Capable of simultaneous 3-tool cutting, C65 features Polygon Generating Capability, 2 Y-axes for turrets, and guide-ways for turrets with slides based on plate-type slide system. Turret slides and counter-spindle slide offer 1 g acceleration rate and rapid traverse rates of 75 and 150 fpm. With 1 5/8 or 21/2 in. bar capacities, machine offers respective max spindle speeds of 6,300 and 5,000 rpm at 20 kW or 26 hp, 100% duty rating and 77 lb-ft torque.

INDEX Corporation introduces its C65 CNC Single Spindle Bar Machine, continuing a 90-year tradition of building successful single-spindle bar automatics featuring a heavy-duty counter-spindle and Y-axis for extended machining flexibility and increased speed.

With optional 42mm (1 5/8inch), or 65mm (2 1/2inch) bar capacity, a maximum spindle speed of 6300, respectively 5000 RPM at 20KW or 26Hp at 100% (60min) duty rating and 105Nm (77ftlbs) torque, the C65 has enough power to do a lot of work in a short time.

Both turret slides and the counter-spindle slide offer a 1g acceleration rate, and rapid traverse rates of 25 and 50m/min (75 and 150 ft/min), adding to the productivity because of its faster motions. These production advantages can often become essential for the survival of a business, particularly for job shops.

According to an Index spokesman, "The new model offers new levels of productivity and flexibility for work done from bar stock. In the past it was either speed or flexibility; with the C- series both goals can be accomplished."

Speed. Three tools are in cut simultaneously almost all the time plus a counter-spindle equipped with the usual Z-axis and X-axis allows the user to complete parts very quickly. Both axes are electronically coupled with the second turret (slave- axes). As a result, the third turret can be working on the part in the counter-spindle while the other two turrets work on the main spindle, so that three tools may be in cut simultaneously. In addition, C65 productivity benefits from higher machining power and higher acceleration and traverse rates.

Flexibility. Two Y-axes for the turrets and a very powerful counter-spindle provide flexibility unmatched by other automatics for machining even complex parts without compromising speed or productivity.

An additional innovation is the Polygon Generating Capability which results from the counter-spindle operating as a polygon generating attachment. The actual polygon generating head is mounted directly on the face of the chuck. No additional equipment is required. The very high rotational inertia and stiffness of the counter- spindle assures vibration-free cuts, as well as long tool life, even on alloy steel.

An innovative highlight of the CS42 is in the design of the guide-ways for the turrets. The slides are not based on the traditional linear system, but on a highly innovative plate-type slide system. The slide surfaces are made of a match between a cast iron plate, and steel strips with ceramic-coated slides. This slide system offers significant advantages over the traditional slide ways: several times greater stiffness, improved dampening characteristics, and it is more compact. The actual axis drive is accomplished by rod-kinematic drive linkages arranged on the rear of the cast iron machine bed.

Despite its large working range, the machine exhibits a compact screw machine size design, requiring little floor space to make sure it fits into every shop that runs screw machines When speed and productivity count, which is the case in a screw machine shop, the C65 will be hard to beat.

With 124.02 x 64.96 in. footprint and 20 in. swing, Model M 20 offers rapid traverse rates of 394 ipm on X-axis and 295 ipm on Z-axis. Belt-driven, cartridge-style, gearless headstock has 15 hp AC GE Fanuc P-type spindle motor with variable speed drive, permitting full horsepower at spindle speeds as low as 275 rpm. Featuring 10.4 in. color LCD, GE Fanuc 21i-T control offers machining cycles for profiling, grooving, threading, drilling, boring, and rigid tapping.

ERLANGER, KY - Romi Machine Tools, Ltd, an industry leader in turning machine technology, has built a reputation providing customer-driven solutions to a broad array of precision turned-part challenges. The M Series of Combination lathes is yet another step in providing these solutions ever-more flexibly. The M Series is ideal for today's mixed-volume, short-run, JIT operations as well as dedicated, high-volume applications.

With a swing of 20", the M 20 combines high performance turning and large machining capacity within a compact 124.02" x 64.96" space-saving footprint. Rapid traverse rates of 394 imp (X axis) and 295 (Z axis) mean accelerated machine cycle times and reduced non-cut time, which increases overall throughput. Also increasing cycle time is an optional automatic electric turret offering a fast 0.48 second index, station-to-station. The turret holds eight tools with pockets for square tool holders and bolt-on I.D. tool blocks.

The M 20 has a rigid cast iron "H" bed design. All guideways are induction hardened and ground. They feature a Turcite-coated carriage and cross-slide that move smoothly on the solid bed and saddle guideways, thus ensuring superior rigidity, accuracy, cutting tool performance and long machine life. The M 20 offers three bed-length options: M 20 by 40, M 20 by 60 and M 20 by 80. Distance between centers is, respectively, 43.15", 62.84" and 82.52"

The spindle. A new belt-driven cartridge-style gearless headstock featuring a high-torque 15 hp AC GE Fanuc "P"-type spindle motor with a variable speed drive permits full horsepower at spindle speeds as low as 275 RPM. Three spindle options allow you to match the spindle speed and size to specific production needs. A2 spindles feature rigid mounting, larger through-hole capacities and higher RPM, while Dl Camlock spindles offer quick chuck changing between three- and four-jaw chucks. The A2-6" has a through hole of 2.56" and a speed range of 3 to 3,000 RPM, while the A2-8" and Dl-8 have a through hole of 3.15" and a speed range of 2 to 2,200 RPM.

To assure the rigidity required for heavy-duty cutting, the spindle is supported by angular contact ball bearings at the nose and a double row of cylindrical roller bearings at the rear. The spindle cartridge is lubricated for life, and the spindle design eliminates the need for oil recirculation or a refrigeration systems to maintain spindle temperature. The result is years of reliable performance with reduced operating and maintenance costs.

A rigid tailstock with dual clamping affords rigidity for supporting heavy parts or manual large diameter drilling. The tailstock has a large manually operated quill with cast-in tang stop and drill knock-out.

Fully automated lubrication, a complete coolant system and splash guards with overlapping doors are standard.

The control. The GE Fanuc 21i-T features the latest technological advancements in a uniquely small space. The 10.4" color LCD and full keyboard conveniently swivel for ease of operation. A shock absorber keeps the control in position when keys are pressed. GE Fanuc CNCs and associated spindle and servo drives have an exceptional reputation for reliability. For example, according to GE Fanuc, sub-system failures per month are nearly unheard of - 0.00495 on the CNC, 0.00099 on the servo drive and 0.00376 on the spindle drive.

Operator-friendly software. Romi Machine Guidance software, standard on all M Series machines, is ideal for operators with varying levels of experience, as it simplifies the transition from manual programming to G code programming. As the operator's skill level rises and/or part complexity increases, the operator can easily move through four levels of part programming generation. These are:

Manual Cutting. The operator uses the electronic handwheels, and the CNC's position registers to cut the part manually. This is the simplest mode, and the moves are limited to X and Z cuts.

Guidance Single Cutting. The operator uses the electronic handwheels, and the GNC's position registers to cut the part. The operator enters additional data and uses one handwheel to cut tapers and radii on the part. In this mode, axis moves and other commands can be recorded as a part program. The "taught" program can be "played back" to produce additional parts.

Guidance Cycle Cutting. The 21i-T GNC has built-in machining cycles for profiling (rough and finish), grooving, threading, drilling, boring, and rigid tapping. These cycles generate a part program based on information the operator enters, as prompted, to describe the part. The CNC automatically generates the part program, which then can be converted to a standard G code format.

Imagine a computer numerical control (CNC) system set free of proprietary hardware. Two shops discuss their experiences with software-based machine controllers.

The controller was as good as dead. The machine it was on couldn't even be traded in.

Almost every longstanding shop has had a machine like this - good iron but the controller is shot. The difference is that Melling Manufacturing Group in Jackson, Michigan, was able to bring their vertical machining center back to life. And it didn't take an expensive maintenance program. All it took was replacing the old hardware-based CNC with a software-based system, running on a mail-order personal computer. This PC control not only resurrected the machine tool, but it also lets the machine run better than it ever did with the old controller.

"The way it was, the most we could get for that VMC as a trade-in was its scrap value," said Melling President Dave Horthrop. This 45-man shop had owned the machine since 1985, and relied on it for years. But over time, the control unit had experienced its share of problems, with downtime getting longer and longer and repair bills going higher and higher.

Even when it was running, the machine was very difficult to program. The proprietary control was badly out-dated and no longer supported by the builder.

"Eventually it got to the point where, at best, we could use it only as a programmable drill press. Even at that, our machinists avoided using this machine as much as possible - most of the time it just took up valuable floor space," Mr. Horthrop recalls.

The shop found the new CNC, which made the turnaround possible, a little over two years ago. Called OpenCNC and produced.by Manufacturing Data Systems Inc. (MDSI) of Ann Arbor, Michigan, this CNC is a software-based system that uses a standard, off-the-shelf personal computer (PC) running a standard CNC software product. Only this software is proprietary; everything else is entirely independent of computer hardware. As soon as the old CNC was replaced with the new, this same machine was running, and running at faster feed rates and better accuracies than it did when brand new. It has become a very productive resource on the shop floor and there is no hesitation among operators when they are assigned to this machine.

"Besides turning what we thought was just a piece of junk into a valuable production asset, software-based CNCs are going to help us get into a new business that we couldn't otherwise compete in," says Mr. Horthrop.

A Different Kind Of CNC

Mr. Horthrop had heard about the new kind of CNC from Great Lakes Industry, Inc., a company also located in Jackson, near Ann Arbor in the southeastern corner of the state. GLI had retrofit several of its machine tools with these software-based CNCs. Almost out of desperation, Mr. Horthrop visited GLI to check it out. What he saw appeared to be the answer to the problems with his shop's VMC, even though the retrofit CNCs he looked at were radically different from the CNCs he was used to encountering. With little to lose, he had the old CNC replaced on the VMC in August, 1995.

The new CNC runs on an office-grade PC interfaced directly to the existing servo system of the machine tool. There is no separate motion control card, programmable logic controller, or other hardware in or attached to the PC. It has standard processors inside, exactly the way it came out of the box.

What it does have is software designed and written to allow an off-the-shelf PC to function as a CNC. This software handles everything that a CNC normally handles, such as the human-machine interface and I/O control, but it also closes the servo loop, a task usually relegated to add-on hardware such as a motion control card in some CNCs using a PC platform.

The reason Melling's VMC is now performing better than ever is that the old control did not have the processing power to keep up with the full potential of the axis drives on this particular machine. The drives' speed and accuracy were limited by the inability of the old CNC to process motion commands and position feedback signals very quickly. The new CNC is considerably faster.

"And when faster and more powerful PCs become available, we can upgrade by simply swapping out the old for the new," notes Mr. Horthrop. "The same control software will be loaded on the new PC. Likewise, if the control software is upgraded, the hardware will not prevent us from moving to the new version."

Hardware Independence

Having CNCs that are completely independent of hardware is an important consideration for both Melling and GLI, though their reasons are different. "We are interested in adding capacity to manufacture timing sprockets and similar workpieces for our parent company," explains Mr. Horthrop at Melling. "But we can't justify the cost of new equipment to produce these parts competitively in a mature market where margins are very low. The problem with used equipment is the controllers. They're either outdated to start with or if they're not, getting repair parts or future upgrades may not be easy or affordable."

CNC Maintenance Training

Most of today's major machine tool builders in conjunction with the CNC supplier offer a wide variety of end-user training on CNC machines. Some of the training is informal, some formal covering a wide variety of technologies such as: programming, machine maintenance, operation, servo drive maintenance, and CNC maintenance. Each of these categories of training plays an important role in the successful installation of a new machine and each imposes a different set of discipline on instructors and students. The following focuses on just one of these categories of training CNC maintenance.

The training methods used in CNC maintenance classes have changed significantly from the class conducted in the early years of NC largely due to the developments of new diagnostic tools in the controls. During the early years of hardwired NC, built-in diagnostic tools were almost non-existent and consequently maintenance training was based on teaching the theory of operation. In fact, control builders provided either a "Theory of operation" manual or a very thick chapter in their maintenance manual on "theory." This philosophy was greatly influenced by the fact that the first instructors as well as the first manual writers were often the engineers who participated in the design of the control since formal training departments as we know them today, had not yet evolved.

Today's CNCs have a high level of built-in diagnostic features and as such the maintenance training classes over the years have gradually been restructured to reflect their use. The amount of theory now taught in the classroom has been scaled down to just enough to provide the student with an overall understanding of the control's operation. Consequently a significant amount of the training time is devoted to understanding and using the diagnostic tools provided in the control. The emphasis has changed from "how it works" to "how to fix it."

Basic CNC maintenance courses offered by almost all control builders today last approximately one week, four and one half days on the average, with many offering in-depth or extended courses lasting two weeks or more. Classes are normally held at the control builders plant where adequate facilities and equipment for hands on experience are available, but a certain percentage of users request that the control builder bring the class to their facility. One control builder for example indicates that forty percent of their training (based on number of students trained) is done at the user's plant. The advantage of on-site training is obvious in that the user can send more employees since there are no travel expenses. The disadvantage is often inadequate training facilities and equipment for lab training. In addition the students are subject to being called out of the class to perform a routine maintenance job, breaking the continuity of the class.

Instructors all agree that adequate lab time with hands on experience is important for a successful CNC maintenance class. Even though instructors would like to see a ratio of one student per control for lab exercises, this is seldom possible. Generally instructors target the CNC maintenance classes for eight students with enough equipment to allow two students per control. Instructors all seem to agree that a class size of 12 with three students per control are numbers that should not be exceeded.

The practice of control builders differs when it comes to testing students. Some control builders require students take written exams, others do not. Cincinnati Milacron is one company that requires student testing and issues certification only when a student meets the requirements. The instructors evaluation of the student is based on both classroom work and lab exercises. The results are sent to the students supervisor since it is felt that companies are entitled to this information so they can properly assess their maintenance resources. But, "what is good for the student is good for the instructor." The student gets a chance to evaluate the instructor by filling out an evaluation form which is reviewed by the instructor's manager. This permits the training manager to assess the effectiveness of the training programs.

In the early years of CNC the most important prerequisite for a good control technician was a sound electronic background. Today a good understanding of electronics is still important but the ability to understand the control from a system standpoint (interrelationship of hardware and software) may have replaced electronic background as the most important factor. With today's diagnostic tools, faults are diagnosed to the module level. The service technicians today replace an entire plug in module rather than replacing individual components within a module. This has led to less emphasis being placed on the function of each electronic component and more on the control as a system.

One problem faced by all training departments is how to get a beginner student up the learning curve so that he does not slow down the class with elementary questions or even worse, not ask questions and stay confused. General Numeric addresses this problem by providing a book on request to students titled "Introduction to NC." Other companies have recommended levels of expertise and experience that a student should be at before they attend a specific class and recommend courses or books for achieving those levels.

The introduction of a Zenith microprocessor-controlled (CNC) drill grinding machine, from Z. Brierley Ltd., Ferry Farm Road, Llandudno Junction, N. Wales LL31 9SF, at the Ford Engine plant in Dagenham, just east of London, England, has improved tool tolerances and reduced the time required to regrind a wide range of pilot subland drills. Drills ground on the Zenith and used in production of the new DOHC engine as well as 1.8 liter and 2.5 liter diesel engines, were found to last longer between regrinds than manually ground tools.

CNC pilot drill grinding was introduced in the precision grinding department to meet a requirement for improved accuracy of the tool pilot length for the new DOHC engine. Tolerances previously were held to [+ or -] 0.025 mm, but the company now requires tolerances to be one quarter of that range.

Ford's established method of regrinding pilot drills required a minimum of two setups on different machines. The first operation was to grind the shoulder using a special fixture and then hand grind the front end of the pilot. As the pilot length is crucial, this operation required considerable manual skill and dedication.

Additionally, it was impossible to manually grind the shoulder and drill land independently, so the shoulder was increased more than necessary to accommodate an undercut. This meant that the drill had to be cut back and the entire pilot section reformed from time to time.

The operators found that with the Zenith machine they could ensure that the undercut is minimal and this more than doubles the useful working life of the drill. Because drills can now be reground in one continuous operation, accuracy is enhanced giving more confidence on the production line. The overall regrind time has been greatly reduced from hours to minutes after program prove out.

The "teach and repeat programming" development time for a "new" drill takes about two hours overall, though the joystick-style input method will allow an operator to input a basic part program in about ten minutes.

The physical setup of a drill in the machine is aided by a simple mechanical fixture. The pilot drills ground on the machine are all high speed steel ranging from three to 25 mm (about one-inch) diameter. An early change to a harder grade of wheel means that dressing is required only once in six months. Ford has found that at the end of the small end of the drill range, the automatic cycle makes regrinding much easier.

The company's engineers planned the workload on the machine by color coding the boxes used to transport the drills. The color coded boxes correspond with a color number code on disk on which the program is stored.

When compared with the previous manual operation, the company has found that they can now regrind in drill batches. By regrinding in drill batches, the system introduces further economies and simplifies product control.

This ancient Chinese proverb is good to keep in mind when thinking about how a factory begins to move toward a plant-wide electronic production monitoring system. The vision of the future destination may be luminous and compelling, but turning this vision into reality is no hop, skip and a jump. It has to be taken earnestly and carefully, step by step.

In the end, plant managers will be able to access the system and get instant, up-to-the-moment reports summarizing the OEE (Overall Equipment Effectiveness) rating of the whole plant, separate production lines or even individual machine tools. Analysis of the collected data used to calculate this rating will pinpoint where problems or opportunities for improvement appear.

Here is an example of what is to come when a production monitoring system is in place: Managers are alerted to a report showing that a certain machine in one of the machining lines needed an average of 3 minutes cycle time during the last shift when it should have been closer to 2 minutes at programmed feed rates and spindle speeds. Reviewing the log of events that occurred during this shift shows that a grinding wheel was not cutting as aggressively as intended and had to be replaced at 50 percent of its expected life as a result of excessive wear. A recent change in wheel grade is recorded in notes entered by the manufacturing engineer. At the start of the next shift, a message to the cell operator gives instructions to install a harder grade wheel. Cycle times monitored during the day show a return to the required output. Problem solved.
This vision is not new. It's been talked about and dreamed about for years. In fact, the software and hardware to make it happen not only exist, but they also have a proven track record. What is becoming clear is that making the transition to this future state will be neither quick nor effortless. The first steps are the toughest, but that is where the journey begins, as the proverb reminds us.

Tecumseh Products' compressor plant near Tupelo, Mississippi, has taken those first steps, and the benefits are already clear and substantial. The plant has installed software-only CNCs on several "bottleneck" machine tools and is running key portions of a bidirectional production monitoring system that integrates the CNCs with the plant's existing computer network and ERP software. Plant management is taking the results of these initial installations as proof that these steps are definitely moving in the right direction.

Under Pressure

Although Tecumseh Products is best known for its small engines found on leading brands of lawn mowers, snow blowers and similar products, the company is a major producer of compressor motors for refrigerators and air conditioners. Consumers are not likely to be aware that the reason these products run so quietly and efficiently is the unseen presence of a Tecumseh-built compressor inside, yet the reliable performance they enjoy is dependent on the quality of those compressors. Because many of the major brands of refrigerators and air conditioners have moved production offshore, Tecumseh has had to redouble its efforts to maintain profitable operation of its compressor plants in the face of the cost pressures brought on by the severe contraction in U.S.-based appliance manufacturing.

In Tupelo, Tecumseh operates three main machining lines that feed an assembly line on which the various compressor models are built in a mix that is determined by a schedule of firm customer orders. This plant houses about 100 active metalcutting machine tools. A shop control system that relies on manual data entry allows managers to monitor production, but the information is at least 1 day old by the time it is available for analysis and response. The system tells managers basic information about labor input, machine output and scrap rates. This gives them a somewhat sketchy picture of where the bottlenecks are and when part shortages may affect the assembly line. It is adequate to tell them how to react but rarely helps them anticipate and avoid shortages that hamper the assembly line. It can't tell them what is happening inside each machine to reveal the causes of bottlenecks.

"What we have in place is now the framework for a much more capable production control and communications system," says Joe Kulovitz, a manufacturing engineering manager.

The system will eventually supplant the existing one and provide a much more detailed picture of machine performance in real time. The new system has two main elements, both from Manufacturing Data Systems, Inc. (MDSI) in Ann Arbor, Michigan. One is OpenCNC, an open-architecture machine control that replaces OEM-installed CNCs. The other is MaximumFactory, a suite of software modules that collect and analyze real-time data generated at machine control units. This software suite is tailored for the ability of OpenCNC to extract data, but the software can also be interfaced (although less conveniently) with proprietary legacy CNCs.

NEWBERG, Ore. -- Due to the success of its strategic business unit (SBU) model in the United States, Climax today is announcing a new offering to serve the needs of international customers in the shipbuilding and repair, and nuclear power generation markets. The new SBU will help Climax better support its overseas clients' needs for engineering consulting and on-site maintenance, repair, and training services, and help their clients improve profitability and gain market advantage in increasingly competitive industries.

Climax's service model has fostered stronger, more seamless relationships with its clients, to help them attain improved profitability and market advantage. Coupled with the company's focus on quality, reliability and excellent customer service, the business model led to 25 percent growth since last year, when it was introduced.

"Our SBU model has helped us meet our vision to advance our world's industries by creating powerful and precise portable machining solutions and offering the consulting and engineering services that our customers need in these demanding economic times," said Climax CEO Geoff Gilmore, Ph.D., P.E. "Internationally, we are already working in China with one of the largest shipyards in the country, providing ship repair tools as well as the engineering and training services they need to help them compete on a global level. In Sweden, our engineers helped a nuclear power service organization develop a maintenance and repair offering that will extend the reactor's life by 20 to 40 years."
During its first year, the new international SBU will focus primarily on serving the shipyard maintenance needs in Japan, Korea, and China, and nuclear power needs in Japan, Sweden, Canada, and Taiwan. Climax will also continue its work in North America in these industries.

Climax provides unique, onsite, comprehensive, single-source machining solutions for the nuclear power industry and for shipbuilders who would like to lower their operating costs and improve overall productivity. The portable machine tools company also works to extend the life of aging nuclear power plants, while minimizing plant down time.

It has particular expertise in providing stern tube and rudder shaft boring tools to meet shipbuilding and repair needs. The company also designs and builds advanced computer numerically controlled (CNC) machines to provide on-site repair of complex nuclear reactor components.

For the past 40 years, Climax Portable Machine Tools has provided portable machine tool solutions in a number of industries, including power generation, shipbuilding and repair, and service and engineering. These industries look to Climax's consulting engineers for innovative new approaches to project development and maintenance management programs. Climax trains machinists to help organizations add more skilled workers, and provides machining tools to meet maintenance demands where it is impossible or impractical to move or dismantle heavy equipment in order to service or re-tool it.

Imagine a computer numerical control (CNC) system set free of proprietary hardware. Two shops discuss their experiences with software-based machine controllers.

The controller was as good as dead. The machine it was on couldn't even be traded in.

Almost every longstanding shop has had a machine like this - good iron but the controller is shot. The difference is that Melling Manufacturing Group in Jackson, Michigan, was able to bring their vertical machining center back to life. And it didn't take an expensive maintenance program. All it took was replacing the old hardware-based CNC with a software-based system, running on a mail-order personal computer. This PC control not only resurrected the machine tool, but it also lets the machine run better than it ever did with the old controller.

"The way it was, the most we could get for that VMC as a trade-in was its scrap value," said Melling President Dave Horthrop. This 45-man shop had owned the machine since 1985, and relied on it for years. But over time, the control unit had experienced its share of problems, with downtime getting longer and longer and repair bills going higher and higher.
Even when it was running, the machine was very difficult to program. The proprietary control was badly out-dated and no longer supported by the builder.

"Eventually it got to the point where, at best, we could use it only as a programmable drill press. Even at that, our machinists avoided using this machine as much as possible - most of the time it just took up valuable floor space," Mr. Horthrop recalls.

The shop found the new CNC, which made the turnaround possible, a little over two years ago. Called OpenCNC and produced.by Manufacturing Data Systems Inc. (MDSI) of Ann Arbor, Michigan, this CNC is a software-based system that uses a standard, off-the-shelf personal computer (PC) running a standard CNC software product. Only this software is proprietary; everything else is entirely independent of computer hardware. As soon as the old CNC was replaced with the new, this same machine was running, and running at faster feed rates and better accuracies than it did when brand new. It has become a very productive resource on the shop floor and there is no hesitation among operators when they are assigned to this machine.

"Besides turning what we thought was just a piece of junk into a valuable production asset, software-based CNCs are going to help us get into a new business that we couldn't otherwise compete in," says Mr. Horthrop.

A Different Kind Of CNC

Mr. Horthrop had heard about the new kind of CNC from Great Lakes Industry, Inc., a company also located in Jackson, near Ann Arbor in the southeastern corner of the state. GLI had retrofit several of its machine tools with these software-based CNCs. Almost out of desperation, Mr. Horthrop visited GLI to check it out. What he saw appeared to be the answer to the problems with his shop's VMC, even though the retrofit CNCs he looked at were radically different from the CNCs he was used to encountering. With little to lose, he had the old CNC replaced on the VMC in August, 1995.

The new CNC runs on an office-grade PC interfaced directly to the existing servo system of the machine tool. There is no separate motion control card, programmable logic controller, or other hardware in or attached to the PC. It has standard processors inside, exactly the way it came out of the box.

What it does have is software designed and written to allow an off-the-shelf PC to function as a CNC. This software handles everything that a CNC normally handles, such as the human-machine interface and I/O control, but it also closes the servo loop, a task usually relegated to add-on hardware such as a motion control card in some CNCs using a PC platform.

The reason Melling's VMC is now performing better than ever is that the old control did not have the processing power to keep up with the full potential of the axis drives on this particular machine. The drives' speed and accuracy were limited by the inability of the old CNC to process motion commands and position feedback signals very quickly. The new CNC is considerably faster.

"And when faster and more powerful PCs become available, we can upgrade by simply swapping out the old for the new," notes Mr. Horthrop. "The same control software will be loaded on the new PC. Likewise, if the control software is upgraded, the hardware will not prevent us from moving to the new version."

Hardware Independence

Having CNCs that are completely independent of hardware is an important consideration for both Melling and GLI, though their reasons are different. "We are interested in adding capacity to manufacture timing sprockets and similar workpieces for our parent company," explains Mr. Horthrop at Melling. "But we can't justify the cost of new equipment to produce these parts competitively in a mature market where margins are very low. The problem with used equipment is the controllers. They're either outdated to start with or if they're not, getting repair parts or future upgrades may not be easy or affordable."

Distributed by Precision International Corp., the Coborn RG8 is equipped with a reciprocating wheelhead and six CNC axes for machining applications such as rotary tools. To grind rotary cutters, helical cutters and multi-toothed saw blades, further axes can be added.

Two mirrored hard drives for "fail-safe" program and software protection are included. The machine incorporates the VS4 in-process vision inspection system, which is said to be more accurate than the previous VS3 system.

Available for use in conjunction with the machine is a range of rotary modules, which can be fitted with adaptors including hydraulic, HSK and ISO types.

CNC's In The Fast Lane Powerful 32-bit computer numerical controls (CNCs) are driving machine tools to higher levels of productivity. But faster controls may pay even higher dividends in accuracy and ease of operation.

The 32-bit computer numerical control has arrived. This new generation of CNCs promises to make machine tools more productive thanks to substantially enhanced processing speed. But that's not all. These powerful new controls are taking the accuracy of the machine tool ever closer to its mechanical limitations--and sometimes beyond, with electronics that can compensate for inherent mechanical deficiencies.

The concept of a more powerful CNC is increasingly being embraced by the world's control builders. Mazak, GE Fanuc, General Numeric, Mitsubishi, Bosch and Cincinnati Milacron all now offer 32-bit processors in some models sold in the U.S. Although the various companies may have embodied differing design philosophies in their respective controls, the one trait they all share is dramatically improved processing speed. One builder reports that its 32-bit units process data up to ten times faster than its best 16-bit control. But computing speed doesn't mean much by itself. What's important is how these powerful computers are making machine tools-and the people who use them-more productive.

To understand how a faster computer can improve machine tool performance, it helps to have a general idea of how all the parts of a control system function together. These parts include the central processing unit (CPU), the electro/mechanical servo control systems for spindle and axis control, and the various machine, human and auxiliary interfaces. And especially important is the mechanism, or bus structure, by which information travels from one portion of the control system to another. These data "roadways" play an important role in the overall efficiency of a CNC.

What sets apart the 32-bit CPU is raw computing power. One measure of this prowess is the speed at which a single command block of three-axis contouring data can be processed. A block includes new coordinate values for each of the three axes. A typical 16-bit control will process a block in 50 to 60 milliseconds (thousandths of a second); a very good 16-bit CNC can reduce the time to 17 to 20 milliseconds. But a 32-bit control can process a block in a little as 2 milliseconds.

This improvement is important in two ways. First, the CPU's primary task of transforming the part program to position control signals for the axis servo drives happens much faster. This speed can serve to improve precision and increase feed rates in contouring motions. Second, the relative ease by which this primary task is accomplished enables the CPU to perform more tasks in a given time frame to reduce total cycle time.

Many people think of a CNC as a single "brain" for a machine tool. Most controls, in fact, have multiple processors that are dedicated to specific tasks and are capable of running multiple tasks when required. The main processor is concerned primarily with generating tool path data. Secondary processors handle functions such as background edit, shop-floor programming, communications with peripheral devices, and so on. Further, most of today's CNCs incorporate programmable logic controllers (PLCs) that can handle a wide range of sequencing functions including tool change logic, portions of probe control, some aspects of torque-controlled machining and so on.

For this "information factory" to function efficiently, there must be a fast and reliable means for passing information between the various control system components. Especially critical is data transfer in the servo loop; that is, the flow of control data to the axis servos and the flow of feedback data to the CPU.

Newer controls have significantly improved "digital data bus" structures. A bus refers to the circuitry by which information is passed between different system components, and sometimes between different functions on a single computer board. Though improved bus communications is not exclusive to 32-bit controls (as a design element, it's been one of the major contributors to improved speed in 16-bit units), the new computers are pushing bus design to higher levels of functionality. These improved information highways are a necessary part of faster CNC performance since slow computer response often is due to information traffic jams rather than inadequate processing power.

Fast In The Turn

High CNC processing speed is of particular advantage in contouring motions. Just a few years ago, this capability might have been considered a solution in search of a problem. But now that more shops are doing sophisticated contouring and that high speed machining is becoming practical, a real need is emerging for faster controls.

Contouring places the heaviest demand on a CNC. When interpolation is employed, each single point-to-point servo command is the result of complex calculations that are being made "on the fly", that is, as the tool is cutting. This real-time computing is further complicated when additional data--such as tool offsets, cutter diameter compensation, axis error compensation or workpiece offsets--must be factored into the calculation.

The company that has already revolutionized the CNC industry by proving that manufacturers can control a complete range of CNC machine tools entirely from unbundled software is once again setting a new CNC standard -- this time for machine tool builders.

With the introduction of OpenCNC(R)/OEM, Manufacturing Data Systems, Inc. (MDSI) presents the same high-performance, open-architecture software CNC technology that has already enabled the company to dominate the software CNC market -- now packaged at a price/performance point designed for volume OEM sales.

OpenCNC/OEM includes the OpenCNC/OEM Software Developer Kit (SDK) and OpenCNC/OEM Runtime. The SDK enables engineers to design, build, test and simulate the CNC application offline, in software, before installing it on the machine tool. The Runtime is the hard real-time kernel that controls the machine tool. The package provides a common control technology across a full range of machine tools, including mills, lathes, drills, routers, mills, grinders, gear hobs, dial machines, and laser manufacturing systems.

"OpenCNC(R)/OEM is MDSI's response to demand from OEMs and end-user manufacturers who are already specifying us on their new machine orders," said James R. Fall, MDSI president and CEO. "We're pleased to provide an industry-leading software CNC solution to the full spectrum of machine tools, from entry level knee mills up to complex, high-precision, multi-axis machining centers."

OpenCNC/OEM reduces engineering costs and enables Original Equipment Manufacturers (OEMs) to bring products to market faster, because it leverages standard software development tools and standard off-the-shelf hardware. Because the CNC is open-architecture software running on Microsoft(R) Windows NT(R), OEMs can integrate third-party technologies and provide value-added competitive features of their own to customers.

In today's manufacturing industries, OEMs increasingly recognize the value of a renewable CNC -- an upgradeable software CNC that will not become obsolete before the machine tool does. "OpenCNC/OEM has established a new benchmark in all-software, high-performance, high-volume CNC solutions for OEMs," Fall said.

MDSI has already signed several major license deals with machine tool builders to install the products in new machines. MHO, manufacturer of production-grade compact CNC milling machines, recently made an initial purchase of 100ness and our customers." MHO's machines are oriented to small-part manufacturing needs.

Cubic Machinery, Inc., another OEM customer for MDSI, produces lathes for a variety of industries including optical, electronics and automotive. "Cubic Machinery has created a special machine designed specifically for OpenCNC/OEM, which is an indication of our belief in the quality and effectiveness of this product. Its flexibility allows us to design and deliver a machine in a relatively short period of time," said Joe Lin, president, Cubic Machinery. "OpenCNC/OEM is the ideal product for our customers working to make machining more productive through robotics and mechanics."

"Our mission at MDSI has always been to revolutionize the factory floor through superior, innovative technology," Fall said. "Providing OpenCNC products to machine tool builders as well as manufacturers is a natural progression for our company as we enter the new millenium."

About MDSI

Manufacturing Data Systems, Inc. supplies factory automation software and services that increase manufacturing flexibility and enable agile manufacturing. The company's primary product, OpenCNC, is a software CNC that reduces machine tool control costs and extends the productive life of machine tools. OpenCNC provides an unbundled, open-architecture, high-performance, low-cost software CNC solution for Original Equipment Manufacturers of electronics fabrication, metal cutting, and woodcutting machine tools.

Unlike traditional CNC controls, OpenCNC uses no proprietary hardware or motion control cards. The entire control is delivered on a CD. Because it's unbundled software that runs on off-the-shelf PCs, manufacturers are not locked into proprietary arrangements for hardware, control repair, or control upgrades.

MDSI's business strategy emphasizes technological and price/performance leadership, hardware independence and comprehensive customer-support. The company's customers, spanning many industries, include Boeing, Caterpillar, Dana-Spicer, Detroit Diesel, Emerson Electric, Ford Motor Company, General Electric, General Motors, Lockheed-Martin, Marconi Precision Aerostructures, Tecumseh Products Company, Teledyne, Textron, and Vickers.

Electric Enterprise opens new control repair division

Electric Enterprise, Inc., of Stratford, Conn., a servicer of servomotors, amplifiers, and controls, recently launched a division for repairing and servicing computerized numerical control products. Called CNC Machine Repair Co., the division will offer repair and preventive maintenance services on computerized numerical control machines tools, including bearings, ballscrews, drives, digital readouts, and spindle and servomotors. Steven Hume is general manager of the new division.

Graybar acquires Florida electrical supplier

Graybar, St. Louis-based distributor of electrical and comm/data equipment and supplies, recently bought the Ocala, Fla., branch of Besco Electric Supply Co. The branch, 66 miles north of Orlando, includes a lighting showroom, warehouse, and counter operation. Graybar's Jacksonville branch manager, Mike Bennett, will oversee the Ocala operation.

Three former executives of Clevelandbased Rockwell Automation Reliance Motor Group have formed a venture with Kirloskar Electric Co. of Bangalore, India, to offer U.S. distributors a line of motors initially to be offered in the 1-150 hp range. Wayne Huron, Glenn Griger, and James Ansberry, all former Reliance executives, will handle sales, marketing, and financial duties for the new KEC North America, to be based in Cleveland. Plans call for the venture's product offerings eventually to include vertical hollow shaft, IEC, mill-duty, and inverter-duty motors.

TECO-Westinghouse launches service division

TECO-Westinghouse Motor Co. has added a large motor service division to its Round Rock, Texas, operation. Designed for large motor repair, the company's 500,000-square-foot facility is outfitted with 200-ton cranes, 675,000 lb. capacity air pallets, and 350,000 lb. capacity lathes. In addition to motor repair, the facility offers engineering services, motor performance upgrades, motor testing, and spare motor parts.

K.J. Electric announces plans for facility expansion

K.J. Electric of Syracuse, N.Y., a distributor of industrial electric and electronic products, recently announced plans to triple the size of its facility in Tonawanda, N.Y., with a $1.4 million expansion. The company estimates that the staff will increase from six employees to around 25, while the facility will grow in size to 18,500 square feet. An existing distribution warehouse is to be expanded and a new repair shop added.

GE Supply introduces online purchasing service

GE Supply, Shelton, Conn., has introduced a Web site for ordering and specification information about General Electric products for original-equipment manufacturers, maintenance engineers, and repair shops. The site, at www.motordirect.rom, lists more than 800 products from an inventory located at sites around the U.S. Motors range from fractional to 400 horsepower. Customers can pay with a major credit card or through a direct-billing account.

Baldor Electric receives two market engineering awards

Baldor Electric Co., Fort Smith, Ark., maker of motors and drives, recently received two Market Engineering Leadership Awards from Frost & Sullivan, the market research firm. The Product Innovation Award was given in response to the company's use of inverter-duty magnet wire in all three-phase motors one horsepower and above. The Customer Service Award was given in recognition of quick customer response, according to Baldor.

Search is on for the oldest working Reliance motor

In celebration of the ninety-fifth anniversary of Reliance Electric products, Rockwell Automation, Reliance Electric's parent company, has issued The Reliance Electric Endurance Challenge to find the oldest continuously operating Reliance Electric motor, drive, and programmable control. The challenge is to find the oldest such product still in use by the end of this year. Rules, applications, and contest updates are available from Rockwell Automation distributors and on the Internet