A leading manufacturer of point of sale and display equipment is looking to expand its range of CNC machining capabilities, and says Alphacam Advanced Router, from Vero Software, is integral to its plans.

Alphacam-Programming-ASH-PlasticsA.S.H. Plastics already uses Alphacam for high quality, accurate machining of its range of sheet material, and working on complex parts that it would not be able to undertake without it.

Joint Managing Director David Archer says it is especially valuable for prototyping, as they can generally get a prototype on the machine ready for cutting, within 20 minutes. “When we were programming manually it could take up to an hour, so there’s considerable time saving.”

They invested in Alphacam when they installed a second Rye CNC router. The software now drives their 8 x 4 three-head MG 240, and a two-tabled machine which has four heads and four tool changers. “Both machines are three-axis – which is why we wanted Alphacam, so we could machine 3D parts.”

He says accuracy is of paramount importance to them, especially where they are bonding and gluing parts together, and Alphacam enables them to machine to high tolerances. “If we were to be out by just half a millimetre it would mean the unit wouldn’t fit together, but Alphacam achieves those hyper-critical tolerances for us.”

As well as providing their 3D capability and accuracy, Alphacam readily overcame a particular major challenge facing the upfront CAD part of the operation. “We use Alphacam’s Automation Manager to import several SolidWorks files into the system at once, automatically set up the machining for different materials and thicknesses, as well as nesting. This saves several hours of programming time a week, compared to when we had to open each part file individually, save as a dxf, import it, and then nest it separately.

“It means that once the customer has approved the part design, we can integrate all the SolidWorks part files into Alphacam, the CNC operator then programs those files for each different substrate, they’re sent to the machine, checked and verified, and then go into production.” He says Alphacam’s Advanced Router module ensures a seamless transition from CAD to CAM. “Setting up the geometries and toolpaths is incredibly easy, compared to how it used to be when we had to plot it all out manually and write line after line of G-code. Now, it picks up the required material and thicknesses, and generates everything for us, creating the NC code within minutes – again, saving considerable time.”

Along with the point of sale material for end-users such as Claire’s Accessories and Tesco, A.S.H. Plastics also manufactures a range of products for the engineering sector, including stillages for car dashboards during transit on transporters.

While some of the products only require lasering on their two laser machines, a growing number need to be finished on the CNC routers. “In particular this is when we need to do rebated slots. ItPart-Machining means we profile on the lasers, then use Alphacam to create a jig which we’d fix into place on the router, and Alphacam programs the CNC to carry out the routing operations and machine the slots as required.

“For example, we needed to create a locking door which we designed in 3D CAD. We had to laser the profile, then used Alphacam to create the NC code for a rebated two-part slot.”

The company, which employs around 35 staff at its 32,000 square foot premises in Wolverhampton, has two front-end operatives working with Alphacam – one of whom also runs the CNC machine, using all aspects of the software – and a further shop floor worker who specialises in running the CNC machines using the programs which have been produced for him.

A member of the Alphacam technical support team helped to set up the software initially, creating their first programs. “We were taking on a new contract which required a certain level of 3D machining, and we didn’t have the capability to carry it out at that time. An Alphacam engineer worked closely with our part files, demonstrating how to program those particular components.”

FANUC CORPORATION, the world’s leading supplier of robotics and factory automation, is collaborating with Cisco, the worldwide leader in IT-enabled digitization, as well as Rockwell Automation, the world’s largest company dedicated to industrial automation and information solutions, and Preferred Networks, a leading provider of Artificial Intelligence solutions. The companies will work together on the development and deployment of the FANUC Intelligent Edge Link and Drive (FIELD) system, a platform that connects not only Computer Numerical Control machines (CNCs) and robots, but also peripheral devices and sensors – to deliver analytics that optimize manufacturing production.

The FIELD system will be a platform for the delivery of advanced analytics for FANUC CNCs, robots, peripheral devices, and sensors used in automation systems. It will drive improved machine reliability, quality, flexibility, and speed – elevating the Overall Equipment Efficiency (OEE) and increasing manufacturing profitability. It will also provide advanced machine learning and deep learning capabilities. By working with Cisco, Rockwell Automation, and Preferred Networks – FANUC will offer a complete solution including network and compute infrastructure, applications, and an enabling middleware platform. With this open platform — application developers, sensor and peripheral device makers, system integrators, and others can build solutions that improve equipment efficiency, manufacturing output, and quality.

Extension of Current Successes

The FIELD system extends the success of the existing FANUC ZDT (Zero Downtime) connected robots project; ZDT is built with Cisco cloud, IOT data collection software, and end-to-end security capabilities.

The companies are working together to implement systems for major automotive manufacturers by leveraging the Allen-Bradley Stratix Ethernet switches from Rockwell Automation to connect robots to a Cisco Unified Computing System (UCS) – all of this running on FANUC and Cisco’s ZDT Data Collection software. Automotive customers who have implemented this system are quickly realizing a significant decrease in production downtime as well as increased cost savings.

Intelligent Manufacturing

The FIELD system will bring the power of advanced machine learning and artificial intelligence into the hands of customers and application developers — driving manufacturing to a new level of productivity and efficiency. FANUC and Preferred Networks have established these new technologies for applications such as Bin Picking robots, anomaly detection, and failure prediction. The FIELD system combines both artificial intelligence and edge-computing technologies – enabling distributed learning. Data is generated from robots and machines and is processed in real time at the edge of the network. This allows those devices to intelligently coordinate and collaborate in a flexible manner – resulting in sophisticated manufacturing practices not before possible.

Who provides What for the FIELD System?

FANUC: Provides CNCs and robots with embedded sensors to track key variables required to improve machine reliability, quality, and speed.

FANUC, Cisco and Preferred Networks : Provides enabling middleware Platform Software, as well as security and application lifecycle management applications. It will also leverage Preferred Networks’ open deep learning framework (Chainer), IoT Stream Engine (SensorBee) – and other advanced machine learning libraries within its Deep Intelligence in-Motion (DIMo) platform.

Cisco and Rockwell Automation : Provides networking, compute and security infrastructure to connect the robots, CNCs, and other cell equipment to the FIELD applications. Based on the Rockwell Automation and Cisco collaboratively developed Converged Plantwide Ethernet (CPwE) architecture – this further drives improved security, connectivity, flexibility, and scalability – all of which allows connection from a single, small cell to a large factory with hundreds of cells.

FANUC, Rockwell Automation and Preferred Networks : Delivers the initial Application Software on top of the FIELD middleware and infrastructure platform. This will extend the LINK-i and ZDT applications currently deployed, along with additional deep learning applications from the FANUC and Preferred Networks partnership. It is planned that Rockwell Automation manufacturing software products (including FactoryTalk View, FactoryTalk VantagePoint, and FactoryTalk Production Center) will seamlessly integrate with the FIELD system to speed deployment.

LEADERSHIP QUOTES

Sujeet Chand, Senior VP and CTO, Rockwell Automation

“By collaborating with world class companies, Rockwell Automation helps maximize manufacturers’ investments by leveraging the data from their intelligent devices they are using today to drive an enterprise-wide analytics strategy. With a secure scalable compute approach to analyze this data – from device to the enterprise – users can improve operations and make more informed decisions tailored to meet the needs of their organizations.”

Rowan Trollope, SVP IoT and Applications, Cisco

“ This collaboration represents a historic shift in the industry, with IoT, industrial automation and machine learning coming together to make the factory of the future a reality. It’s been talked about for years, but now it is really happening. Cisco couldn’t be more thrilled to be a part of this effort, one that will be key to our positioning in other industries that want to realize the benefits of digitization .”

Toru Nishikawa, CEO, Preferred Networks

“PFN is excited that this collaboration will further accelerate the advancement of the manufacturing industry. Since the start of our work with FANUC, leveraging machine learning and artificial intelligence has been aimed not only at making machines and robots smarter, but also towards a continuous improvement of manufacturing productivity through intelligent real-time coordination and collaboration between robots and machines. We are confident that FIELD will play a central role in making that vision a reality.

The demand for higher automation level in structural steel fabrication industry is putting pressure for the BIM information needed in the fabrication prosesses.

Demand for automation in steel fabrication is increasing all the time. The market requirements vary from automatic robotic welding & surface treatment solutions, automatic material handling to fully automatic steel fabrication “factories”.

The need for higher productivity through automation has created new challenges for the information required to plan and manage the steel fabrication processes. In the past the CNC automation was relying on DSTV format to fabricate individual steel parts. The focus at the moment has moved to increase the productivity in the assembly phase as it is still very laborious part of the fabrication process.

The widely used DSTV standard was struggling to fulfill the demands on the market for various reasons:

Limitations in extending the current standard to include additional data e.g. scribing, welding, GUIDs, information (status, scheduling, costs, etc.), etc.

• Assembly hierarchy not defined for fabrication purposes
• The production planning and management with many individual files very difficult – no hierarchy
• No support for parameters e.g. pipe beveling connection definition
• Different versions of the standard in each implementation causing problems
• Limited in types of materials:
  • 3D geometry for pipes was not supported
  • Bended and cambered parts
  • Special profiles not supported

All these drawbacks led FICEP and Steel Projects to take the Tekla Open API in to use to develop an application and a file format with much more structured and rich information taken directly from the Tekla models. This enabled processes like scribing to be developed.

For the similar reasons a Dutch company HGG, specializing in pipe beveling, worked together with Tekla to create a direct information flow from the Tekla models to the HGG machines for pipe beveling.

To drive the steel fabrication industry to the automation and to take new technologies more widely in to use FICEP, Steel Projects, Tekla and HGG decided to put all the knowledge gained from the individual development works done to define and create a new standard for the steel fabrication industry that would meet the current and future demands.

IFC (Industry Foundation Classes) is an open, neutral and standardized specification for Building Information Models, BIM. Up to now the IFC based workflows have been more common in the design processes. The idea to expand the IFC format also for steel fabrication industry originated from Tekla. The first meeting was held already in 2009 in Germany with BuildingSmart to discuss the definition process. One important element within IFC was the fact that by taking this format in to use it would bring the whole steel fabrication industry into the BIM workflow.

As AISC revised their strategy regarding the information standards it became obvious to work together on the same goal. AISC and Georgia Tech made it possible to have a neutral party (Georgia Tech) to do the official definition of the standard (MVD, Model View Definition) based on the requirements brought in by the vendors.

The results of this work has brought FICEP to be the first in the world to manage the whole process using IFC. This was demonstrated in USA at the NASCC – Steel Conference, last April. From design and detailing through the PLM software all the way to the most advanced CNC lines on the market.

Grind Master has a history of building Special Purpose Machines for Metal Finishing and Deburring Applications. For components requiring complex motions for processing, Robotics opened a new avenue for Automation. Grind Master Automation group was started to provide customers with Robotic Applications in metal finishing, deburring and fettling/deflashing. These applications are considered difficult to automate and prove, as demonstrated by numerous failures visible in the market in form of cells lying idle.

Grind Master could succeed because of its strong base in machine building, domain expertise in process and understanding of Robotics.

Mr. Sameer Kelkar, Executive Director at Grind Master, joined the business after completing Masters in Robotics, followed by Work experience in Automation in Switzerland. Under this leadership, Grind Master Automation group has built and proven Robotic Cells/Machines in varied applications including Front Axle Beam Grinding, Sanitary Ware Parts Polishing, Crankshaft Deburring and Stainless Steel Fabrication Polishing.

Grind Master is Extremely Proud to announce the Dispatch of our 25th Robot.

These turnkey solutions provided by Grind Master are in operation all across India, and also in the Middle East. The 25th Robot Cell is a sophisticated Coated Abrasive Belt Testing R&D Facility for a Major Global Abrasive Manufacturer, being used for experimenting with new materials.

Grind Master is closely associated with KUKA Robots. “Grinding, Machining, Polishing requires mechanically sturdy and reliable robots. Our collaboration with KUKA with their excellent range of products and services  since 2010 provides customers solutions that exceed expectations”.

Recently developed products in Robotic Automation include Robotic Iron Casting Fettling Machine RCF Series and Robotic Aluminium Deflashing Machine RCP series. Used in Foundry Sector in hazardous operations, these solutions are on the spur of a revolution in Indian manufacturing in foundry and die casting industry, by transforming the way that these traditionally “Dirty” processes have been done.

Under the motto “All-in-One: Safety & Automation”, Pilz will be presenting industry solutions, product innovations and services for complete automation solutions at this year’s Hannover Messe from 13-17.4.2015. Visitors can also experience how the challenges of Industry 4.0 can be resolved even today and how Pilz is promoting safe automation in the exhibition’s partner country, India.

“The factory of the future will be networked. This means that the complexity and demands on automation will increase. Pilz meets this challenge with complete, easy to manage automation solutions. In a nutshell: Automation. We keep it safe”, emphasises Renate Pilz, Chair of the Board of Pilz GmbH & Co. KG.

At the Hannover Messe 2015, Pilz will be presenting product and system solutions for every industry. On various exhibits Pilz will be demonstrating the interaction of Pilz automation solutions. Visitors can take on our Pilz automated table football team. The particular focus here is on complete solutions for motion, along with sensor and control technology, including visualisation. The company can provide advice and support over the whole machine lifecycle – from risk assessment to CE marking. The wide range of training courses, including our CMSE® – Certified Machinery Safety Expert – completes the services portfolio.

Innovations in the field of motion monitoring and sensor technology
Innovations at Pilz include motion monitoring modules for the automation system PSS 4000: Users benefit from reduced reaction times and higher productivity due to the fast shutdown of drives. As a complete supplier, Pilz offers the right solution for speed and motion monitoring – whether integrated in the drive or as an external system.

New products Pilz will be showing from its sensor technology range include new versions of the safety gate system PSENslock: PSENslock with advanced diagnostic functions is particularly suitable for series connections. This new version enables OSSD outputs (Output Signal Switching Device) to be switched, independently of guard locking. This increases the room for manoeuvre when implementing applications.

Industry 4.0: Model plant …
Industry 4.0 stands for the increasing networking of industrial processes, enabling flexible, efficient manufacturing. Pilz has a model plant on its stand to show how the distributed, modular control architectures required can be implemented today using the automation system PSS 4000. With this Industry 4.0-compatible automation system, plants can be broken down into manageable, independently functioning modules. As a result, the cost of engineering, commissioning and maintenance can be significantly reduced.

… and SmartFactory KL
As a member of the research platform SmartFactory KL, Pilz will be a co-exhibitor in Hall 8, Stand D20. A production line will be on show, which has been developed in conjunction with partners from SmartFactory KL. It demonstrates the practical application of some key aspects of Industry 4.0. The demonstrator includes a storage module from Pilz, which operates as intelligent, automated storage for the workpiece carriers.

Partner country India
Automation technology is a key to further growth of the Indian economy. Pilz has been represented in India, the official partner country of this year’s Hannover Messe, since 2011, with its own subsidiary supporting both domestic and international companies. As “ambassador for safety”, Pilz is promoting local knowledge building and acceptance with regard to the issue of machinery safety. “In India today, the name Pilz is synonymous with safe automation”, says Sanjay Kulkarni, Managing Director of Pilz’s Indian subsidiary.
He adds: “We want to use the Hannover Messe to show that intelligent safety solutions are economically worthwhile in India too.”

The Technical University of Liberec has introduced the second generation of its special service robot, the ROBOTUL® Vertical Climber 02, which uses a unique stepping movement to traverse both smooth and structured surfaces such as the glass walls of buildings. Its safe and highly precise operation is guaranteed by an advanced B&R control system with compact ACOPOSmicro servo drives.

The new approach taken by the Institute for Nanomaterials, Advanced Technologies and Innovation ensures linear movement, track stability and smooth rotation while enabling the robot to step over discontinuous surfaces and mounting holes. It can move with a high degree of safety on vertical – and even negatively sloped – walls. Based on feedback and experiences with its predecessor, this new generation is being developed in the context of the 3-year pre-seed project “New Technologies and Special Machine Components”.

Wide range of applications
The Vertical Climber 02 is designed to clean walls and perform surface inspections such as checking mounting points on glass panels or checking the integrity of stainless steel pressure vessels. It can also be used as a mobile platform for other technology, including cleaning and dust-removal equipment. The robot has compact dimensions of 112x112x30 cm and weighs 48 kg. The maximum workload for the robot is 20 kg. Up to 80 sq m can be cleaned per hour, or up to 90 sq m inspected.

The body consists of a compact duralumin frame with a rotary servo drive connected to a rotary chassis. Its four moving legs are each driven by a separate rotary servo drive. The duralumin frame and the legs are equipped with articulated active suction caps combined with smart ejectors. Multiple smart sensors identify the position of the robot in space and with respect to the contact wall plane.

Every James bond fan eagerly awaits the next release for action and complete automated entrainment with gadgetry display.

In India this was also on display during this parliamentary elections; the worlds’ populist democracy using EVM (electronic voting machines and online registrations of voters, apps to identify the nearest polling booth etc) 007 promotes and executes automation in every possible way and brings enterprising spirit in taking benefit of automation either to nab culprits or kill his opponents. Every movie of 007 promotes automation to mitigate the risks and challenges at normal as well as adverse conditions. The business environments find similar situations in disguise of terminology like issues/challenges/market conditions etc.

What Bond stands for is courage, extremely high loyalty towards his employer, out of the box problem solving techniques benefiting from the technology. To achieve the expected out of the brand” Bond”, he undergoes fitness test before any new assignment, same way automation products must be courageous to manage the situations, loyal to the business owner and adopt new processes to de-risk and evolve beyond business challenges.

Automation product need to undergo security testing as today’s business reality of managing complex security issues of BYOD (Bring Your Own Device) and existence multiple software solutions, compliance requirements at customer and customer’s customers.

Every bond movie comes with different actors playing the same characters as per Bond series involved in solving different plot in every movie. Though, the actors are different but the character has a specific role to play. Similarly employees change at organisations but their profile remains the same. The employee is expected to deliver using the existing ecosystem. The customer aspiration changes with market dynamics like the plot of a bond movie but the business outcome remains the same – Profitability.

M of 007 (ERP/ALM/PLM) – Every automation product aims at removing the bottlenecks either from the human resource or the process point of view. But final authority to control the process lies with ERP, which may be already integrated with PLM or ALM. How well the product adheres to requirements of ERP provides insight of ROI. It would not be practical for the customer to have multiple databases due to automation there by creating company inside the company, complicating the decision making process based on bureaucratic system of using spreadsheets than online data.

In every plot of 007 “M” gives unconditional freedom to 007 to perform duties for his majesty; including license to kill. Automation products also need to provide process automation with respect to business goals of the customer including even license to question any bottleneck which includes the decision making as well.

Q of 007 (technology/platform) – This is the character that pioneers automation. Q enables 007 for every eventuality with precision automation which works effective and efficiently. Q also does live testing and showcasing before handing over the gadget to 007 to make sure effectiveness is not compromised on.

The customers aspires for automation product or platform to brings the umbrella cover to mitigate business risks and process challenges of today and tomorrow. Customers also expect solid testing of the solution well before the usage, like “Q” cares for life of the bond. Automation products need to follow live solid testing and showcasing to increase healthy business life.

Money penny of 007 ( Security software, BYOD, Cloud etc) This character of 007 makes every attempt to reach 007 at every possible location and arranges all his comforts – from air tickets, money to passports Automation product needs to integrate with every security application at customer place and provide passport window to integrate with upcoming security applications as customers will spend more and more on their data security due to emergence and acceptance of BYOD with organizations.

007 Agents- Group agents who also have license to kill for his majesty’s assignment. Customers will expect automation products or solutions to bring the utmost transparency in the system by which no hoarding of information which directly /indirectly effects the business health of the customer.

007 car (Pricing) – The automobile bond comes with the aspirational features and control mechanisms by which 007 can travel comfortably and help him to uncover the challenges. This automobile is made specifically for 007. Automation products need to optimise the investment of the customers on the solution and bring the risk mitigation at optimum cost which is directly proportional to business risks.

Skyfall brought generational shift in 007 ecosystem by bringing in new M and Q. The security software’s, emergency of cloud solutions and BYOD bringing the generational shift in business environment already. Customers expect their Automation solutions to be new 007 who is going to co-exist with new M and many Q’s.

Disclaimer: Views expressed above are the author’s own.