A grinding machine controller with enhanced process monitoring integration John Moruzzi GERI / AMTReL A grinding machine controller with enhanced process.
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A grinding machine controller with enhanced process monitoring integration
John MoruzziGERI / AMTReL
A grinding machine controller with enhanced process monitoring integration
M. N. Morgan, X. Chen, D.R. Allanson
A grinding machine controller with enhanced process monitoring integration
AMTReL 1300X Grinding Machine
• Universal grinding machine• External and Internal wheelheads• SAMM control (Servo Assisted Manual Machine)• Prototype machine based on Format 15 model• Built circa 1994, modified 2001• Closed control system – Industrial PC / MS-DOS
LJMU: M/C and Initial Control Arrangement
Aims of the project
The objectives are to:
•Replace old ‘closed’ CNC control – new PC hardware•New simplified operator panel•Touch screen operation•Implement existing cycles for External grinding•Enhance cycle programming and machine setup•Interface and integrate external process control equipment•Demonstrate optimised cycle
•Modern software design and implementation•Expandable for intelligent and adaptive grinding features
A Low-Cost, Expandable, Open-Architecture Grinding Machine Control System
New System Components
A grinding machine controller with enhanced process monitoring integration
Control system modifications:
•Industrial rack PC •Workhead servo drive•Motion control card•Touchscreen monitor•Console switches / lamps•Cabling / connectors•Process control unit
Quality, Efficiency and Safety Issues
A grinding machine controller with enhanced process monitoring integration
Quality Issues Efficiency Issues Safety IssuesSize tolerance Air grinding time before machining Wheel collision
Surface roughness Dwell time after machining Wheel failure
Roundness Incorrect wheel dressing intervals Wheel overspeed
Burning Material removal during dressing
Spindle wear Damaged dressing tool
In practice the physical variability of the grinding process, such as wheel wear, machine deflections, wheel vibrations and temperature variations mean that adjustments to the grinding parameters need to be made in order to improve the quality of the finished part .
Auxiliary process monitoring equipment will help operators and machine controls to identify, optimise and correct key machining issues.
Improving the grinding process
A grinding machine controller with enhanced process monitoring integration
In machining, and particularly grinding, it is desirable to have a control system that can integrate and adopt the latest Process Control and Monitoring equipment, and implement enhanced production cycles.
Grinding optimization technologies include wheel balancing, in-process gauging, touch detection (power and acoustic emission) and other sensor-based strategies.
A selection of such features may be included in higher-end grinding machines in response to specific requirements, however this involves significant customisation and application engineering from the machine builder.
It has proved to be impractical or uneconomic to apply the benefits of this technology to simpler, cheaper grinding machines, despite the fact that low-cost process control equipment is becoming increasingly available.
Monitoring of the grinding process
A grinding machine controller with enhanced process monitoring integration
As various programmed conditions are met during machining, appropriate signals and visual indications are set by the device. The operator or machine control will then respond to this information according to a defined strategy.
Auxiliary Process Monitoring equipment is generally a stand-alone unit, connected to the machine control via a wiring or communications interface. The operator will set the device operating parameters and monitor its behaviour via a control panel.
Key monitoring and control features are:
• Wheel Balancing (vibration sensing / correction)• Touch Detection (Acoustic Emission or Power sensing)• Gauging (Size / Position measurement)
The enhanced system design implements a simpler integration of process monitoring equipment with the machine control system.
Main equipment suppliers
A grinding machine controller with enhanced process monitoring integration
• Lack of standardisation between CNC and equipment manufacturers• Different interfacing hardware and strategies for Process Control equipment. • Different levels of functionality / complexity
CNC
Fanuc
Mitsubishi
Siemens
Heidenhain
Fagor
Num
OEM / Custom
….
Gauge
Marposs
Movomatic
Balance Systems
Control Gauging
Touch
Dittel
Movomatic
Balance Systems
Marposs
Balance
Balance Systems
Schmitt
Dittel
Marposs
MPM
Elaso
Challenges leading to the development of a generic type interface:
A grinding machine controller with enhanced process monitoring integration
Key Control System Elements
The main features of a machine tool control system are:
Operator HMI panel
Operator input and control
features
Axis control and position
measurement
Additional measurement
and control equipment
Computer processing unit with setup and
program storageOperator
program and status display
featuresMachine <=> Control
signal interfacing
Many of these elements can be treated as interconnected devices or packages that compose the complete system.
Interfacing of System Equipment
A grinding machine controller with enhanced process monitoring integration
System devices are interconnected to transmit and exchange:
• Control signals• Status signals• Process data• Configuration data
N.B. There is a wide variety of communications and signalling hardware and protocols.
CNC IO modules
CNC main module
Process Monitoring unit
PC unit
RS232
Digital IO
Ethernet
ProfibusDigital IO
Bus
Bus
CNC axis drives
Digital IO
Bus
Analog
Ethernet
New Control Objectives and Innovation
A grinding machine controller with enhanced process monitoring integration
An innovative new software design strategy has been designed to directly address the issue of improved process control integration.
The aim is to unify the design and implementation of key machine tool features such as hardware configuration parameters, operational parameters, process variables and machining cycles into a rationalized, extendable, Object-Oriented framework suitable for implementation using current PC hardware and software.
In order to implement such a framework it is necessary to identify and specify the key features and requirements of the new system:
The main items for consideration are:• Cycles and Part programs (Grinding, Dressing, Balancing)• Hardware features (Connectors,Interfaces)• Communication features (Protocols, data structures)• Operational features (Functions, signals, data)• Software features (Configuration, displays)
Open Control Systems: the idea
• Commercial or Industry standard hardware (increasingly moving in this direction)
• Modular software structures (now common practice)
• Well defined software interfaces - standardised
• Vendor-neutral architectures and application modules
• Flexible and reconfigurable , adaptable to new technologies and processes
• Layered approach to structure hides hardware-specific features
A grinding machine controller with enhanced process monitoring integration
The new system builds on the Open Control Systems concept, originating in the 1990s for Machine Tool Control applications:
Key interactions with Devices
A grinding machine controller with enhanced process monitoring integration
Main actions :
• Device configuration
• Device operation
• Device monitoring
Main data:
• Control, status and alarm signals
• Process signal values
• Device parameters
What we need our control system to do…
John Moruzzi:Open Device Interface (ODI) framework
Level 5 : User program (application)
Level 0 = Low level (hardware) API libraries
4 levels of OPI Software Classes / Objects:
Level 4 : Application Object LayerObject Instances: Actual data items e.g. actual devices (e.g. MyGauge)
Level 3 : Data Presentation LayerDerived Classes: More specialised device class (e.g. VM9TD)
Level 2 : Session Management Layer Base Classes: Basic definitions to be enhanced (e.g. TDevice TParam)
Level 1 : Data Transport LayerAPI routines: Libraries for access to specific hardware (e.g RS232)
A newly proposed Object-Oriented design that enables the structuring of Device software classes (Base and Derived) to provide a standardised top-level programming interface with abstracted levels of specific functionality at the lower levels.
A grinding machine controller with enhanced process monitoring integration
Example ODI device implementation
A grinding machine controller with enhanced process monitoring integration
Level 4:Application Object
Object Instances
Level 3:Data Presentation
Derived Classes
Level 2:Session Management
Base classes
Level 1:Data Transport
API routines
TouchDetectorUnit_1 TVM9_TD_Device TDevice
TouchDetectorUnit_2 TVM20_TD_Device
GaugeUnit TVM9_GA_Device
BalancerUnit TVM9_BA_Device
TDIOInterface TInterface
DigitalIO(1) TDV004_DIO_Device Deva.get_digital_inputw
DigitalIO(2) TBB48D_DIO_Device BB.write_output_port(B)
VM9Unit.Serial TSerial_Interface Win.Com1.Output = ..VM20Unit.Profibus TProfibus_Interface DevInitBoard()
TouchCycle1.Active TSignalState TProcessSignal
AE.Channel(1).Value TDataValue TProcessData
AE.Channel(1).Gain TParameterValue
GapCycle.State TGapElim_Cycle TProcessCycle
GaugeCycle2.State TGauge_Cycle
AutoBalanceCycle.State TAutoBalance_Cycle
This diagram indicates the levels of Abstraction and Inheritance in Classes using the Object-Oriented Approach :
A grinding machine controller with enhanced process monitoring integration
Example Device Class : BS VM20–TD
Config Data (Acyclic)Report device details
Command data (Cyclic)Turn features On /Off etc
Status data (Cyclic)Reporting of device events
Monitor Data (Cyclic)Live device signal values
Parameter Data (Acyclic)Read / Write setup info
Signal Data (Cyclic)Digital Inputs / Outputs
Key data structures and operations of a typical device:
A grinding machine controller with enhanced process monitoring integration
VM20 TD – Parameter & Config data
Parameter Data :
Device <=> ControlConfig Parameters(Gain,Filter,…)
Working Parameters(Limits,…)
Parameter Item:Device <=> Control Accessed from Address on Page in Device memory.
Command sent to Request or Update parameter data
A grinding machine controller with enhanced process monitoring integration
VM20 TD – Monitor & Control data
Monitor Data :Device => Control
Process data valuesSelectable content: AE1 & AE2 AE1 & PWR1 …….
Control Data :Control => Device
Activate featuresSelect programStart / Reset Cycle
Summary of studied ODI devices
A grinding machine controller with enhanced process monitoring integration
Devices implemented:
Jones & Shipman 1300X Operator Panel (RS232)Balance Systems VM9TD Touch Detector Unit (RS232)Balance Systems VM20SYS System Rack (Profibus)Balance Systems VM20BA Balancer Card (Profibus)Balance Systems VM20TD Touch Detector Card (Profibus)Balance Systems VM20GA Gauge Card (Profibus)
Devices studied:
Deva004 Motion Control (Digital IO)Fanuc CNC CNC Interface (Ethernet / FWLIB)
Heatmiser UH1 Building Heating Control (RS485 / TCPIP)
Applications of the ODI Library
A grinding machine controller with enhanced process monitoring integration
Overall software and hardware structure:(and its uses beyond this application)
ODI Device Library
TDeva_004TVM9_TDTVM9_BA
TVM20_TDTDTLM5000_BA
…..T1300X_Panel
THM_UH1Control
BS VM9BA
BS VM9TD
BS VM20SYSBS VM20BABS VM20TD
Dittel M5000 MA
J&S 1300X Panel
Dittel AE4000
CNC Program(Machine control)
e.g. J&S 1300X
Monitor Program
IGAIGPS
HeatMiser UH1
Deva 004
User Application Virtual Device Actual Device
The IGA application example
A grinding machine controller with enhanced process monitoring integration
The IGA (Intelligent Grinding Assistant) was developed previously at AMTReL as an external PC program that interfaced between the Fanuc CNC of the Jones & Shipman Ultramat grinder and its installed VM20 Balancer, Touch Detection and Gauging Unit.
It was able to demonstrate Adaptive Control of the grinding cycle parameters, by monitoring live process data values (e.g. spindle power, wheel acoustic emission) at various points in the cycle, and performing analysis and calculations on the data.
Quantities such as the system Time Constant τ can be calculated from the power signal (least mean squares method) during the initial contact or dwell phases of the grinding cycle.
The Time Constant can be used to adapt the wheel infeed rate parameter or the sparkout dwell time parameter.
IGA implementation with ODI
A grinding machine controller with enhanced process monitoring integration
IGA ProgramBS VM20SYSBS VM20BABS VM20TDBS VM20GA
J&S Fanuc CNC
EthernetLink
ProfibusLink
Cycle parametersCycle phaseCycle commands Balancer Data
Touch / Power dataGauge data
Config parametersSystem Status data
Programmed cycle parametersOptimised cycle parameters
Time Constant ModelBurn Model
Grinding Database
ODI device libraryUltramat Machine
The existing IGA program was studied and adapted to work with the ODI implementation of the external system devices.
Summary
A grinding machine controller with enhanced process monitoring integration
• A revised and modernised Control System package for a grinding machine has been specified, designed and developed.
• An Open Device Interface (ODI) to facilitate the integration of various Grinding process Control and Monitoring devices has been designed and demonstrated.
• The Object Oriented Framework allows a common access strategy for different makes and models of equipment (a generalised Device Object) by using layers of hardware and software abstraction.
• Application software can now interact with different Devices much more easily, and Harmonised user interface allows the operator to work with different devices easily.
• Different communications methods between devices are supported
• The concept is extendable for the control of other Device types such as Motion / Axis Controllers or even Building heating controllers.
End of Presentation
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A grinding machine controller with enhanced process monitoring integration
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