Tag Archives: Sinumerik Operate

Three Convenient Functions for CNC Turning and Milling Applications

By Bernard and Company Tags: CNC machine tool, industrial ad agency, Industrial PR, Siemens Industry, Sinumerik Operate No Comments

Three new functions for the Sinumerik Operate operator interface simplify the operation of turning and milling machines
Time-saving program handling
High-speed setting cycle with plain text function
Retraction function for manual retraction of tools

Siemens has added three new functions to the Sinumerik Operate graphical user interface making it easier to operate turning and milling machines. A new program management system, plain text reading in the high-speed setting cycle, and the new retraction function support operators during standardized turning and milling operations using the Sinumerik 828D compact CNC — or in high-end applications using the modular Sinumerik 840D sl CNC.

The Sinumerik Operate program manager has been supplemented with a new program management system providing direct access to all connected drives. Users can now work simultaneously on all connected drives and their file structures. In addition, a larger number of different file formats can be displayed than before.

In the powerful cycle package of Sinumerik Operate, the high-speed setting cycle has been simplified by plain text reading for a host of machining methods. This high-speed setting cycle supports machine tool operators in all tool- and mold-making applications by transferring the machining tolerance.

In the new version, machining methods such as roughing, pre-finishing or finishing can be output as plain text, and the orientation tolerance can also be entered. Users only have to specify a few parameters for this purpose.

The new retraction function in Sinumerik Operate now supports users when retracting a tool following an interruption caused, for example, by power failure or NC reset.

In JOG mode and in the swiveled machine state with Cycle800 or Traori five-axis transformation, machining can now be continued from the point of interruption following manual recovery.

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For specific product information and inquiries, call (800) 879-8079 ext. Marketing Communications or send an e-mail to: SiemensMTBUMarCom.industry@siemens.com.

The Siemens Industry Sector is the world’s leading supplier of innovative and environmentally friendly automation and drive technology, industrial software and technology-based services. The Sector’s comprehensive portfolio covers the entire industrial value chain, from product design, engineering and production to services. Siemens enhances its customers’ productivity, efficiency, and flexibility in a wide variety of different industries. With a global workforce of more than 100,000 employees, the Industry Sector comprises the Divisions Industry Automation, Drive Technologies and Customer Services as well as the Business Unit Metals Technologies.

AeroDef 2014 Siemens Round-Up: Machine Tool Solutions That Increase Aerospace Part Manufacturing Productivity

Did you miss Siemens at AeroDef 2014? Here’s what you missed!

At this year’s AERODEF conference in Long Beach, California, Siemens will demonstrate new CNC solutions and services for machine tool builders and end-users. Under the theme, “Productivity in motion,” the presentation will focus on turnkey solutions for the aerospace manufacturing industry.

Broad-based CNC competence: Siemens will be demonstrating how productivity, flexibility and safety can be increased in CNC production with an array of smart additions to its Sinumerik portfolio

For the aerospace market, the Sinumerik 840D sl offers the latest in CNC technology that increases machine tool performance and user productivity. The 840D sl is a universal and flexible CNC system based upon the innovative Sinamics S120 drive platform 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, handling and robotics technologies. It offers users innovative features that increase productivity on the manufacturing floor, especially the challenging aerospace segments of high-speed and five-axis machining.

For the job shop, the Sinumerik 828D numerical control is the ideal CNC solution for mid-range machine tools. It is designed to address the needs of complex milling and turning machines in the job shop segment by combining CNC, PLC, operator panel and axis control for six CNC measurement circuits into a single, robust operator panel.

The 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, 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.

SOLUTIONS FOR CNC TRAINING

Recently introduced to the American machine tool industry, and based upon the new Sinumerik Operate graphical 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 manner, 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 an additional benefit, programs generated through SinuTrain can then be used on actual machines.

Offered in several languages, SinuTrain is available for different needs and budgets including a trial version, a study version, a single-user license and an educational license.

For more information about advanced CNC solutions for the aerospace industry,
please visit: www.usa.siemens.com/aerodef-pr.

Download this article as a PDF: Siemens AeroDef14

Download the Siemens Aerospace Brochure: Siemens Aerospace

Download the SINUMERIK Integrate Run MyRobot Brochure: SINUMERIK Run MyRobot

For specific product information and inquiries, call (800) 879-8079 ext. Marketing Communications or send an e-mail to: SiemensMTBUMarCom.industry@siemens.com.

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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.

Fabtech 2013: Siemens Sinumerik 840D sl

By Bernard and Company Tags: Ad agencies, Bernard & Company, BernardandCompany, CNC, Fabtech, Industrial PR, milling, Siemens 840D, Siemens Drive Technologies, Siemens Industry, Siemens Machine Tool Systems, Simotics, Sinamics, Sinumerik, Sinumerik 808D, Sinumerik 828D, Sinumerik Operate, Tim Daro, turning 2 Comments

Open, flexible, powerful – Siemens Sinumerik 840D is the premium CNC for machine tools.

View the Sinumerik 840D sl Brochure and visit Siemens at Fabtech, Booth S-4686.

For additional product information and inquiries, call (800) 879-8079 ext. Marketing Communications or send an e-mail to: SiemensMTBUMarCom.industry@siemens.com.

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Fabtech 2013: On the Road to the Future in CNC Technology with Sinumerik from Siemens

Visit Siemens at Fabtech 2013, Booth S-4686

UPDATE! See the video of Siemens at FabTech HERE.

More integrated solutions needed in machine tool construction
Enhancement of CNC machining productivity and flexibility through a more highly developed Sinumerik portfolio
Sinumerik and Integrated Drive Systems (IDS): optimum added value through consistent integration across the entire life cycle

Broad-based CNC competence: Siemens will be demonstrating how productivity, flexibility and safety can be increased in CNC production with an array of smart additions to its Sinumerik portfolio

Industrial corporations are facing deep-rooted changes in the world of manufacturing. These changes are taking place alongside increasing integration of product development and production processes with the benefit of innovative software systems and high-performance software – a decisive step on the road toward a new industrial age in manufacturing. “Siemens has invested a lot of work in the integration of automation technology along the entire value chain over a period of many years, and is playing a cutting-edge role in shaping the future of production,” stated Robert Neuhauser, CEO of the Motion Control Systems Business Unit of the Siemens Drive Technologies Division, at a press conference held in the run-up to the EMO 2013. “In the Sinumerik environment in particular, and consequently in the field of CNC production in general, Siemens has been heavily involved for many years already in the area of simulation and the virtual machine, as well as the integration into factory IT systems. Our aim is to drive this process of integration forward to ensure that the field of machine tool construction is also prepared to embrace the next step in the industrial revolution,” continued Neuhauser.

Siemens Sinumerik 808D

With its Sinumerik family, Siemens offers an integral portfolio of CNC for everything from simple machine tools through standardized machine concepts to modular premium solutions, complete with “smart machine” solutions for the economical manufacture of high-end workpieces. It is working towards the consistent expansion of this CNC technology expertise. “In the future, production models will demand ever greater productivity, flexibility and efficiency, while at the same time expecting simplified machine operation and production sequences. As it continues to develop the Sinumerik CNC portfolio, Siemens is working to satisfy all these expectations,” said Joachim Zoll, Head of Machine Tool Systems Business Segment within the Motion Control Systems Business Unit. The innovations presented by Siemens at the Fabtech 2013 will consequently focus on smart function improvements, which will make for greater CNC operating convenience, increase precision at the workpiece and allow greater machining safety across every category of machine, from the compact to the high-end solution. A new function to protect against unwanted component collisions will be showcased by Siemens, for example, alongside improvements to its cohesive Sinumerik Operate user interface, including upgraded simulation options.

Siemens Sinumerik 828D Basic Family

The Sinumerik CNC portfolio is additionally playing an increasingly important role in preparing the ground for the next step in the evolution of CNC production, also within the framework of the Siemens Integrated Drive System (IDS). With a view to optimizing the addition of value across the entire process chain through consistent integration, IDS is used to integrate all the components of the drive train consistently into the complete production process environment. This also applies to Sinumerik CNC system solutions.

For every Sinumerik application, ideally coordinated system components such as high-powered Sinamics drives and Simotics motors have always been used as the ideal complements. Alongside horizontal integration of the entire drive train, with Sinumerik Integrate for Production, Siemens is also allowing vertical integration within the control architecture of industrial manufacturing automation. As the example of a leading passenger car manufacturer illustrates, this type of vertical and horizontal integration within the production process can speed up the series start for a new vehicle by up to 50 percent.

Siemens is extending its preparations for the next step in manufacturing to offer the machine tool building industry an emerging series of integrated solutions. An integrated workpiece measurement system, with a measurement accuracy of 30 nanometers deployed in the world’s biggest precision optics machine, allows the production of telescopes capable of seeing up to 13 billion light years into space

The integration across the entire product life cycle can in turn be implemented using suitable Product Lifecyle Management (PLM) software solutions from Siemens. This concept is already being implemented by leading metals processing industries such as the automotive, aerospace and medical technology sectors. This entails the increasing execution of product development and production planning onscreen, before a single machine tool has even been installed. If a modular machine is developed on a virtual basis right from the outset so that it can be fully simulated, time savings up to 40 percent can be achieved. In running operation, productivity increases of 10 percent or more are also made possible by continued simulation and optimization. At this year’s Fabtech, Siemens will be showcasing the further development of its PLM software, which encompasses scalable solutions for component production and further improved IT integration from the workpiece model through to the machine tool. Siemens will also be revealing the next stage in productivity for NC programming with the further development of its already popular PLM software, NX CAM. Going forward, this software will include special industry-specific machining functions as well as access to a new Manufacturing Resource Library.

For more information on Siemens SINUMERIK CNC, visit www.usa.siemens.com/cnc.

For specific product information and inquiries, call (800) 879-8079 ext. Marketing Communications or send an e-mail to: SiemensMTBUMarCom.industry@siemens.com.

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Dynamic Workpiece Handling with Sinumerik Integrate Run MyRobot

By Bernard and Company Tags: Ad agencies, BernardandCompany, EMO 2013, Industrial PR, KUKA, Run MyRobot, Siemens Drive Technologies, Siemens Machine Tool Systems, SINUMERIK 840D sl, Sinumerik Integrate, Sinumerik Operate, Tim Daro, Trade-shows No Comments

Integrated operation, programming, and diagnostics of KUKA robots via the Sinumerik Operate user interface from Siemens

Automation of machine tools will immediately become more flexible: with Sinumerik Integrate Run MyRobot, Siemens Drive Technologies Division and KUKA Roboter GmbH presented a solution for integrated operation, programming, and diagnostics of a KUKA robot in Sinumerik at EMO 2013. For example, in conjunction with the new “Run myRobot” technology, the CNC control Sinumerik 840D sl package can optimally enable KUKA robots to perform handling tasks on machine tools, in particular, loading and unloading of machining cells. Interaction, such as operation, tool retraction, teach-in, and diagnostics of robots, can be performed through just one operator panel with the Sinumerik 840D sl, thus increasing the efficiency and flexibility of the machine tools. Customer can order this technology package with immediate effect from Siemens.

As part of the dynamic automation solution, functions for handling are one hundred percent available at the Sinumerik Operate user interface. The execution of the machine tool and robot program can be tracked and controlled on screen on parallel channels. This gives the operator a quick overview of the current status of the machine tool and robot. The Sinumerik hand-held terminal HT8 and the user interface can be used to “teach” not only machine tool-related setup actions but, as part of the same operating philosophy, also the path points and functions of the robot.

Execution of the robot movements, provision of robot safety functions, and other robot-specific functions are still performed by the KUKA robot control KR C4. The Sinumerik 840D sl is connected to the KUKA control via a command interface.

With the mxAutomation function block library from KUKA, the motion sequence of the robot can be programmed completely in the Sinumerik control 840D sl. In this way, the robot program can be created completely without any knowledge of Step 7, the Siemens tool for PLC programming.

This press release and further press material are available at http://www.siemens.com/press/emo2013

For more information on this story, contact:

Siemens AG, Media Relations
Franz-Ferdinand Friese, phone: +49 911 895 7946
E-mail: franz.friese@siemens.com

KUKA Roboter GmbH, Corporate Communications
Wolfgang Meisen, phone.: +49 821 4533 1981
E-Mail: WolfgangMeisen@kuka-roboter.de

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The Siemens Drive Technologies Division (Nuremberg, Germany) is the world’s leading supplier of products, systems, applications, solutions and services for the entire drive train, with electrical and mechanical components (Integrated Drive Systems). 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 fulfills the key requirements of its customers for productivity, energy efficiency, and reliability. For more information, visit http://www.siemens.com/drivetechnologies

The KUKA Roboter GmbH, with its headquarters in Augsburg, is a member of the KUKA Aktiengesellschaft and ranks among the world’s leading suppliers of industrial robots. Core competencies are development, production and sale of industrial robots, controllers and software. The company is the market leader in Germany and Europe and the number three in the world. KUKA Roboter GmbH employs about 3180 people worldwide. In 2012, sales totaled 742,6 million Euro. 25 subsidiaries provide a presence in the major markets of Europe, America and Asia.

Precision Processing for Fast Bikes

By Bernard and Company Tags: Ad agencies, BernardandCompany, five-axis G550 machining center, Grob, Industrial, Industrial PR, ShopMill, Siemens, Siemens General Motion Control, Siemens Industry, Siemens Machine Tool Systems, SINUMERIK 840D sl, Sinumerik Operate, Tim Daro No Comments

To guarantee perfect workmanship and the highest possible product quality, BMW uses five-axis machining centers equipped with Sinumerik 840D sl and a range of new user interfaces for machining operations in its Berlin motorcycle plant.

BMW motorcycles enjoy an outstanding reputation around the world for their reliability, quality, performance and safety. This is not achieved by chance, however. BMW’s motorcycle plant in Berlin uses around 50 machine tools to create numerous key components on-site, from frames and valve shafts to connecting rods and cylinder heads. Among these tools are Grob’s horizontal five-axis G550 machining centers equipped with Sinumerik 840D controllers, which are used in the manufacture of cylinder heads for flat and 4-cylinder engines. Prices are obtained from suppliers at regular intervals, especially when the company is investing in new machining centers. The aim is to ensure that BMW can manufacture its components more cost-effectively than external contractors, while at the same time comparing the prices offered by the various machine suppliers. One of the major reasons for choosing the G550 was because it was equipped with a Siemens CNC.

The horizontal design of the Grob five-axis G550 guarantees the highest levels of rigidity, which keeps axial deviations below 10 µm.

Thanks to previous positive experience with Siemens, the BMW manufacturing specialists in Berlin already employ technology from Europe’s market leader for 90 percent of their controllers. This allows both operators and tool setters the flexibility to work on almost all the machines in the plant. Other key requirements noted in the specification were adequate space for manufacturing all relevant components, the highest levels of precision and surface finish, compliance with pre-defined cycle times, and the ability to reuse all current tools and equipment.

The highest levels of precision on even the hardest material

Before committing to the new investment, the responsible BMW production engineer worked with a colleague from process engineering to investigate the effectiveness of the Grob machines in cylinder head production. Initially, it was the G550’s near-identical sibling, the G350, that was under consideration. As a first traditional single-workplace machine tool, it already met almost all the main criteria, but the space available inside was deemed too small to accommodate all the required processing tasks. However, the G550 satisfied this requirement as well. Among other factors, the horizontal design of this five-axis machine, which has both rotary axes in the work area, contributes significantly to its outstanding rigidity. As a result, axial deviation remains process-compliant at values under 10 µm. The level of precision that can be achieved is correspondingly high, even when processing extremely hard materials, as with valve seat inserts, for example.

The machine also produces a high-quality surface finish, with roughness (Rz) of up to 2 µm. Christian Heiß, applications engineer at Grob, explains a further benefit of the horizontal design: “Tool life can be increased by approximately 30 percent compared with that of vertical machining centers. And the problem of jammed slivers is almost completely eliminated because they are not able to fall onto the workpiece in the first place, but instead fall right through to the ground.”

One of the G550’s strengths is its compact size, at only 3800 mm x 6300 mm. However, despite its size, it still features an extremely long z-axis stroke of 1020 mm, meaning that tools up to 500 mm long can be retracted completely out of the work area and into the so-called spindle tunnel. The swivel-mounted shuttle table is another feature that helps deliver high levels of productivity. While one workpiece is being processed, the next can be clamped and set, thus minimizing costly downtime.

Programmed and set in no time at all
Employees find the new Sinumerik 840D sl CNC especially easy to operate because, in the production of BMW cylinder heads, only Siemens controllers are used. Despite this, the user interface presented on the Grob machines looks completely different from the others. Until now, operators and setters have been used to the DIN-based HMI Advanced user interface, but the new CNC on the G550 features the Sinumerik Operate animated graphical display. Siemens has integrated a new operation and programming structure, with practical functions such as copy and paste that are well known to users from their daily use of PCs. This allowed BMW employees to quickly adapt and master the new Sinumerik user interface in no time at all.

Thanks to its excellent usability and intuitive operation through various technology cycles, measurement cycles, and setting functionality, the new G550 machines can be set up for new batches much more quickly than before. As Heiß explains: “This means our customers are much faster than before. Previously, it might have taken several hours to set up the machine and the workpiece, now it can be done in just a few minutes.”

Highly trained employees and specialist suppliers help BMW motorcycles maintain their excellent reputation for reliability, quality, and safety.

Quick and reliable with remote maintenance
Along with the tools and equipment from the current machines, the German motorcycle manufacturer was able to reuse all its existing programs as well. It took a single employee only two days to upgrade these programs to be compatible with the latest software, which can be loaded onto the relevant machine as required either over the network or from a USB stick. The modern Windows Explorer-style program manager means that complex programs can be managed either on the CF (Compact Flash) card or directly on the CNC.

If problems arise while the machine is operational, BMW production engineer Taner Ögretmen and his colleagues use the network-based remote maintenance functionality provided by Grob. This has rarely been required so far – but when it has, it proved to be extremely smooth and efficient, stresses Ögretmen. Grob can also perform minor optimizations together with Siemens using the teleservice. This is usually done automatically and without any disruption to ongoing production. The Sinumerik-controlled Grob machines have met every expectation in full, which is why BMW has already ordered an additional four G550s.

Programming and operation using Sinumerik Operate

Sinumerik Operate provides several different programming methods to let users program and set the workpieces: ShopMill graphical user interface, programGUIDE for G-code with cycle support, and pure DIN/ISO programming. If the user decides to use ShopMill, he or she receives an animated graphical work-step programming environment for simple dialog programming. The interface is designed to
be clear and self-explanatory, so that even operators with no programming experience can learn the basics in no time at all. To write programs in programGUIDE, the operator will need some knowledge of G-code. The highlights here include new cycle support functionality and animated elements that can be used to represent the cycle graphically. Tooltip support is also provided.

For more information on this story:

SIEMENS INDUSTRY, INC.
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 Communications

On the Road to the Future in CNC Technology with Sinumerik from Siemens

By Bernard and Company Tags: Ad agencies, Bernd Heuchemer, Drive Technologies, Drive Technologies Division, EASTEC, EMO 2013, Integrated Drive Systems, Motion Control, Motion Control Systems Business, Product Lifecyle Management, Rajas Sukthankar, Siemens, Siemens Industry, Siemens Machine Tool Systems, Sinumerik, Sinumerik CNC, Sinumerik Operate, Tim Daro No Comments

Press Conference for the Americas — EMO Hannover / Hall 25, booth D33

More integrated solutions needed in machine tool building
Enhancement of CNC machining productivity and flexibility through a more highly-developed Sinumerik CNC portfolio
Sinumerik and Integrated Drive Systems (IDS): optimum added value through consistent integration across the entire lifecycle
Broad-based CNC competence: Siemens will be demonstrating how productivity, flexibility and safety can be increased in CNC production with an array of smart additions to its Sinumerik portfolio.

Industrial corporations are facing deep-rooted changes in the world of manufacturing. These changes are taking place alongside increasing integration of product development and production processes with the benefit of innovative software systems and high-performance software — a decisive step on the road toward a new industrial age in manufacturing. “Siemens has invested a lot of work in the integration of automation technology along the entire value chain over a period of many years, and is playing a cutting-edge role in shaping the future of production,” stated Bernd Heuchemer, Vice-President, Global Marketing and Communications, Siemens AG, Drive Technologies Division, Motion Control Systems Business, at a press conference held in the run-up to the EMO 2013 recently. “In the Sinumerik environment in particular, and consequently in the field of CNC production in general, Siemens has been heavily involved for many years already in the area of simulation and the virtual machine, as well as the integration into factory IT systems. Our aim is to drive this process of integration forward to ensure that the field of machine tool construction is also prepared to embrace the next step in the industrial revolution,” continued Heuchemer.

With its Sinumerik family, Siemens offers an integral portfolio of CNC for everything from simple machine tools through standardized machine concepts to modular premium solutions, complete with “smart machine” solutions for the economical manufacture of high-end workpieces. It is working towards the consistent expansion of this CNC technology expertise. “In the future, production models will demand ever greater productivity, flexibility and efficiency, while at the same time expecting simplified machine operation and production sequences. As it continues to develop the Sinumerik CNC portfolio, Siemens is working to satisfy all these expectations,” said Rajas Sukthankar, General Manager, Siemens Industry, Inc., Machine Tool Systems Business. The innovations presented by Siemens at the EMO 2013 will consequently focus on smart function improvements, which will make for greater CNC operating convenience, increase precision at the workpiece and allow greater machining safety across every category of machine, from the compact to the high-end solution. A new function to protect against unwanted component collisions will be showcased by Siemens, for example, alongside improvements to its cohesive Sinumerik Operate user interface, including upgraded simulation options.

The integration across the entire product life cycle can in turn be implemented using suitable Product Lifecyle Management (PLM) software solutions from Siemens. This concept is already being implemented by leading metals processing industries such as the automotive, aerospace and medical technology sectors. This entails the increasing execution of product development and production planning onscreen, before a single machine tool has even been installed. If a modular machine is developed on a virtual basis right from the outset so that it can be fully simulated, time savings up to 40 percent can be achieved. In running operation, productivity increases of 10 percent or more are also made possible by continued simulation and optimization. At this year’s EMO, Siemens will be showcasing the further development of its PLM software, which encompasses scalable solutions for component production and further improved IT integration from the workpiece model through to the machine tool. Siemens will also be revealing the next stage in productivity for NC programming with the further development of its already popular PLM software, NX CAM. Going forward, this software will include special industry-specific machining functions as well as access to a new Manufacturing Resource Library.

For more information on Siemens SINUMERIK CNC, visit www.usa.siemens.com/cnc.

For specific product information and inquiries, call (800) 879-8079 ext. Marketing Communications or send an e-mail to: SiemensMTBUMarCom.industry@siemens.com.

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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.

Siemens and Biglia Offer Full Flexibility in New “Quattro” Series of Turning Centers

By Bernard and Company Tags: 1FK 7 G2 series, 1PH8, Ad agencies, Biglia, Drive Technologies, Motion Control, permanent-magnet synchronous motors, Siemens, Siemens Industry, Siemens Machine Tool Systems, Sinamics S120, Sinumerik, SINUMERIK 840D sl, Sinumerik Operate, Tim Daro No Comments

Highlights include two-sided machining and servo drive technology

Recently, Northern Italian machine tool manufacturer Biglia introduced its multi-functional turning centers of the ‘Quattro’ series with the Sinumerik 840D sl CNC. The mechanical concept, together with the scalable control, provides users with the most diverse standard turning and milling operations. The result is increased flexibility and higher speeds for end users. That quality machine tools are built in Northern Italy is nothing new. And this fact is confirmed again by the “Quattro” series from the machine tool manufacturer Biglia. These machines are multifunctional turning centers that are valued throughout Europe for their high reliability and performance power. The machines are available in different versions from 11 to 15 CNC axes. They are also intended for different turning diameters (45, 52, 65, 71 and 80 mm).

Biglia has equipped its turning centers of the ‘Quattro’ series with the Sinumerik 840D sl CNC control. The individual machines have 11 to 15 NC axes.

The two opposing spindles form a special feature of the “Quattro” series. This allows the workpiece to be machined from two sides, which reduces the machining time. The second spindle can also be moved linearly in two directions (lengthwise and crosswise). This provides some leeway in the case of additional milling operations, but it can also be used for automatic workpiece unloading. Two turrets, mounted on the y-axis, ensure proper positioning of the necessary tools.

The turning centers from Biglia have two spindles and two independent tool turrets for simultaneous machining.

This innovative machining technology allows the creation of not only rotary but also prismatic workpieces – including polygons. Dealing with everything in one setup not only reduces cycle times, it also enhances accuracy. The machines are developed on the basis of a modular concept that ensures flexible application options – from the universal CNC lathe, to complete machining of complex workpieces with powered tools (c- and y-axis).

Getting it right, from the start

By offering the Siemens Sinumerik 840D sl CNC control, Biglia now wants to expand its previous options and its own market by combining its technologies with that of the Siemens control. “In this project, which is of personal significance to all of us who worked on it and of strategic significance for Biglia, we wanted to do everything perfect right from the start and to get the most out of it,” says Giovanni Delmondo, Business Development Manager for machine tools with Siemens Italy. The result is an all-round successful machine series with a highly modern control that already includes the innovative system expansions of recent months – including increased energy efficiency options offered by the control and drive systems from Siemens.

To illustrate this, Giovanni Delmondo points out that “the fans on the spindles are shut down automatically when they are not required, or certain services such as hydraulics, lubricant supply, or compressed air are deactivated during machine standstill times. This is handled via special screen forms on the control and is extremely simple, using the Run MyScreens function.”

Also notable is the standard energy efficiency solution from Siemens in the Sinamics S120 drives onboard this machine series. This includes automatic power factor correction or regenerative feedback of the energy generated in braking operations, a substantial factor in energy savings.

Performance and scalability

The Sinumerik 840D sl control is based upon the Sinamics S120 drives platform.

The centerpiece of the automation concept of these Biglia turning centers is the Sinumerik 840D sl control. This is a universal and flexible CNC system, implemented in the Sinamics S120 design (see Fig. 3). It is suitable for up to 31 NC axes. Whether you are turning, drilling, milling, grinding, laser-machining, nibbling or punching, the Sinumerik 840D sl is suitable for use in the most diverse machining technologies. The CNC control also has PLC (programmable logic controller) functionalities, so that a special PLC can be eliminated, if applicable.

This high-end control from Siemens is ideally suited to medium and complex tasks and production and can be adapted to the task, thanks to scalable hardware. The CNC is also characterized by openness, so the operator interface and also the software present few limits to specific job adaptability. This applies all the way to supplementing the NC core of the control; however, a special license is required for this adaptation.

On the Biglia turning centers, the control was equipped with the Sinumerik Operate user interface, making operation simple and intuitive. Three different methods of parts programming are possible: Classic ISO code programming, programming with the help of the integrated ProgramGuide with graphical support of the selected cycles, and the new two-channel ShopTurn with graphical 3D simulation. The user is led step-by-step through the cycles, whether for simple metal removal, drilling, thread cutting, pocket milling, groove milling or engraving. Complex programming cycles for complex contours are also possible. The “ProgramSync” function for automatic synchronization of the machining programs via two channels ensures a significant increase in machine productivity. The control is equipped with a 15″ monitor and integral keyboard.

Siemens CNC in metalcutting applications.

The Quattro series from Biglia also uses the highly effective personnel and machine protection system provided by the Sinumerik control concept with the Sinumerik Safety Integrated package.

Biglia is also breaking new ground with servo drives. Thus, the new servo motor generation 1PH8 from Siemens is used for the main spindle motors in this series. The linear axes are further equipped with the new 1FK 7 G2 series of permanent-magnet synchronous motors. These motor types from Siemens enable onsite replacement of the encoders without having to dismantle the complete motor. This combination of machine and CNC control in the Quattro turning centers from Biglia provides users with greater flexibility.

For more information about Siemens CNC solutions for the machine tool industry, visit our website: www.usa.siemens.com/cnc.

For more information on the this story, contact:

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

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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.

Retrofitting for Success

By Bernard and Company Tags: Ad agencies, Cincinnati U5 Gantry, Major Tool & Machine, MTM, Siemens, Siemens 840D, Siemens CNC platform, Siemens Industry, Siemens Machine Tool Systems, Siemens Tool Management, Sinumerik 840D, SINUMERIK 840D sl, Sinumerik CNC, Sinumerik Operate, Tim Daro No Comments

With the right CNC platform, this large, state-of-the-art job shop has discovered “anything is possible”…

CNC upgrade enhances performance and precision

Major Tool & Machine (MTM) is a large job shop, producing precision milled and turned hardware throughout the company’s 500,000 square foot Indiana facility. Performance is essential, because MTM contracts with aerospace, energy, nuclear and defense companies on many mission-critical, one-off projects. Owner and CEO Steve Weyreter will tell you openly, MTM is more competitive by way of a significant CNC technology change, starting with an aggressive retrofit strategy.

Major Tool & Machine, Inc. retrofitted two of their machining centers in 2010 changing to a CNC technology platform that was completely new to the company. Ten more such large-scale retrofits have followed, bringing increased enthusiasm, momentum and productivity.

Günther Zimmermann, CNC Controls Engineer at MTM, says the company’s retrofit program and the decision to change to the Siemens SINUMERIK CNC platform have brought a new enthusiasm and momentum to the company. Over the last two years the change has also brought significant time and cost reductions, especially in the areas of programming, maintenance engineering, and machine operations.

“The initial goal in early 2010 was to retrofit two Cincinnati U5 Gantry machines,” Zimmermann recounts. “We evaluated two CNC technology platforms and after considerable analysis our CEO Steve Weyreter announced that Siemens would best support the company’s future.”

The decision to reduce costs by moving to a single CNC platform was the least difficult decision for the company to make, Zimmermann explains. The larger challenge for MTM was the integration of a new CNC technology platform that was new to the company.

Bill Henderson, MTM’s manager of large machining and maintenance, agrees that the decision to change to a Siemens CNC platform integrated with advanced part and tool probing was critical, because the shop manages constant changeovers from one complex job to the next, making setup times a critical time/cost constraint for the company. Another big advantage is the increased flexibility by only having to train machinists and maintenance personnel on one type of control.

Henderson went on to say “the decision to change to a new control has signaled higher expectations for the company, along with new challenges for those who program, operate and maintain the company’s big machines.

Naturally, there’s a resistance to change,” Henderson says. “People are comfortable with what they normally run, but after our discussions with the people on the plant floor, they understood the overall objective. Our retrofit program is not finished, yet it’s already showing tremendous benefits.”

Heads-up interchangeability

An advantage MTM gained by its retrofit strategy has been the ability to interchange heads and rotary tables from machine to machine. Easy-to-use head storage and tool management programming provided by the Siemens CNC platform support the new interchange capability.

Retrofitter Doug Huber says having Siemens as a new CNC technology partner has made a difference for Major Tool & Machine, but it’s also been an evolutionary uplift for his own retrofitting company, Indiana Automation.

“Indiana Automation has increasingly retrofit using Siemens controls in recent years, Huber explains. “On a retrofit, we always try to exceed what the original machine could do, and that’s just kind of inherent when you put on a Siemens 840D. Major Tool’s first retrofits were the Cincinnati U5 machines, a bridge model and two gantry models. These are five-axis machines and five-axis is the 840D’s forte. The processing power of the control is so much better, that it just whips through the blocks faster. So right off, cycle time is a major performance enhancement.”

Huber says something else happened this time. As his firm finished retrofitting the first three giant machines with Siemens five-axis controls, drives and motors, the reaction within the company was not just that the machines were now predictably more efficient, but that they performed as very different machines. A new advantage is the ability to interchange machining heads from machine-to-machine, and all driven by the Siemens CNC platform.

“On many of the U5 machines, the axes come off with the heads,” Huber explains, “and we rebuilt these machines to accept any one of three different heads. That’s one of Major Tool’s key strategies. They insist on having flexible machine capabilities, so that they can run all kinds of different parts. They have straight heads for serious metal cutting, contour heads for five-axis work and finesse work. They have 90-degree heads for more flexibility than a straight head, but it’s also not as fragile as the contour head. And they wanted to interchange all of these heads to automatically go pick up a head out of the shuttle and, on the fly, reconfigure the axes and the zero positions. To do this, the compensation tables all had to be updated. Everything needed to be done with the macro program so that each head came on ready to run.”

The interchangeable head strategy was a challenge, Huber says, because the machines were not originally capable of sharing heads. But with support from Siemens, the strategy has worked, including the ability to interchange rotary tables as well as heads. “Each head or rotary table has a configuration file that has all the settings and compensations and travels with it from machine to machine. So now when you mount that head the control just runs the configuration file that goes with it and its all set up for you. We also incorporated Siemens Tool Management for each machine’s 60-pocket tool chain. We used the feature on these machines to manage all the different tooling MTM uses, both in the automatic tool changer as well as the ones manually loaded.”

Huber says, “MTM’s ability to smoothly transition to more advanced CNC is largely due to the HMI’s ease of use. The Operate interface is a huge help to us and to Major Tool. The HMI helps make better parts. And it didn’t take very long for the operators to fall in love with it.”

Leveraging the machinist’s skills

Central to MTM’s retrofit program has been the Siemens SINUMERIK 840D sl control, which features the SINUMERIK Operate interface. The highly intuitive interface enables both programmers and operators to easily capitalize on the broad capabilities of the control.

“I had never used a Siemens control before,” admits MTM machinist Mike Burthay. “I have extensive knowledge of G-code and CNC controls and I would say the Siemens 840D sl with the Operate interface is the easiest one I’ve ever run. It’s user friendly, that’s exactly the words for it.”

Burthay reports several ways in which the Siemens SINUMERIK Operate interface has made his life easier. “There’s not as much G-code,” he says. “The control does it all for you as long as you put in the parameters as to size, length, width. Then once you’re in Job Mode, there’s a screen where you can tool change or jog the machine around to certain positions, or turn the spindle on, turn the coolant on, anything that traditionally required G-code. So now you can push a cycle stop button to pause the machine, enter a change such as turning coolant on, then restart the program.

Programming as easy as 1-2-3: Using the SINUMERIK Operate interface, a machinist can turn on coolant flow by 1) pressing Cycle Stop to stop the machine, 2) Coolant On, and 3) Restart.

“Another function I love is Block Search, which allows me to start or restart right in the middle of a program. Say you’re finishing a pocket and you have to run the tool two or three times to get a tight tolerance, I can enter in a line number and hit Block Search, the control picks up every line before that, restarts the spindle and everything for you.”

Burthay says the Siemens control also enables him to program parts right on the machine whenever necessary, using a simple yet robust program called ShopMill. “I can go into ShopMill, type in some parameters and it will kick out that G-code program for me automatically. Say I want to drill a hole two inches deep. I open ShopMill, pick my tool, tell it the depth and these steps are all interactive on the screen. It even shows me 3D motion images of the tool path, confirms the drill going down as expected into the part. So I hit go and it puts a drill cycle into the program for me.”

Programmed for collaborative growth

Lead Programmer, Tim Hayden, has from the beginning conducted all processor setups for the newly retrofitted machines. Hayden says integrating the Siemens CNC platform has been an empowering experience he had not expected, given the fact that he had never before set up a post processor to run a Siemens control, nor had he ever before operated a Siemens control.

“Now, when I look at the Siemens control, I think man, it would have been so much better to have had it all along,” Hayden says, “because the other control I’ve been using is just a lot more cryptic. The Siemens control with the SINUMERIK Operate interface is more powerful for writing macros and the language seems modern, whereas the other control seems like it is still based on an old FORTRAN type language.”

Work offsets for compound angles can be scaled and rotated using the Frames function of the Siemens SINUMERIK Operate interface. Many advanced machining operations can be managed simply, without the use of time-intensive manual G-code programming.

Hayden points to the Frames coordinate and offset programming function of the Siemens interface as an example of improved programming convenience.

“We do a lot of work on compound angles,” Hayden explains, “and with the Siemens Frames function, you can scale and rotate your coordinate system on the control, just plug it in with your work offsets. Whereas, on the other control you will see a G54 request, you’ve got to enter G-code. You can’t just plug it into your work offsets like you can with the Siemens control.”

Hayden says the SINUMERIK Operate interface brings greater programming flexibility. The HMI enables him to enter G-code using a comparatively more advanced manual data entry (MDI) function; however the HMI has all but eliminated the need for G-code entry by way of its intuitive design and evolved capabilities.

Another example of such HMI evolution is in the area of data management.

“When we post a program, we no longer have to use a G-code based MDI,” Hayden explains. “We no longer need to type in T= and enter a nine digit number and then enter M6 to make a tool change. With the Operate HMI, you pick your tool off a screen and hit cycle start. It’s just as easy to program going to a position. Instead of doing things the old way by typing G0X0Y0Z0 into the MDI, you open the Operate interface, click position, then click how you want to wrap it and then you just type the numbers into those fields. So it’s a lot more user friendly.”

Hayden says the Siemens CNC platform has supported greater collaboration at MTM between him and the machinists, and this is helping the company find ways to increase performance and efficiency. He agrees with his coworkers’ assessments that shorter setup times and greater operator freedom are making a significant difference.

“One of our production bottlenecks has been programming,” Hayden says. “The machinists that run our machines are professionals, they’re not button pushers, and with the SINUMERIK Operate interface, we can now rely on them to control and program certain parts right on their machines, while we programmers work on the more complex projects.”

“Siemens was the best fit for all of us,” Hayden concludes. “Siemens CNC is set up as an open control, and with that kind of flexibility, it seems anything is possible.”

See Siemens CNC at Major Tool & Machine in action HERE!

For more information, contact:

SIEMENS INDUSTRY, INC.
MOTION CONTROL
MACHINE TOOL BUSINESS
John Meyer
Manager, Marketing Communications
Siemens Industry, Inc.
(800) 879-8079 ext. Marketing Communications
www.usa.siemens.com/cnc
SiemensMTBUMarCom.industry@siemens.com

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