1. STEP-NC Solutions Martin Hardwick David Loffredo info@steptools.com STEP-NC Manufacturing Center Watervliet Arsenal, Building 20 Metal Processing Manufacturing Division Watervliet, New York 12189 (518) 687-2848 / (518) 687-4420 fax http://www.steptools.com

2. Slide 2 M. Hardwick Introduction “4 CAM’s – 2 Controls – 0 Postprocessors” AB Tool Tilt BC Table Tilt AP-238

3. Slide 3 M. Hardwick AP-238 Functionality Benefit Functionality TCP Lines & Arcs Drilling Cycles Toleranced Splines Feature parameters Feature tolerances Other Models Turning (in AP-238 ed1) EDM Contouring Inspection Robotics Parametric Operations Probing Workingsteps Toleranced Surfacing Conditional Operations Better Process Control Better Process Monitoring Flexible Manufacturing Today Tested during research phase Product Geometry

4. Slide 4 M. Hardwick Smart Process Control Base level configuration –Eliminates post –Enables faster operator prove-out –Creates pathway for on-machine optimization Converter dll Control HMI Motion Controller TCP Motion Codes New components CNC Vendor components CAM Writer dll AP-238 File Expresso Data check STEP-NC Simulator Subs bi-directional

5. Slide 5 M. Hardwick Smart Process Monitoring Monitor dll Control HMI Motion Controller CNC Loader Process Monitor configuration –Allows customer to verify correct operation of the control –Timings, operational parameters –Feature, operation and tool id for each workingstep New components CNC Vendor components TCP Code Block Number Customer Report CAM Writer dll AP-238 File Expresso Data check STEP-NC Simulator Subs bi-directional

6. Slide 6 M. Hardwick Smart Manufacturing Interpreter dll Control HMI Motion Controller CNC Loader Subs CAM Writer dll AP-238 File Expresso Data check STEP-NC Simulator STEP-NC Interpreter configuration –Execution flow depends on sensor values –Sensor values are connected to NC Variables of the program –Executive tells Interpreter when to start and stop TCP Code Block Number Customer Report Executive Sensor value Run WS1-N Program Status System Integrator component

7. Slide 7 M. Hardwick Applications Smart Process Control –CNC Operator needs to change a speed for all pocketing operations –Converter identifies all workingsteps that use this feed. –CAM operator guided to operations that need to be edited Smart Process Monitoring –Motion control records maximum Z tool tip position –Monitor dll adds data about workingstep and feature id –OEM checks hole feature has required depth. Smart Manufacturing –CAM creates program including probing operations –Executive relates probe value to STEP-NC Variable –Interpretation of program decides how to adjust finish allowance

8. Slide 8 M. Hardwick The Dynamic OEM Shop CNC Vendor ISO Standard “Accept jobs defined by AP-238 so I will know how they are machined” “I need AP-238 so I need to upgrade my controls to include the TCP option.” “Put the AP-238 dll’s on my TCP controls” “Here are dll’s to read and write STEP-NC data”

9. Slide 9 M. Hardwick Current Status Can machine NAS 979 CDS part with 5 axis cone –3 and 5 axis tool paths, lines and arcs –Machine functions and technology Draft International Standard in review –A few EXPRESS errors being found –Some scope for data compression –Enhancements for process monitoring Writer and Converter dlls ready for Beta use –Stage 1 – replace RS274D but keep same procedures –Stage 2 – optimize procedures using new intelligent data

10. Slide 10 M. Hardwick Conclusion AP-238 delivers rich data to the control The benefits are well known –Design anywhere, build anywhere –Cross enterprise re-use of CNC programs –Fewer operational errors –Faster machining The post was always in the way –Delivering low level machine codes –No connection between a feed and the reason for the feed The combination of Open Controls, TCP Programming and AP-238 eliminates the barrier.