in a deterministic mode, the manual stations nonetheless utilize the same software to execute quick tooling changes, machine sequence variations, line balancing and report tracking. Operators received training from both Siemens and Elite Engineering personnel for these tasks.
All part build histories, troubleshooting and machine debugging are recorded for further analysis.
Federal Broach machines perform large transmission gear production.
CONTROLS CALL THE BALL AT EVERY STEP
Throughout the metalcutting process here, mostly in the gear and spline forming, hobbing, grinding and finishing, CNC technology is onboard dozens of machine tools. Most of the machines here are controlled by Sinumerik® 840D, the highest-level CNC offered by Siemens. The control not only processes the particular part dimensions in the cutting theater of the machine, it also coordinates all motion control and movements into and out of the machine. Working in tandem with the other hardware and communication network software in the line, for example, ring gears cut on a Wera Profilator machine are indexed from one station to the next, in timed sequences, to coordinate with predetermined production requirements. This operation occurs in a fully automated mode, requiring no operator intervention, except for maintenance and planned inspections.
Likewise, in the machining of valve bodies and transmission cases, each step of the process is controlled by the Siemens CNC to produce the required components in the proper sequence for subsequent assembly and testing operations. During those subsequent operations, other motion control devices and software solutions provided by Siemens execute, monitor and control the assembly process, through the SIFACS solution set. (See sidebar.)
PROFINET TALKS THE TALK
Through a decentralized and cabinet-less design, GM achieves highly integrated RFID control with easy access and true out-of-the-box solutions for the control architecture installed on this line. A Profinet solution provides GM with a high-performance, reliable network with minimum bandwidth impact or additional network load achieved at this plant, all with no special hardware required, a further cost savings for GM.
SAFETY FIRST — AND LAST
Safety features are numerous here, resulting in a complete failsafe system across all Siemens Simatic PLC, I/O devices and safety-integrated drives. All safety devices are networked over Profisafe protocol, a certified safety network, eliminating time-consuming and difficult to maintain traditional hardwired safety connections. All safe I/O, failsafe drives are part of the Siemens Totally Integrated Automation (TIA) protocol. Since it is fully integrated, this protocol provides comprehensive system diagnostics,
Rear wheel drive, six-speed line has been in full production, while the new line is producing front wheel drive, six-speed transmissions for vehicles such as the Chevy Malibu and new Cruze models.
which can help guide maintenance staff to exact fault location and mitigate downtime. Since the drives, starters and machine safety are integrated into the multi-functional machine mount I/O system, Simatic ET 200pro, the overall engineering complexity is reduced because of simplicity in panel design, wiring architecture and seamless integration to the project level hardware configuration, which is reduced due to the totally integrated automation design. For service requirements in the event of a fault, hot swapping of an I/O module is possible during operation, without switching off the entire station. There is nonetheless a very high degree of integral protection, to IP65/67 standards. The fact that an enclosure is not required also helped save on the total cost of the project for GM.
MAJOR INVESTMENT PAYING OFF
Between the two lines here, GM Toledo has invested $872 million on its six-speed, rear- and front-wheel drive transmission production at this 2 million square-foot facility, which currently employs 1400 employees, most members of UAW Local 14.
The highly fuel-efficient rear-wheel drive Hydra-matic 6L80 transmission is now joined by the GF6 front-wheel drive, six-speed
units being produced on this new line under the FACS control solution that supports flexible manufacturing while driving standard processes.
As George Jewell, the GM engineer who spearheaded the implementation of FACS, stated, “From our first installation in Ramos Arizpe (Mexico) to this Toledo plant, we’ve seen great results, with activities that took months reduced to weeks and what took weeks reduced to hours. There’s less ramp-up time, plus the changeover and line balancing upsides are already proving this was a beneficial investment.”
Testing station with FACS configuration terminal in background.
Please direct all inquiries generated by this story to:
John Meyer
Siemens Industry, Inc.
Marketing Communications
390 Kent Avenue
Elk Grove Village, IL 60007
Phone: 847-640-1595
Fax: 847-437-0784
Email: SiemensMTBUMarCom.sea@siemens.com
Wera Profilator gear profiler run by a Sinumerik 840D, the highest level CNC in the Siemens line, used for fully automated production of ring gears.
SIFACS — THE SIEMENS SOLUTION FOR THE FLEXIBLE ASSEMBLY CONFIGURATION SYSTEM (FACS)
Working in tandem with GM process specialists and Elite Engineering, the third party provider of the unique Flexible Assembly Configuration System (FAC
S) used at this GM Toledo transmission plant, Siemens personnel created SIFACS, a solution that integrates the host IT system at the facility with all hardware and software in the line.
SIFACS is quite literally the hub of the information management system for this line, as it coordinates all demand input from the GM server and FACS configuration stations, transmits it via the Profinet communications network in the plant to all the onboard PLC, HMI, motor starters, frequency converters, safety-integrated drives and other controls at the various machine tool, assembly and test stations.
Likewise, the feedback data from all RFID, smart sensors, RS-232 interfaces, hand scanners and other I/O devices are tracked and captured for detailed analysis by production management here.
Faessler gear honing machine works in tandem with robotic load/unload stations.
In this way, not only is the system’s production output closely controlled, but also the line stations themselves can be reconfigured, using a unique Siemens micro memory card that allows easy component replacement, without a laptop. All PLC logic, hardware configuration and process data are embedded on the card, which is interfaced to three Ethernet and one Profibus ports for instant communications.
Critical for a continuous moving line such as those found here, the Siemens Simatic control systems are executing motion commands read from the RFID devices at 8000 bytes/sec, far in excess of the ISO 15693 standards for read and write performance.
SIFACS HMI screen extensions with Cognex Vision View further permit constant monitoring by both a team leader and a conveyor controller, eliminating a PC dedicated to a vision system.
All the smart devices on the line are also interfaced to the SIFACS solution, including fastening, leak test and pressing systems, plus barcode readers, barcode printers, robotic articulation and handling devices, vision systems and protocol gateways.
eFACS functionality is finally integrated into the SIFACS, as this feature of the Elite Engineering system provides connection establishment and monitoring, as well as configuration, process and status data exchanges, plus management of the model configuration data, all stored on the system.
On the most practical of levels, even the data structures feed to the Andon boards for in-plant display is integrated through the resident IT system via SIFACS.
Process Improvement Tools and Process Efficiency Tools, provided with the FACS, enable both process and production engineers to collect data and fine tune the system in real time, keeping build status and cycle time information always current. Line and station balancing can likewise be achieved on-the-fly, with complete process efficiency, operator loading, anticipated cycle time, even individual process operation time calculations being made, charted, displayed and rapidly analyzed by the team leader or station control personnel, in a hierarchy of need-to-know, need-to-act protocol.
The net effects of the Siemens SIFACS® system and the Elite eFACS are sustainable, highly flexible production scenarios, coupled with lower life cycle costs, as the controls and station hardware need not be re-invented for each new model, as well as lean manufacturing strategies, since the line can be constantly tuned without interruption. The flexibility, data analysis and transparent metrics of these systems further allow all employees to understand the current line performance in real time and to make suggestions for improvements that can be implemented almost immediately.
“It’s a win-win-win for all parties involved,” commented George Jewell of GM, whose team pioneered the development and application of these systems for his company’s various plants. Further advancements in FACS and SIFACS are currently being introduced at other GM facilities worldwide, according to Jewell.
For additional product information and inquiries:
SIEMENS INDUSTRY, INC.
DRIVE TECHNOLOGIES
MOTION CONTROL
MACHINE TOOL BUSINESS
390 Kent Avenue
Elk Grove Village, IL 60007
Phone: 847-640-1595
Fax: 847-437-0784
Web: Email: SiemensMTBUMarCom.sea@siemens.com
Attention: John Meyer, Manager, Marketing Communication
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Siemens Industry Sector is the world’s leading supplier of innovative and environmentally friendly products, solutions and services for industrial customers. With end-to-end automation technology and industrial software, solid vertical-market expertise, and technology-based services, the sector enhances its customers’ productivity, efficiency and flexibility. With a global workforce of more than 100,000 employees, the Industry Sector comprises the Industry Automation, Drive Technologies and Customer Services Divisions as well as the Metals Technologies Business Unit. For more information, visit http://www.usa.siemens.com/industry.
The Siemens Drive Technologies Division is the world’s leading supplier of products, systems, applications, solutions and services for the entire drive train, with electrical and mechanical components. Drive Technologies serves all vertical markets in the production and process industries as well as the infrastructure/energy segment. With its products and solutions, the division enables its customers to achieve productivity, energy efficiency and reliability. For more information, visit http://www.usa.siemens.com/drivetechnologies.
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Practical Operation
The SCHÖMA machine factory opted for a cycle turning machine with Sinumerik 840D solution line CNC for the manufacturing of individual parts and small batches of locomotive wheels; this machine also features Siemens ShopTurn with Manual Machine function. This hardware and software solution combines the flexibility and benefits of conventional machining with the productivity and efficiency of a CNC and this is what tipped the balance in its favor for one customer.
Christoph Schöttler Maschinenfabrik GmbH (SCHÖMA) is based in Diepholz, Germany. The company specializes in the development and production of diesel-engine locomotives. The model range includes tunnel and shunting locomotives; service, field and narrow-gauge locomotives; handcars, passenger carriages and gang cars. Around 90 percent of the locomotives produced each year at SCHÖMA are destined for use in tunnel construction.
Each construction project brings its own specific requirements and each country through which the locomotives travel has different environmental and safety legislation. SCHÖMA uses a modular system to meet a diverse range of customer requirements and the resulting need for a variety of equipment and product versions. One of the tasks facing the company is working out how to equip the locomotives for transportation by rail on differing track widths. Another requirement is locomotives with driving wheels featuring diameters between 600 mm and 900 mm, depending on local track usage.
The right decision
Faced with even more demanding requirements in terms of production capacity and flexibility, SCHÖMA’s Managing Director, Christoph Schöttler, last year decided to add a cycle-control Seiger Record LC 1400 lathe to his inventory of machines. “We opted for a head turning machine, as we do not need a tailstock to produce driving wheels, axle bearing housings and gear wheels. It is working just as we envisioned, so we obviously made the right decision,” says Schöttler.
SCHÖMA constructs around 120 locomotives each year, which equates to 480 wheels. In addition, there are also repair orders, which increase the workload to between 560 and 600 driving wheels per year. These wheels are produced in two mountings from forged blanks on the cycle turning machine. The first mounting is used to machine the wheel flange on the reverse side and the wheel hub. The shaft locating bore is pre-turned. In the second mounting, the first task is to pre-turn the driving wheel profile, then the rolling circle level and the wheel shaft locating bore are finished.
Careful approach
The cycle turning machine is controlled by a Siemens Sinumerik 840D sl CNC, equipped with the ShopTurn software package with Manual Machine feature. If required, ShopTurn programming can be performed on a separate PC as part of an operator’s work planning, without interrupting the work sequences on the machine. The programs are routed to the machine via the network, where they are called up as required, depending on the workpieces to be produced. The Sinumerik CNC is used for both numerically controlled machining and manual operation with the ShopTurn’s Manual Machine functions. In manual mode with electronic handwheels, the machine behaves just like a conventional lathe with an actual value display.
During face and longitudinal turning, the process operates with the entered feed and spindle speed. The real highlight of the system is that every cycle can be used straightaway, without having to create a custom program. At SCHÖMA, the option for manual intervention is used for setting the zero point or for simple contours. Diameters are determined manually, if driving wheels have been newly profiled or if driving wheel profiles require resurfacing. The wheel profiles abrade as a result of the high loads experienced in heavy-duty operation or on poor-quality tracks or as a result of the driven wheels skidding.
“With a machine that uses only CNC, it is difficult to rework the driving wheels, as it is not possible to determine how much material needs to be removed. With this optional manual mode, however, users can adopt a careful approach. This sums up the ease of control,” explains Walter Horstmann, head of mechanical production and wheel set construction at SCHÖMA.
Siemens ShopTurn with Manual Machine for the job shop
After machine start-up, the basic MANUAL screen is immediately displayed and offers direct access to choosing machining options without having to create a parts program.
Machining procedures such as “taper turning” and “straight line face and longitudinal turning” can be executed immediately. The operator simply selects tool, feed speed, spindle speed and orientation, plus, if required, machining angle, then presses “Start”. The active direction is graphically displayed in the basic screen, using a compass rose symbol. All machining steps such as entry, thread grinding and drilling can also be started in manual mode.
For additional product information and inquirie, contact:
SIEMENS MACHINE TOOL BUSINESS
John Meyer
Manager, Marketing Communications
Siemens Industry, Inc.
(847) 640-1595
www.usa.siemens.com/cnc
SiemensMTBUMarCom.industry@siemens.com
Follow us on Facebook: www.facebook.com/SiemensCNC or Twitter: www.twitter.com/siemens_cnc_us.
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Siemens Industry Sector is the world’s leading supplier of innovative and environmentally friendly products, solutions and services for industrial customers. With end-to-end automation technology and industrial software, solid vertical-market expertise, and technology-based services, the sector enhances its customers’ productivity, efficiency and flexibility. With a global workforce of more than 100,000 employees, the Industry Sector comprises the Industry Automation, Drive Technologies and Customer Services Divisions as well as the Metals Technologies Business Unit. For more information, visit http://www.usa.siemens.com/industry.
The Siemens Drive Technologies Division is the world’s leading supplier of products, systems, applications, solutions and services for the entire drive train, with electrical and mechanical components. Drive Technologies serves all vertical markets in the production and process industries as well as the infrastructure/energy segment. With its products and solutions, the division enables its customers to achieve productivity, energy efficiency and reliability. For more information, visit http://www.usa.siemens.com/drivetechnologies.
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Fryer Easy Turn Combination Lathe with Siemens SINUMERIK 840D sl CNC lets operators at Continental Machine program, set-up and run faster; critical for one-off operations
By definition, says Josh Johnson, vice-president, Continental Machine, Rockford, Illinois, his prototype and short-run production shop must constantly run lean. There can be no tolerating excessive programming, set-up or machining time of any kind, otherwise the shop loses and, in this economy, Johnson notes, that is simply unacceptable.
Continental Machine is a seven-person, 13,000 square-foot facility that houses a variety of CNC milling, turning, wire EDM, hole popping and grinding machines, as well as various sheetmetal and plastic injection molding machinery. Therefore, the shop is well positioned to produce a wide variety of metal and plastic prototypes used by its diverse customer base, which spans markets such as window hardware, bicycle components, automotive parts, chemical processing, medical devices and foodservice equipment. Materials processed here are just as wide-ranging, including aluminum, CRS, tool steels such as A2 and D2, zinc, brass, copper, bronze, titanium and a variety of engineered plastics such as glass-filled Delrin.
Recently, this job shop purchased a Fryer Easy Turn-21 CNC Combination Lathe, controlled by a Siemens SINUMERIK 840D sl numerical control. The two operators responsible for this machine upgrade at Continental had limited experience with CNC and none whatsoever with the Siemens protocol, as this was the first of its kind at the shop.
The Easy Turn-21 was particularly appealing to Josh Johnson, who comments, “The set-up is extremely easy. Teaching the tools, altering the lengths and diameters is kept very simple. After the initial learning curve, which took only a few days, the operators picked up on the conversational programming, right away. Also, one of the best features on the machine was that you could still turn the parts by using the electronic handwheel and just one function, such as hogging off material automatically or putting on a tapered thread.” He noted this feature was not only more comfortable for the operators, but it also allowed them to quickly and efficiently prove out part programs. Johnson commented that this would not have been possible on previous machines, owing to the flexibility of the control onboard the Fryer. The result has been a minimum 20% improvement in the overall cycle time on most part programs run at Continental. For this primarily prototype job shop, that fact translates into a substantial increase in the work product possible here.
Echoing this sentiment, Sue Ostrander, sales manager, Fryer Machine Systems, explained the process that led her company to select the SINUMERIK 840D sl numerical control for all its milling and turning machines, a move that was recently formalized by the company and announced to the trade.
“Since its inception 26 years ago, family-owned Fryer Machine Systems has based its operation on three core principles: build a quality product, price it fairly and provide quality service. This philosophy has allowed Fryer’s business to grow even in challenging times,” she said.
Fryer manufactures a diverse line of over 50 models of high-quality CNC machine tools in its 50,000 square-foot facility in Patterson, New York. Over the years, Fryer has become well-respected for its quality and innovation, throughout the job shop and production machining market segments.
“Moving to the Siemens 840D sl platform was the next step in Fryer’s ongoing commitment to provide our customers with the most innovative machine tools available in the market today,” Ostrander continued. “The Siemens solution allows machine tool end-users to achieve higher productivity through easy and intuitive features and step-by-step, on-screen programming. This enables them to dramatically reduce set-up, programming, and tooling times, while significantly increasing output.”
“The SINUMERIK 840D sl modular design allows us to take full advantage of the superior mechanical features in our machines,” continued Larry Fryer, president and CEO, Fryer Machine Systems. “Fryer has always been known for our easy conversational controls and the move to Siemens has allowed us to greatly enhance this feature,” Fryer noted. “The 840D sl menu-driven system combines an advanced geometry calculator that displays the part while the operator is programming it. Sophisticated solid model graphics allow the operator to verify the part program with more clarity than ever before,” he said.
Larry Fryer has also been impressed with the automatic tool set-up and easy part set-up, made possible by the Siemens CNC. Fryer explained that auto-run mode is where many operators experience difficulty. Siemens and Fryer Machine Systems worked together to create an electronic handwheel run mode that gives the operator a safer way to prove out program execution, both forward and backward, using a standard electronic handwheel.
Fryer further stated, “Siemens provides us with a highly flexible solution that is critical to our ability to meet the specific needs of each customer. Our enhanced capability to offer the same control for both turning and milling gives Fryer machines a unified platform that is very important to customers both in the short-term and for long range expansion. Coupled with Siemens quality and reliability, they are invaluable to us in competing in today’s aggressive marketplace.”
Johnson added this comment on the service and training received by his operators at Continental. “Siemens has been helpful and very thorough in their training and after-sale service. The ShopTurn program, being integral to the control, now enables us to accurately determine tool path, potential collisions, tool changes and real world run time. This makes our operators’ jobs much easier, with the added benefit of allowing us to estimate much more accurately than ever.” Johnson further noted the CNC has substantial hard drive space, thus allowing most programs to be stored directly on the machine, though the company does maintain a back-up system.
For more information on this story, please contact:
CONTINENTAL MACHINE CO.
Email: conmach@onecommail.com
FRYER MACHINE SYSTEMS, INC.
Web: www.fryermachine.com
SIEMENS MACHINE TOOL BUSINESS
John Meyer
Manager, Marketing Communications
Siemens Industry, Inc.
(847) 640-1595
www.usa.siemens.com/cnc
SiemensMTBUMarCom.industry@siemens.com
Follow us on Facebook: www.facebook.com/SiemensCNC or Twitter: www.twitter.com/siemens_cnc_us.
—
Siemens Industry Sector is the world’s leading supplier of innovative and environmentally friendly products, solutions and services for industrial customers. With end-to-end automation technology and industrial software, solid vertical-market expertise, and technology-based services, the sector enhances its customers’ productivity, efficiency and flexibility. With a global workforce of more than 100,000 employees, the Industry Sector comprises the Industry Automation, Drive Technologies and Customer Services Divisions as well as the Metals Technologies Business Unit. For more information, visit http://www.usa.siemens.com/industry.
The Siemens Drive Technologies Division is the world’s leading supplier of products, systems, applications, solutions and services for the entire drive train, with electrical and mechanical components. Drive Technologies serves all vertical markets in the production and process industries as well as the infrastructure/energy segment. With its products and solutions, the division enables its customers to achieve productivity, energy efficiency and reliability. For more information, visit http://www.usa.siemens.com/drivetechnologies.
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Bertsche iJet waterjet deburring system built for Linamar combines waterjet deburring with part cleaning for one inline system.
Canadian automotive part supplier realizes significant gains with Bertsche-designed multi-function system in its plant
With factory floor space at a premium and capital equipment funds scarce, Linamar, a Tier One Canadian automotive part supplier, turned to Bertsche Engineering recently for an all-in-one part deburring, final rinse and drying solution.
Typically, complex machined automotive parts with multiple intersecting holes require feature-specific part deburring to insure that parts are burr-free. After deburring, parts also need a final cleaning/washing to insure removal of microscopic particles that might adversely affect performance. They are then preserved with a rust or oxidation inhibitor and dried for shipment (transport) to be assembled. Usually, this involves separate pieces of equipment linked by conveyors or robots to transport parts to each machine.
To solve the problem of densely filled factory floor space, Bertsche Engineering developed a machine that handles all these processes in one machine, in one deburring cycle. The machine takes oil and chip contaminated parts, previously machined on CNC milling centers and mill/turn machines, then selectively deburrs critical features using high pressure water, blasting chips out of internal cavities, knocking off all feather-edge burrs and fan washing the outside of the part, using a CNC for full cycle control.
Close-up shows parts infeed and outfeed station, where considerable space savings were realized by the customer, Linamar, a major Canadian Tier One automotive parts supplier.
This process is accomplished by a series of rotating lance nozzles that probe small diameter internal holes in order to blast feather edge burrs clean at intersection points and wash chips out of dead-end passages. External features are then blasted with a series of direct nozzles that release up to 10,000 psi of water at the burr while tracing the part edges. The part is then washed with high-pressure rotating fan nozzles. Note: When required, additional mechanical wire and filament brush tooled deburring stations can be incorporated into the Bertsche system to mechanically remove burrs.
The same machine moves the deburred part to an agitated wash and rinse station, where the part is rinsed, cleaned and preserved with an aqueous rust inhibitor (providing up to 24-day protection) and is finally dried. The part is then ready for final assembly.
Close-up shows parts being indexed over high-pressure (10,000 psi) waterjet nozzles for full wash cycle and rust-inhibiting aqueous coating process
For more information on this application, please contact:
BERTSCHE ENGINEERING CORPORATION www.bertsche.com
PR agency contact: Tim Daro Bernard & Company www.bernardandcompany.com
Release: BERTSCHE ENGINEERING CORPORATION
Date: December 28, 2009