presentation date: 2017-10-25 jasper sanders room name ... · pdf fileücomplete 840d...
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Unrestricted © Siemens AG 2017
Presentation date: 2017-10-25Presenter Name: Manfred Moritz
Jasper SandersRoom name: Estrel HallPresentation Title: Added value of a Digital Twin - realized for Georg Ultraturn 4000MC by
leveraging NX-VNCK and Sinumerik
Unrestricted © Siemens AG 2017
Added value of a Digital TwinSeamless process safety realized for a Georg UT4000MCleveraged by a machine simulation with NX VirtualMachine based on Sinumerik VNCK
Unrestricted © Siemens AG 2017
• 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
Agenda
Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)23.10.2017Page 3
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Founded 1906Employees ca. 750Production area 49.000 m²Office area 5.200 m²Production ca. 200 Machines/YearExport quote 96%
Siemens Dynamowerk Berlin
Page 4
Business assignment:Custom-built Machines in big and biggestpower range in the complete engine-speedrange, up to 100 MW and up to 15.000 rpm.
23.10.2017 Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)
Unrestricted © Siemens AG 2017
We develop custom-built engines for different industrybranches
Page 5
Oil & Gas Energy
MetalIndustry
ShipbuildingMining
23.10.2017 Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)
Unrestricted © Siemens AG 2017
Part manufacturing processes of Mill-Turn parts in theDynamowerk
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 6 23.10.2017 Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)
Unrestricted © Siemens AG 2017
• 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
Agenda
Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)23.10.2017Page 7
Unrestricted © Siemens AG 2017
Realization:
• Procurement of a combined Mill-Turn CNC machining center:ü technologically uniqueü maximum effectivenessü maximum flexibilityü complete housingà max. health & safetystandard / Zero Harm
• Manufacturing of a rotor in „one“Setup using all technologies
• Turning / Lathe• Milling• Grinding• Measuringà Reduction of manufacturing time
6 axis heavy duty machining center that combines milling,turning, grinding and measuring in one setup: „GEORG“
Page 8 23.10.2017 Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)
Unrestricted © Siemens AG 2017
Maximum component load
§ Peak width ca. 11.000mm§ Peak height ca. 2.100mm§ 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
Georg ultraturn 4000 MC
Page 9
Ø Programmed in Siemens NX-CAMØ Simulation with Siemens NX-VCNKØ Usage of Simotion, Sinumerik and Sinamics
componentsØ Connected via Sinumerik Integrate
23.10.2017 Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)
Unrestricted © Siemens AG 2017
• 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
Agenda
Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)23.10.2017Page 10
Unrestricted © Siemens AG 2017
Simulation technologies in NX-CAM
Page 11 23.10.2017 Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)
Unrestricted © Siemens AG 2017
Simulation technologies in NX-CAM
• Toolpath verification • Toolpath verificationwith material removal
• Toolpath verificationwith machine kinematic
Toolpath movements
23.10.2017Page 12 Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)
Unrestricted © Siemens AG 2017
Simulation technologies in NX-CAM
§ 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
NC-Code ofPostprocessor
23.10.2017Page 13 Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)
Unrestricted © Siemens AG 2017
Simulation technologies in NX-CAM
23.10.2017Page 14 Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)
Unrestricted © Siemens AG 2017
Comparison of Simulation-Technologies
Simulation“before Postprozessor“
Simulation based oncontroller emulation
Simulation based onvirtual machine
+ 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
+ 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
+ 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)
23.10.2017Page 15 Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)
Unrestricted © Siemens AG 2017
• 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
Agenda
Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)23.10.2017Page 16
Unrestricted © Siemens AG 2017
SINUMERIK VNCK
ü NCU Linkü multichannelü technology/special functions ascompilecycleü Siemens-, OEM- and User-Cycles
ü complete 840D languageü all movements (spline, polygone)ü all kinematic transformationsü original transformation algorithmsü measuring, travel to fixed stop
VNCK ApplicationAPI
SINUMERIKOperate
orHMI Advanced
HM
ISer
vice
Digital Twin of Sinumerik 840D CNCController
23.10.2017Page 17 Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)
Unrestricted © Siemens AG 2017Page 18
NX Virtual Machine
NX Machinekit (machine specific dataset)
RunMyVNCK NX CAM
Inte
rfac
e(N
X324
07)SINUMERIK
Operateor
HMI Advanced
HM
ISer
vice
Create MyVNCK
23.10.2017 Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)
Unrestricted © Siemens AG 2017
• 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
Agenda
Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)23.10.2017Page 19
Unrestricted © Siemens AG 2017Page 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)
23.10.2017 Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)
Unrestricted © Siemens AG 2017Page 21
Creating a VNCK Driver
SINUMERIKNC Archive
CreateMyVNCK
VNCKDataset
(SRAM-File)
23.10.2017 Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)
Unrestricted © Siemens AG 2017Page 22
How to get it?
SiemensPLM
Software
VNCKSupportCenter
MachineUser
OEM Channel
23.10.2017 Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)
Unrestricted © Siemens AG 2017
• 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
Agenda
Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)23.10.2017Page 23
Unrestricted © Siemens AG 2017
Georg VNCK project goals
23.10.2017Page 24 Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)
• NC Simulation that is topmost precise and as close to reality as possible to ensure processsafety 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 endmachine with the most advanced Siemens products on the market
Unrestricted © Siemens AG 2017
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 10.0.3• 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)
23.10.2017Page 25 Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)
Unrestricted © Siemens AG 2017
NX-VNCK – Georg UltraTurn 4000 MC
23.10.2017Page 26 Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)
Unrestricted © Siemens AG 2017
• 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
Agenda
Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)23.10.2017Page 27
Unrestricted © Siemens AG 2017
• HMI with the original look and feel of the real machine
• Exact simulation of all available manufacturingtechnologies of the machining center (e.g. grinding,measurement cycles, measurement equipment, etc.)
• Same program errors as on the machine (e.g. syntaxerrors, missing tool correction, circle endpoint errors,wrong cycle parameters, etc.)
VNCK – HMI & other Benefits
Page 28 23.10.2017 Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)
Unrestricted © Siemens AG 2017
• Block search with calculation (equal to the originalmachine!)
• Simulation in Dry Run possibleà meanssimulation in rapid movement speed = fastsimulation with same error detection but no timecalculation
• Calculation of machining time at a quality of >98%à except of PLC times, they are missing!
VNCK – HMI & other Benefits
Page 29 23.10.2017 Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)
Unrestricted © Siemens AG 2017
• Postprocessor development and bugfixing in the Simulation without on machine time / secondarytimes
• 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
VNCK – HMI & other Benefits
Page 30 23.10.2017 Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)
Unrestricted © Siemens AG 2017
• 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
Agenda
Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)23.10.2017Page 31
Unrestricted © Siemens AG 2017
Real Machine Virtual Machine
Page 32
Open Topics – Head-Spindle Issue
Several spindles+ Spindle coupling
inside VNCK
One Spindle +mechanical
coupling with tool
23.10.2017 Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)
Unrestricted © Siemens AG 2017Page 33
Open Topics – Turning Toolpath issue
Toolpath is fixed to workpiece(needed for milling)
NX CAM is gettingactual values for
angle of theturning spindle
Updating the Toolpathbetween operations results
in shifting it out of theturning plane.
23.10.2017 Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)
Unrestricted © Siemens AG 2017Page 34
Open topics – VNCK and ROBX
VNCKCompile Cycle Support
Full support of robotscontrolled by 840D
Controllers, includingrobotic machining.
23.10.2017 Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)
Unrestricted © Siemens AG 2017Page 35
Further Open Topics
23.10.2017 Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)
• 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
Unrestricted © Siemens AG 2017Page 36
Future Topics
23.10.2017 Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)
• Physical influence on the workpiece
- Calculate the deflection by workpiece weight
- Calculate the right pressure to compensate deflection (e.g. with steady rests andtailstock)
- Calculate thermic influence due to material removal
- Calculate effect of thermal energy on tool (e.g. tool wear)
Unrestricted © Siemens AG 2017
• 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
Agenda
Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)23.10.2017Page 37
Unrestricted © Siemens AG 2017Page 38
NX Virtual Machine Business Model
SiemensPLM
Software
VNCKSupportCenter
MachineUser
… as proven in 15 otherpilot projects!
OEM Channel
Direct Channel
23.10.2017 Manfred Moritz (PD LD AP DW FP IE NC) / Jasper Sanders (RC-DE PD CSO 1 SD3 1)
Unrestricted © Siemens AG 2017
Manfred MoritzSiemens AGPD LD AP DW FP IE NC
Nonnendammallee 7213629 Berlin
E-Mail:[email protected]
siemens.com
Jasper SandersSiemens AGRC-DE PD CSO 1 SD3 1
Franz-Geuer-Straße 1050823 Köln
E-Mail:[email protected]