Unrestricted Siemens AG 2017

Transcription

1 Presentation date: Presenter Name: Manfred Moritz Jasper Sanders Room name: Estrel Hall Presentation Title: Added value of a Digital Twin - realized for Georg Ultraturn 4000MC by leveraging NX-VNCK and Sinumerik

2 Added value of a Digital Twin Seamless process safety realized for a Georg UT4000MC leveraged by a machine simulation with NX Virtual Machine based on Sinumerik VNCK

3 Agenda Dynamowerk Berlin Georg Mill-Turn machining center NX-CAM NC-Simulation Sinumerik VNCK NX-VNCK (development, implementation, engineering) About the Project VNCK HMI & other benefits Open topics Future business model Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

4 Siemens Dynamowerk Berlin Page 4 Founded 1906 Employees ca. 750 Production area m² Office area m² Production ca. 200 Machines/Year Export quote 96% Business assignment: Custom-built Machines in big and biggest power range in the complete engine-speed range, up to 100 MW and up to rpm Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

5 We develop custom-built engines for different industry branches Oil & Gas Energy Shipbuilding Mining Metal Industry Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

6 Part manufacturing processes of Mill-Turn parts in the Dynamowerk Lathe roughing Setup 1 Lathe rouhging Setup 2 Milling Setup 3 Milling Setup 4 Milling Setup n Lathe finish Setup n+1 Lathe finish Setup n+2 Lathe grinding Setup Setup 1: lathe roughing, milling, lathe finish Setup 2: lathe finish, milling, grinding Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

7 Agenda Dynamowerk Berlin Georg Mill-Turn machining center NX-CAM NC-Simulation Sinumerik VNCK NX-VNCK (development, implementation, engineering) About the Project VNCK HMI & other benefits Open topics Future business model Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

8 6 axis heavy duty machining center that combines milling, turning, grinding and measuring in one setup: GEORG Realization: Procurement of a combined Mill- Turn CNC machining center: technologically unique maximum effectiveness maximum flexibility complete housing max. health & safety standard / Zero Harm Manufacturing of a rotor in one Setup using all technologies Turning / Lathe Milling Grinding Measuring Reduction of manufacturing time Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

9 Georg ultraturn 4000 MC Maximum component load Peak width ca mm Peak height ca mm Max. outer diameter 4.000mm Max. comp. weight in face plate 10t Max. comp. weight in center peaks 75t Max. comp. weight in two steady rests 180t Programmed in Siemens NX-CAM Simulation with Siemens NX-VCNK Usage of Simotion, Sinumerik and Sinamics components Connected via Sinumerik Integrate Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

10 Agenda Dynamowerk Berlin Georg Mill-Turn machining center NX-CAM NC-Simulation Sinumerik VNCK NX-VNCK (development, implementation, engineering) About the Project VNCK HMI & other benefits Open topics Future business model Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

11 Simulation technologies in NX-CAM Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

12 Simulation technologies in NX-CAM Toolpath verification Toolpath verification with material removal Toolpath verification with machine kinematic Toolpath movements Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

13 Simulation technologies in NX-CAM NC-Code of Postprocessor Simulation of the on-the-fly created NC-Codes Interpretation of the NC-Codes by - Controller Emulation (CSE) or by - original Controller Kernel (VNCK) Movement of the machine kinematics Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

14 Simulation technologies in NX-CAM Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

15 Comparison of Simulation-Technologies Simulation before Postprozessor + available at an early point + no machine definition needed - kinematic conditions can not be simulated - errors from the postprocessor can not be evaluated - no simulation of free NC-Code Simulation based on controller emulation + one platform for many different machines + controller types that do not provide a virtual controller can be simulated - emulated controller are very often insufficent to simulate complex machining center Simulation based on virtual machine + contains the full functionality of the controller + handling and look&feel are identical to the real machine - performance is usually lower than with controller emulation (Cf. Volkwein G., 2006, Konzept zur effizienten Bereitstellung von Steuerungsfunktionalität für die NC-Simulation, page 16) Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

16 Agenda Dynamowerk Berlin Georg Mill-Turn machining center NX-CAM NC-Simulation Sinumerik VNCK NX-VNCK (development, implementation, engineering) About the Project VNCK HMI & other benefits Open topics Future business model Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

17 SINUMERIK VNCK SINUMERIK Operate or HMI Advanced HMI Service VNCK API Application Digital Twin of Sinumerik 840D CNC Controller NCU Link multichannel technology/special functions as compilecycle Siemens-, OEM- and User-Cycles complete 840D language all movements (spline, polygone) all kinematic transformations original transformation algorithms measuring, travel to fixed stop Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

18 NX Virtual Machine SINUMERIK Operate or HMI Advanced HMI Service Run MyVNCK Interface (NX32407) NX CAM Create MyVNCK NX Machinekit (machine specific dataset) Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

19 Agenda Dynamowerk Berlin Georg Mill-Turn machining center NX-CAM NC-Simulation Sinumerik VNCK NX-VNCK (development, implementation, engineering) About the Project VNCK HMI & other benefits Open topics Future business model Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

20 Setting up the NX Virtual Machine Import and prepare 3D Model Create Kinematic Model (MTB) Create VNCK Driver (SRAM- File) Subsitute non-nck functions (ACL Programs & MCF File) Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

21 Creating a VNCK Driver SINUMERIK NC Archive Create MyVNCK VNCK Dataset (SRAM-File) Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

22 How to get it? Siemens PLM Software OEM Channel Machine User VNCK Support Center Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

23 Agenda Dynamowerk Berlin Georg Mill-Turn machining center NX-CAM NC-Simulation About the Project VNCK HMI & other Benefits Sinumerik VNCK NX-VNCK (development, implementation, engineering) RobX Open Topics NX Virtual Machine Business Model Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

24 Georg VNCK project goals NC Simulation that is topmost precise and as close to reality as possible to ensure process safety by collision free NC-Programs Development of a NC machine simulation in NX, based on Sinumerik VNCK Pilot project to evaluate the engineering effort of a NX-VNCK for a complex machining center Cooperative development together with Siemens PLM and the VNCK Support Center, supported by the machine manufacturer Heinrich Georg GmbH and the Dynamowerk Completion of the CAM-CNC process chain from programming to the machine Support of the lighthouse project for Siemens Large Drives division to fit out this high end machine with the most advanced Siemens products on the market Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

25 Work packages in the Georg VNCK Project Work package 1: Simplify machine geometries for simulation purposes Work package 2: Creation of the machine kinematics and additional adjustments of the machine geometry assembly Work package 3: Implementation of the new machine and its devices in NX-CAM and installation of NX-VNCK in NX Work package 4: Development of PLC replacement programs in ACL and in the machine archive Work package 5: Adjustments of the simulation_ini.tcl Work package 6: Creation of the first tool load into NX native library Work package 7: Manufacturing time evaluation of PLC auxillary process times Work package 8: Problems/Workarounds: C-Axis & SPM-Axis Spindel SPM2 in different head devices VNCK bug in the drive assignments Idleness survey (Stillstandsüberwachung) Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

26 NX-VNCK Georg UltraTurn 4000 MC Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

27 Agenda Dynamowerk Berlin Georg Mill-Turn machining center NX-CAM NC-Simulation Sinumerik VNCK NX-VNCK (development, implementation, engineering) About the Project VNCK HMI & other benefits Open topics Future business model Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

28 VNCK HMI & other Benefits HMI with the original look and feel of the real machine Exact simulation of all available manufacturing technologies of the machining center (e.g. grinding, measurement cycles, measurement equipment, etc.) Same program errors as on the machine (e.g. syntax errors, missing tool correction, circle endpoint errors, wrong cycle parameters, etc.) Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

29 VNCK HMI & other Benefits Block search with calculation (equal to the original machine!) Simulation in Dry Run possible means simulation in rapid movement speed = fast simulation with same error detection but no time calculation Calculation of machining time at a quality of >98% except of PLC times, they are missing! Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

30 VNCK HMI & other Benefits Postprocessor development and bugfixing in the Simulation without on machine time / secondary times NC-Code is editable in the HMI (e.g. development and test purposes, placement of stop points (M0)) Retranslation of cycles like on the real machine Development and testing of NC user functions Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

31 Agenda Dynamowerk Berlin Georg Mill-Turn machining center NX-CAM NC-Simulation Sinumerik VNCK NX-VNCK (development, implementation, engineering) About the Project VNCK HMI & other benefits Open topics Future business model Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

32 Open Topics Head-Spindle Issue Real Machine Virtual Machine One Spindle + mechanical coupling with tool Several spindles + Spindle coupling inside VNCK Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

33 Open Topics Turning Toolpath issue Toolpath is fixed to workpiece (needed for milling) NX CAM is getting actual values for angle of the turning spindle Updating the Toolpath between operations results in shifting it out of the turning plane. Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

34 Open topics VNCK and ROBX VNCK Compile Cycle Support Full support of robots controlled by 840D Controllers, including robotic machining. Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

35 Further Open Topics Performance - Unattended Simulation - 3D quality (applying to the Workpiece dimensions of the Dynamowerk) - PLC auxiliary process times Collision detection of NX-CAM turning module (fixed with NX12?) VNCK Drive Configuration Issue Since NX11 the Driver-File is copied to the Part-Folder Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

36 Future Topics Physical influence on the workpiece - Calculate the deflection by workpiece weight - Calculate the right pressure to compensate deflection (e.g. with steady rests and tailstock) - Calculate thermic influence due to material removal - Calculate effect of thermal energy on tool (e.g. tool wear) Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

37 Agenda Dynamowerk Berlin Georg Mill-Turn machining center NX-CAM NC-Simulation Sinumerik VNCK NX-VNCK (development, implementation, engineering) About the Project VNCK HMI & other benefits Open topics Future business model Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

38 NX Virtual Machine Business Model Siemens PLM Software OEM Channel Direct Channel Machine User VNCK Support Center as proven in 15 other pilot projects! Page Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)

39 Manfred Moritz Siemens AG PD LD AP DW FP IE NC Nonnendammallee Berlin Jasper Sanders Siemens AG RC-DE PD CSO 1 SD3 1 Franz-Geuer-Straße Köln manfred.moritz@siemens.com jasper.sanders@siemens.com siemens.com