Computer Integrated Manufacturing INDU 411 Computer Integrated Manufacturing Lab01

Labs 6 Labs Attendance is Mandatory Lateness will not be tolerated Switching lab sections is not permitted

Lab Structure 1st Lab 2nd Lab 3rd Lab Introduction & Safety NC Codes Project Description 2nd Lab Introduction to NC Milling programming Lab assignment #1 Project Progress Report #1 3rd Lab Introduction to NC Lathe Programming. Lab assignment #2 Project Progress Report #2

Lab Structure 4th Lab 5th Lab 6th Lab Robots Introduction Robots Pick and Place Programming Project Progress Report # 3 5th Lab Introduction to CIM Manager Production Run Simulation Project Progress Report # 4 6th Lab Project Run Production optimizing Final Report Preparation

Lab Safety No Food / Drink in either Lab Safety Glasses must be worn when in proximity of the equipment A lab instructor or technician is required to be present to operate any equipment in the lab Call 3717 for any emergencies Notify technician or lab instructors of any personal or equipment accidents / incidents Only one team may be in proximity of a machine or robot while in operation

Lab Assignments & Project There will be two lab assignments during the semester Lab assignments are to be done individually Each Session is considered as one team Each Team is divided to 4 sub team Every sub team must work on one selected Chess Pieces which are King, Rook, Bishop and Pawn with appropriate base design

Lab Assignments & Project Each lab group must give project Progress report and Final Report Submission on April 18th,2013, include Soft Copy and Hard copy The softcopy must contain all programming code and simulation optimization methods and comparison

OPEN CIM INTRODUCTION CIM LAB OBJECTIVE a fully computerized manufacturing system that covers transformation of raw materials to finished parts/products The lab components includes Three robots (two ER-9 and one ER-5) 3-axis CNC mill (ProLight Machining Center) 2-axis CNC lathe (ProLight Turning Center) Automated storage and retrieval system (ASRS) Closed loop continuous conveyor Quality control center

OPEN CIM INTRODUCTION Stations OpenCIM cell is composed of a set of stations located around a conveyor ASRS Station Machine Station Assembly Station QC Station Each station is controlled by a Station Manager PC A CIM Manager PC coordinates the activities of all stations Station devices are Robot, Robot Controller, Station Manager, and machine.

OPEN CIM INTRODUCTION Material Flow Material Flow Components Templates Primary Material Handling: transportation of parts between stations Conveyor Secondary Material Handling :handling of parts within a station Robot Material Flow Components Templates Conveyor and Pallets

OPEN CIM INTRODUCTION Robot and Controller move parts within a station (secondary material handling) and perform assembly operations Robotic programs inform the robot what path to follow and what task to perform once it reaches a destination. The controller (ACL) provides the power supply to the robot and moves the robot by controlling the power to the motors inside the robot.

OPEN CIM INTRODUCTION Communication Interface Send commands from the CIM Manager to Device Drivers (e.g. data such as part ID #) Send real-time production status messages from Device Drivers to the CIM Manager Allow Device Drivers to retrieve process programs (e.g. G-code) stored on the server Send real-time production status messages to the Graphic Tracking software Transfer CIM messages between different device drivers Transfer CIM messages between devices and a user application running on a networked PC

OPEN CIM INTRODUCTION Device Drivers A device driver translates OpenCIM messages in two directions: OpenCIM instruction messages into a set of commands understood by the target device. A response from the device into an OpenCIM status message.

OPEN CIM INTRODUCTION CIM MANAGER CIM manager is used for operating the open CIM system and production Real Mode : communicates with all device drivers, whether or not hardware is in use Simulation Mode : is not communicate with device drivers

OPEN CIM INTRODUCTION Production Operations Supplied parts (raw materials) are loaded into storage locations. Manufacturing orders are generated by the CIM Manager Parts are removed from the ASRS and transported on the conveyor to production stations. Robots take parts from the conveyor and move them to various production machines (e.g. CNC machines) at a station (machine tending). Typical production tasks include: Processing in a CNC machine Assembling two or more parts Quality control tests Robots return processed parts to the conveyor for transportation to the next station. Finished products are removed (unloaded) from the cell.

OPEN CIM INTRODUCTION Part and Machine Definition A product is manufactured from a group of subparts (bill of materials) that are put together according to a specified set of machine processes The process name enables the CIM Manager to determine which machine is capable of performing the specific process required to produce a part (as defined in the Process field in the Part Process Table in the Part Definition form).

OPEN CIM INTRODUCTION Real Time Monitoring The Device View is a complete list of every robot and machine (including QC devices) in the CIM cell and a description of the current action being performed by each The Leaf View provides a detailed description of the production activities of the CIM cell, describing the current operation being performed on each item and the operation that will immediately follow

NC PROGRAMMING G Code N0 G90 G01 X.5Y1.5 Z0 F1 NC programming generally incorporate two types of instructions: those which define the tool path (such as X, Y and Z axis coordinates), and those which specify machine operations (such as turning the spindle on or off). An NC program is composed of blocks (lines) of code. An NC word is a code made up of an alphabetic character (called an address character) and a number (called a parameter) Each block of NC code specifies the movement of the cutting tool on the Machining Center and a variety of conditions that support it N0 G90 G01 X.5Y1.5 Z0 F1 N0: This is the block sequence number for the program G90: This indicates absolute coordinates are used to define tool position G01: This specifies linear interpolation

NC PROGRAMMING G Code N0 G90 G01 X.5Y1.5 Z0 F1 X.5: This specifies the X axis destination position as 0.5” Y1.5: This specifies the Y axis destination position as 1.5" Z0: This specifies the Z axis destination position as 0". The cutting tool will move to the absolute coordinate position (0.5, 1.5, 0) F1: This specifies a feed rate of 1 inch per minute, the speed at which the tool will advance to the specified coordinate points

NC PROGRAMMING G Code The Units Group G70 : Inch Unit G71: Metric Unit If the code is placed at the beginning of the program before any tool motions are made, that unit of measure is assumed for the entire program. Otherwise, it affects the rest of the program following the code. The Wait Group G04 (wait):Pause between motions on all axes for the number of seconds specified by the F code, then continue the program For example: G04F10; //Wait for 10 seconds

NC PROGRAMMING G Code The Programming Mode Group G90 : Absolute Programming Mode G91: Incremental Programming Mode Programming mode G codes select the programming mode, absolute (G90) or incremental (G91). These codes remain in effect until superseded by each other. With absolute programming, all X, Y and Z coordinates are relative to origin (0, 0, 0) of the current coordinate system. With incremental programming, each motion to a new coordinate is relative to the previous coordinate.

NC PROGRAMMING G Code Preset Position Group G28 Set reference point: This code moves the machine to its home position. The G28 code performs an automatic calibration of the axes. G92 Set position: The X, Y and Z coordinates following a G92 code define the new current position of the tool. Preset Position Group

NC PROGRAMMING G Code G00 Rapid linear motion (no cutting) G01 Linear movement (accompanied by Z, Y, or X coordinate) G02 Circular interpolation clockwise G03 Circular interpolation counterclockwise G Code Linear and Circular Interpolation The end point is defined by Z, Y, or X coordinate. The center of the arc is defined by I, J, and K coordinate. The radius of curvature can be defined with R interpolation using center point: G03 X0Y1 I0J0 F2; CCW interpolation using the arc radius G03 X0Y1 R1 F2; CCW

NC PROGRAMMING G Code Cutter Compensation Group G40 Cancel cutter compensation. G41 Invoke cutter compensation left. G42 Invoke cutter compensation right D Specifies the offset number from the Offset Table (D1, D2, D3,…). compensation left G41 compensation right G42 Without programing with cutter compensation commands coordinates are obtained from offset contour Active the compensation command before any movement to the desired path G41 D3; active cutter compensation left with offset number 3 G00 X2 Y1 G01 Z-0.063 F5 G01 X4 Y5 F10 G02 X5 Y6 R1 . G02 X2 Y1 R1 G00 Z0.1 G40` Cancel cutter compensation after retracting the tool away from the part

NC PROGRAMMING F Code Feed Rate Specify the rate of speed at which the tool moves (feed rate) in inches per minute (ipm). For example, F3 equals 3 ipm.. Feed Rate Formula To determine the Feed Rate use the following formula: fm = ft nt N ft = Feed per tooth in inches per minute (IPM). Use a ft of 0.010” for Acrylic. nt = Number of teeth N = Spindle speed in RPM Plexiglas recommended cutting speed (CS) is 300 feet per minute.

NC PROGRAMMING The cardinal rule in machining is to remove as much material as possible within the limits of machine capability. That is, to machine as quickly as possible. It is not so much a question of minimizing time wasted machining, but one of maximizing cutting tool life. Feed rates that are too low produce excessive heat which may cause premature failure of the cutting edge. Feed rates that are too high may cause the cutting edges to fracture or cause more catastrophic failure. Cutter speeds outside the recommended range may cause the cutting edges to experience buildup, wear excessively, crater, chip, or produce poor work piece surface finish.