step nc e manufacturing using step dave loffredo
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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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7/18/2019 STEP NC E Manufacturing Using STEP Dave Loffredo
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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.
Slide 3 Copyright 2001 STEP Tools, Inc.D. Loffredo
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.
Slide 4 Copyright 2001 STEP Tools, Inc.D. Loffredo
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
Courtesy WZL RWTH Aachen
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7/18/2019 STEP NC E Manufacturing Using STEP Dave Loffredo
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STEPTools, Inc.
Slide 5 Copyright 2001 STEP Tools, Inc.D. Loffredo
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.
Courtesy WZL RWTH Aachen
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7/18/2019 STEP NC E Manufacturing Using STEP Dave Loffredo
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STEPTools, Inc.216 River StreetTroy, NY 12180
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.
Slide 7 Copyright 2001 STEP Tools, Inc.D. Loffredo
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.
Slide 8 Copyright 2001 STEP Tools, Inc.D. Loffredo
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.
Slide 9 Copyright 2001 STEP Tools, Inc.D. Loffredo
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.
Slide 10 Copyright 2001 STEP Tools, Inc.D. Loffredo
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.
Slide 11 Copyright 2001 STEP Tools, Inc.D. Loffredo
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
System 2STEP Interface
CAD
System 3STEP Interface
CAD
System 4STEP Interface
CAM CAPP NC Milling NC Turning
Ford GM Boeing Lockheed
STEP Interface
Supplier 1STEP Interface
Supplier 2STEP Interface
Supplier 3STEP Interface
Supplier 4
One database replaces hundreds of PDM files
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STEPTools, Inc.
Slide 12 Copyright 2001 STEP Tools, Inc.D. Loffredo
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.
Slide 13 Copyright 2001 STEP Tools, Inc.D. Loffredo
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.
Slide 14 Copyright 2001 STEP Tools, Inc.D. Loffredo
Year One Pilot in Detail (2 of 3)
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.
Slide 15 Copyright 2001 STEP Tools, Inc.D. Loffredo
Year One Pilot in Detail (3 of 3)
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.
Slide 16 Copyright 2001 STEP Tools, Inc.D. Loffredo
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