STEP NC E Manufacturing Using STEP Dave Loffredo

7/18/2019 STEP NC E Manufacturing Using STEP Dave Loffredo

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STEP-NC: E-ManufacturingUsing STEP

David [email protected]

STEPTools, Inc.216 River Street, Troy, NY 12180

(518) 687-2848 / (518) 687-4420 faxhttp://www.steptools.com


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STEPTools, Inc.

Slide 2 Copyright 2001 STEP Tools, Inc.D. Loffredo

Model Driven e-Manufacturing

Direct control of machine tools from 3D data

Using STEP-NCspecification under developmentin Europe and Far East for 3 years Milling, Turning, EDM, Grinding, Bending

Extensions for Robotics and Assembly anticipated

Benefits 35% reduction in time for job shop to set up machining job

75% reduction in time for OEM to prepare data for job shop

50% reduction in computer infrastructure costs

Faster, safer, more adaptable machine tools


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STEPTools, Inc.


Current NC programming using ISO 6983

%N05 G54

N10 G00 Z10.000

N15 G91 G0 Z200

N20 T5 D1 WW

N30 G90 M5

N35 G00 X0.000 Y-150.000

N40 G00 Z5.000

N45 M08

N50 S3183.000

N55 M03

N60 F1477.000

N65 G00 X60.000 Y-150.000

N70 G00 Z5.000

N75 G00 X60.000 Y-150.000

N80 G01 Z-0.500

...

machine-specific part

program with axis

data generated by a

postprocessor

vendor-specific

extensions of the

original standard

only primitive motion

and switch commands

no standardized dataformat for spline

processing and

sophisticated NC

technology

Courtesy WZL RWTH Aachen

STEP-NCreplaces this with a

rich, integrated data format


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STEPTools, Inc.


STEP-NC Is Integrated

workpiece

machining_feature

S[0:?]

pocket plane regionhole

1 S[0:?]

machining_operation

workplan

machining_workingstep

L[0:?]

plane_milling side_milling drilling

1

tool

technology

strategy

L[0:?]

cutter_contact_trajectory parameterised_pathcutter_location_trajectory

1

toolpath

geometry

geometry

geometry



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STEPTools, Inc.


Use Cases for STEP-NC (ISO 14649)

CAMsystem

Shopfloor

programming

PlanningDepartment

Shopfloor

New data model and interface (ISO 14649)

Post-processor

ConventionalNC controller

CAD workpiece data

New, IntelligentNC controller

Intelligentfunctions

e.g. automatic

- path generation

- tool selection

- technology support

- retract strategies

- machine limits

Design

ModernNC controller

STEP-NC enablesdirect control of NC

machine tools from3D data.



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STEPTools, Inc.216 River StreetTroy, NY 12180

[email protected]

Model Driven Intelligent Control ofManufacturing

Function

Design

Mfg

Design

Process

Capture

AP-203

AP-214

AP-224AP-xxx

AP-213, PSL

ISO 14649

ISO 13399

Intelligent

ControllerSTEP-NCDatabase

Intelli

gent

Interface

..

Super Model

Electro-Mechanical Integrators

Honeywell

Liberty Consulting

RPI


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STEPTools, Inc.


MDICM Industrial Review Board

GE Fanuc

CNC Data (MASTERCAM)

CADKEY

Alibre

Boeing

General Electric

General Motors Gibbs and Associates

Hurco Companies Inc.

Lockheed Martin

IBM

Monarch Machine Tools

NASA (GSFC)

NASA (JPL)

NCMS

Unigraphics Solutions

NIST Intelligent Systems

Lawrence Livermore

Chrysler

Watervliet Arsenal (Benet)

General Dynamics

The Design Edge RMC Associates

Fala Technologies

Cambridge Valley Maching

Allied Signal

Bridgeport Controls

Liberty Consulting

RPI


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STEPTools, Inc.


Software tools to make implementing and

using the STEP ISO standard easy. Forerunners in STEP technology since

1991 Founders working on product data since 1978

First commercial software tool kit

First solid model data exchange using STEP

First STEP Repository

Contributors to STEP and STEP-NCmeetings

Owner of Parts 14, 21, and 24 of STEP Owner of Parts 3 and 51 of STEP-NC

300+ customers use our tools to defineand implement STEP and STEP-NC

Who We Are


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STEPTools, Inc.


End User Benefits

With STEP Saving

Max Min Average

Time to make a process plan 100 4 16 12 25%

Time to replan a process plan 20 1 4 3 25%

Number of iterations 3 2 33%

Total Hours 28 18 36%

Number of plans per Year 1000 1000

Burdened cost per hour $50 $50

Total Cost $1,400,000 $900,000 36%

Without STEP

The supplier creates the production process from a

3D product model instead of paper drawings

Measured by Lockheed Martin


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STEPTools, Inc.


50% of total process plan effort iscomposing visuals.

STEP-based system using to produceprocess plan visuals.

Projected 75% reduction in man hours

spent in visuals preparation (25 hoursvs. 100 hours).

GOAL: Reduce manufacturing costs

End User Benefits

STEP is used to automatically prepare visuals forprocess plans.

Measured by Raytheon


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STEPTools, Inc.


The Super Model Solution

CAD

System 1STEP Interface

STEP Interface

Supplier ASTEP Interface

Supplier BSTEP Interface

Supplier CSTEP Interface

Supplier D

Super Model = STEP +++ database on the Internet

CAD


CAD


CAD


CAM CAPP NC Milling NC Turning

Ford GM Boeing Lockheed

STEP Interface

Supplier 1STEP Interface



Supplier 4

One database replaces hundreds of PDM files


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STEPTools, Inc.


Bridgeport

Controller

MDICM Year One Pilot Project

FBMACH

EASYMILL Virtual

Gibbs

CAD

Process Planning

Benet Laboratories

Watervliet Arsenal

Demonstration

General Dynamics

Land Systems

Demonstration

Bridgeport

Controller

Work PlanSTEP-NC

Database

Tool Path

Generation

Milling

Machine

AP-203

STEP-NC AIM

XML ISO 14649-11 Work plan

CADKEY

STEP-NC AIM has

not yet been given

an AP number by

ISO STEP


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STEPTools, Inc.


Year One Pilot in Detail (1 of 3)

Enhanced FB Mach CAM system to write STEP-NC datafor holes, pockets and slots Developed the STEP-NC AIM model

Reviewed by ISO STEP

New Work Item being submitted to get an AP number

ST-DeveloperTMand ST-ACISTMare STEP programming tools developedby STEP Tools

CADKEY

FBMACH

Work Plan

AP-203

STEP-NC AIM

ST-ACIS

ST-Developer


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STEPTools, Inc.



Work Plan generator Bridge between STEP and XML

Feeds XML data to EASYMILL shop floorprogramming system

An application of the STEP Tools databaseproduct ST-RepositoryTM

BridgeportController

Work Plan Generator

EASYMILL

STEP-NC AIM Database

XML Work Plan

ST-Repository


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STEPTools, Inc.



STEP-NC Controller Modified EASYMILL to read XML Work

plan

Put Controller and EASYMILL onto PC

Working with General Dynamics LandSystems for second demonstration

Bridgeport

Controller

EASYMILL

XML Work plan

ST-Developer

ST-Repository+


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STEPTools, Inc.


Consequences of STEP-NC

No more post processors! Every tool reads the same instructions

New market for CAM software! Every controller needs tool path generation software

More efficient CAD! Less tedious process planning

Self correcting manufacturing! Every work plan includes the nominal geometry of the part

Faster, safer, more intelligent machine tools! Verify set up

Dynamic optimization

STEP NC E Manufacturing Using STEP Dave Loffredo

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