CNC has become one of the leading production interfaces

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The operating comfort is comparable to that of a modern PC. Graphically animated pictorial elements explain important operating steps and the obscure details of the ISO and cycle programming. CNC and machine functions, which would otherwise only be accessible after an in-depth initial training, can be used intuitively in Sinumerik Operate by a skilled operator. This is one of the reasons why this system software has so quickly become established as a benchmark among the HMIs for machine tools.

A unified operating philosophy of this kind, applicable across all production technologies and machine types, simplifies enormously for operators the changing from machine to machine. It helps to avoid errors and reduces basic training work. And the advantages go much further: an unified look-and-feel in all individual technologies enables sensible integration of a number of clamping technologies in one machine, making multi-tasking machines possible. The latter save floor space, make production flexible and rational, and eliminate many re-clamping procedures. Not only does this save time and effort, but it also favours high production precision.

Multi-tasking machines have thus become a key trend in manufacturing industry. How well this high-performance concept can be exploited in practice, however, depends critically on simple access to machine functionality via the CNC.

The technological and operational functions of the Sinumerik Operate operator interface are, moreover, continuously being expanded, providing an optimum supply of information available in the CNC to the operator and the production process. Most recently, for example, the performance potential and user-friendliness in high-speed cutting was improved further.

Collision avoidance and extended retraction function

Collisions in the machine working space can cause severe damage. Although the technical preconditions for constant and effective collision monitoring in real time for all cutting procedures are not yet available, it has been possible for a long time now to reliably prevent collisions between tool and workpiece in the course of program-controlled machining. These are provided by, for example, off-line functions within the NX-CAM process chain available for Sinumerik.

The greatest need for avoiding collision-related damage is when the operator intervenes in the process, i.e., during program interruptions and adjustment procedures: because of the concentration on workpiece and cutting edge, it is easy to fail to notice, for example, that pivoting table and spindle are on a collision course. The new Sinumerik function Collision Avoidance prevents costly damage, repairs and down-times in such situations. Static and dynamic machine components, and also tool cutting-edges, are monitored effectively by the CNC regarding collision avoidance – even in complex technologies such as 5-axis simultaneous milling or turning with the B axis. Even on the screen, the collision risk can be recognised early using 3D visualisation.

A new extended retraction function can be used to allow the operator to retract the axes in a machine securely brought to rest after a power loss. Both the tool and workpiece emerge undamaged, and the processing can be continued at the point of interruption immediately after a block search. The end result is that the resulting costs and delays due to the interruption of work are reduced to a minimum.

Industry 4.0: a needs-related, scalable interface to IT

The central element in Industry 4.0 is the networking of mechanical and electronic systems at data level. In manufacturing firms with cutting-edge IT, machine tools are already being networked intensively as intelligent systems. Important end-customers have thus availed themselves of considerable rationalisation potential – e.g., in automobile construction. The typical aims of such IT integration are also interesting, however, for small and medium-sized firms: better machine utilisation, faster production initiation, production-related design, stress-dependent preventive maintenance, machine-pool-wide tool management, automated assignment of production instructions along with supply of part programs and tool data, calculation and optimisation of the energy piece-costs – all these are topics relevant to future-oriented and sustainable manufacturing management.

Yet high initial costs for connecting the machines to the IT world and the lack of extendability in entry-level solutions have until now represented a major hurdle on the way to IT integration.

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