No 41 - November 2004

T H E C N C A N D S E R V O M O T O R S + D R I V E S M A G A Z I N E

informationnum

Num : CNC Complete Solutions

Rotary Transfer MachinesRotary Transfer Machines

PRODUCTSAxium Power :always more!

SOLUTIONSMorealli : 100.000 gears

per month

num information No 412

CORPORATE NEWS

To date, the conso-lidated results for2004 show thatwe have made

the right choices". This ishow Philippe Toinet,Business and MarketingDirector at Num commentson the company’s currentsituation. It is true that ina rather flat market,where investments are stilllow, notably in France andGermany, Num hassucceeded in avoidingpitfalls by concentratingon its strong points:"First, without ever neglec-ting volume markets liketurning and milling, wehave always paid specialattention to increasinglyspecific requests to thepoint that in certainsectors we have becomerecognized specialists(precision machining,transfer machines, 5-axis

Num : Major StrategicChoices!

machines etc.)," explainsPhilippe Toinet. "Thisapproach has resulted inthe enrichment of ourknow-how. But thisdiversification also enablesus to better withstandunp lanned marketevents", he continues.High added value projects,with a strong technicalbent, are not postponedas often as more ordinaryprojects because theyoften correspond to a vitalneed for efficiency. "Then", continues PhilippeToinet, "we have enthu-siastically integrated ourclients’ need forproductivity in thedefinition of our newproducts. Often, thisinvolves improving equip-ment flexibility. That is whysince its release in 2003,we have continued todevelop our Axium Power

and Num Power rangeswith the integration ofVisual Tool, for example,that avoids breaks in thedigital chain betweendesign and productionthus reducing certainadjusting steps andsecuring data transfer’’.

Poles of ExpertiseNum can also congratu-late itself on havingbeen able to adaptits organization to makethe most of its flexibilityand responsiveness."By setting up our MTCs(Machines TechnicalCenters), we have foundthe way to consolidate ourpresence in countries byimproving the adequacybetween our offer and thespecific needs of eachcountry." recounts PhilippeToinet. "Now, each MTCis sufficiently independent

to develop its ownservice offering, or evensupplement its productoffering. This has lead tothe development of polesof expertise for particulartrades: tool sharpening inSwitzerland, gear cuttingin the U.S., grinding andthe wood workingindustry in Italy, the stoneindustry in Spain etc.This enables us tomultiply our targets. Assoon as a solution hasproven itself, it becomeseasy to duplicate it inanother country and usethe skills acquired."It is certainly true that thisease of adaptation isgreatly facilitated by theopenness of the Numrange.

2004 results confirm the appropriateness of Num’s strategicchoices in terms of sales and product policies.

Philippe Toinet,Sales andMarketing Directorof Num

Num Shows Off at ITMS 2004!

Last September, Num participated in the ITMS tradeshow held in Chicago. This provided Num Corp withthe opportunity to introduce, among others, newcylindrical and surface grinding, gear cutting andtool sharpening solutions to American users.A demonstration showing a Num CNC equippedwith Visual Tool was also exhibited on theDP Technology stand. Remember that Visual Tool isthe result of a partnership between Num andDP Technology. This concept aims to integrategraphic programming and simulation functions intoNum CNC systems and showed DP Technology’sEsprit CAM system in the CNC. This can result inconsiderable improvement in the efficiency andspeed of actions performed down on the machine.

“

3num information No 41

Since its launch in 2003, Num’s Axium Power CNC system has continued to evolve,enriched with new functions and breaking through its previous boundaries. A quick lookat these new possibilities is a must.

PRODUCTS

Axium Power :Striving to AlwaysBring you More!

A xium Poweri s nowcapable ofhandling up

to 32 axes in eightgroups (sets ofsynchronized axes).This new performance,combined if necessarywith the multi-CNCconfiguration features,yields a particularlyattractive solution fortransfer machine typeapplications (up tomore than 100 axes –see articles followingpages). In addition,with this new 32-axisconfiguration, Num isable to cover the fullrange of applicationspreviously covered byits analog bus CNCs.

Open and User-friendlyAt the same time,Axium Power nowincludes an EthernetTCP-IP link greatlysimplifying wiring of thesystem. This will make

it much easier to sup-port multi-panel andmulti-CNC processesas well as remotemaintenance anddiagnostics by allowingthe use of off-the-shelfsoftware.The HMI has continuedto expand towardsever greater user-friendliness, in parti-cular through a VisualTool function thatoffers an especiallyaccommodating 2.5Deditor and a highlyrealistic 3D simulation.It should also beremembered thataccess to Esprit’s(DP Technology) CAMmilling or turningfunctions allow theuse of all Num’sspecific integratedcycles, as well as adifferent approach tomachining strategies.Finally, the range ofpanels available hasbeen expanded toinclude two industrial

screens, FS151 andFS151-KBD, and aniPC Compact PCpanel.

Axium Power offersnow a wide choiceof PC panels

Since theM T C s( M a c h i n eTe c h n i c a l

Centers) were set up,certain managementchanges have takenplace: Num Germanywas entrusted toJean-Marie Amman,Num Italy to RobertoBrignolo and, after 22

very successful yearsat the head of NumSwi tze r land ,HansB a c h m a n n i ssucceeded by hisassociate Peter vonRüti, previously SalesD i rec to r. Be fo rere t i r i ng howeve rHans Bachmann willdevote his remainingt ime to Num’s

marketing strategy.As for the newmanagers, there is nodoubt that you’ll findin these men thequalities you’ve cometo value from Num.

Changes in MTC Management

num information No 414

SOLUTIONS

When Axium Power Controlsmore than 60 Axes!

The Precitrametransfer machines

feature 4 to 16machining modules.

Transfer machines, rotary or otherwise, are a world apart in machine-tools.Specializing for many years in this area, Precitrame Machines is an excellentexample.

Rotary Transfer Machine

One often thinks that end-users best knowthe particular features of their business.But taking the step of becoming amanufacturer because you can’t find

the machine that meets your needs is a riskydecision indeed. Precitrame’s decision to doso proved successful. First born as a divisionof the company of the same name, theMachines business became independent in 2001when it became Precitrame Machines. Better

yet, since 2004, the company has a new plantentirely dedicated to building its machines andtoday this manufacturer has carved out itsreputation in the rotary transfer machinesector (see also article page 10).

The Art of Optimization!"We specialized in production machines for smallsize parts (about 50 mm3) and very large series"confides Olivier Voumard, the company’sGeneral Manager. "All our added value stemsfrom our aptitude to offer a machine that helpsimprove our clients’ productivity, at the bestcost", he continues. The transfer machine isthe ultimate production tool since it allows theproduction of parts based on elementarymachining operations occurring in parallel, asthe passage from one station to the next isautomatic. "It’s all a matter of optimization"adds Olivier Voumard, ‘’If you set up onestation less you are too slow; if you incorporateone more, you’re too expensive!"In response to its client’s needs, Precitrame hasdeveloped a certain number of different

machining stations (milling, turning, grinding,engraving etc.) that it assembles according toneed. "Our clients come in with a plan of a part"continues Olivier Voumard, "and informationconcerning the speed they need, thequantities they want to produce, etc. and wepropose a turnkey solution that takes into accounttheir manufacturing process requirements".The new Precitrame range pushes the conceptof modularity to the limit, thus satisfying

sectors as varied as automotive,medical, audiovisual and naturallythe sector in which Precitramebegan, watch making … all busi-nesses that require both highvolume and precision.

60-axis plus!The nature of transfer machines issuch that each module performs avery simple action. However, thesimultaneous management of all themodules is essential. It is essentialthat each station perform operationsof equivalent duration and thepositioning systems and those thattransfer the part from one stationto the next must be perfectlycoordinated.This requires an accu-rate CNC system that features advan-

ced axis group control. "Each module isconsidered an independent entity" specifiesOlivier Voumard, "so the CNC has to be ableto control several channels simultaneously andseparately. Our machines feature between12 and60 axes, from axes dedicated to machining, tothose used for loading and unloading, and thedifferent measuring systems.The CNC systemmust be able to support a great many axes and,as there are no 60-axis CNCs, several CNCsystems must be combined entirely transparentlyfor the end-user"."With its Axium Power system" he adds, "Numhas succeeded perfectly in meeting ourrequirements. Furthermore, the system’sflexibility and the involvement of the Num teamshave enabled us to set it up easily. But the allianceof our machines and Num’s CNCs yields a rareidiosyncrasy: according to our clients, thanksto the Axium Power interpolation algorithms,the systems achieve a surface finish presentingunique aesthetic qualities, and in certainsectors this is an essential asset!".

Today, even aproduction machineshould be beautiful,

as shown by thefuturistic design of

the Precitramemachines.

5num information No 41

In Freiberg, Germany, a medium size companycalled D-H-G Knauer GmbH, produces bicyclehelmets under the KED marque with a pro-duction rate of nearly 100%. In addition to

its success in its own domestic market, D-H-GKnauer exports 80% of its production worldwide.For example, it is the market leader in South Korea.D-H-G Knauer GmbH was founded in 1985.Originally, it was a service provider in the machi-ning and transformation of synthetic materials.

Several thousand helmets in 48 hours!Hans-Georg Knauer, the founder-manager of thecompany explains his success this way: "We ima-gined a rapid, flexible chain of processes, whichwe succeeded in achieving in practice, with theemphasis on the best possible quality". Here arethe results. When a sports store orders bicyclehelmets for its current collection, those helmetsleave the company no more than 48 hours afterthe order was received – even if the order is forseveral thousand units.They are produced accor-ding to the just-in-time principal since Knauerhas no inventory.To be able to produce to order,the company has set up highly flexible manu-facturing operation with one or two shifts accor-ding to the need.The key phase of manufacturing at D-H-G Knaueris the mechanical machining of the thin ther-moplastic outer shell. It is first held on a jig adap-ted to the shape of the helmet, in the machiningcenter. The flashing is removed by a clampingdevice, the ventilation openings are milled andholes are drilled for the helmet fastenings.Whenit leaves the machine, the helmet shell is readyfor assembly.To control this process which combines speedwith reliability, Hans-Georg Knauer uses Huber& Grimme machining centers, 14 of which arein the plant. He has remained loyal to the brandsince the foundation of the company.

Cooperation for more than 10 yearsSince its creation, HG Bearbeitungs-SystemeGmbH Huber & Grimme, established in Wie-dergeltingen, has specialized in CNC systems formachining synthetic materials and producingmodels. Since the mid-90s, Huber & Grimmehas equipped all its machines with Num nume-rical controls. And this is not by chance,explains Peter Fendt, the sales manager: "We arevery satisfied with this co-operation, which wouldnot have lasted 10 years otherwise. The nume-rical controls meet our requirements in terms ofcalculation power, with short processing times

Bicycle Helmets – Made in Germany Thanks to its clever ideas and modern equipment, D-H-G Knauer GmbH has risen to a top position amonghelmet system manufacturers. The eight most recent machines are controlled by Num CNCs.

and easy programming. We also appreciate thehighly flexible personnel at Num, as well as theirimmense know-how of special applications."Using Num CNCs is very easy: all the programsare taught directly on the machine. "There isno question of using any another programmingmethod due to the thinness of the syntheticmaterial shells we machine", explains Hans-GeorgKnauer. "We have already tried to useconventional programming on the machine; wehave also tested a CAD/CAM system. Unfortunatelythe final results were not good enough."To facilitate teaching, Num has developed itsown mobile teach-in-box for Huber & Grimmethat gives the programmer greater flexibility.If success continues, the installed base ofmachines at Knauer should soon grow.The listof candidates certainly includes the manufacturerHuber & Grimme and the numerical controlspecialist, Num.

SOLUTIONS

Machining Synthetic Materials

Eight in line: The new HG 1400 machining centersenabled productivity at Knauer to be increased.Machining times were reduced by at least one third.

The helmet slots are milled into the shell using a high speed spindle. Theother tools necessary are housed in the magazine.

Hans-Georg Knauer:"With the new Numnumerical control,we can makecorrections to thecurrent programwhile stillmachining."

num information No 416

S ince the early fifties, the Italian companyMoreali, established in the Italian“Technology Valley” (Emilia Romagna),has specialized in the manufacture of

high quality gears.Two thirds of its productionare intended for the domestic market and onethird for export to France, Germany and Canada.Production is composed of gears foroil-hydraulic pumps, straight bevel gearing,spiral bevel gearing, of the “Gleason” Hipoidsystem, amongst others. “High quality, highproductivity, high value added services (design,dimensioning, packaging etc.) are the keys tothe success of our activities’’ declaresGianfranco Macca, owner of the company.“Designing a gear is a specialist’s task’’ hecontinues “as there are a multitude of possiblesolutions depending on the characteristicsdesired for the transmission. One must be ableto cleverly combine tooth geometry, thematerial, the transmission torque, etc.”

Combining quality, variable batchesand automatic production‘’Producing 100,000 gears per month, withconsistent quality, the least possible rejects,batches that vary from a few dozen to twothousand items, working non-stop, allautomatically, that’s the challenge we must meet”explains the Design Department Manager.“Today, this is possible thanks to theknow-how of Remaut, responsible for themaintenance and overhaul of our machines,and to the know-how of Num.”

The design andproduction of gears is a

specialist’s activity

Gear cutting

A professional attitude provides the Italian manufacturer with a flexible, highperformance production tool.

“Our latest gear hobbing machine, a Gleason106 is now controlled by a Num Power 1040CNC’’ says the manager of bevel gearing, “Wehave a high speed spindle that reaches cuttingspeeds of 100 to 130 m per minute, hence asignificant reduction in machining time, aboveall, an improvement of the final crowning cut”.Easy programming, simple setup and theavailability of special cycles make this machineextremely flexible and simple to use. “Thisflexibility was obtained” explains SilvanoNutini, technical manager for Remaut, “bypersonalizing the human machine interface withNum development tools: MMITool andProcam”. MMITool can change the HMI viaan object-oriented language, by displaying onlythe information the operator needs. Procamis an interactive automatic program creationpackage, where data is entered into fieldsproposed by the graphical interface.“Furthermore”, adds Silvano Nutini, “we wereable to develop gear machining cycles (cuttingetc.) in the form of a parameter file, thanksto structured programming and sophisticatedmacros resident in the Num CNC.”

A HMI dedicated to grinding In the Grinding Department, the Tacchellagrinding machine, recently renovated andequipped with the Axium Power CNC system,is particularly important. “The choice of a PC-based CNC system (Axium Power)’’ explainsSilvano Nutini, “enabled the development ofa dedicated grinding HMI by using standardsoftware tools (Visual Basic, Visual C++).Moreover, the presence of an applicationsserver in the CNC (PCToolkit) gives free accessto the information of the CNC, the digital drivesand the programmable controller.These wereintegrated in the display pages in order tofacilitate surveillance and machine maintenance’’.The Num HP Drive servodrives provedindispensable in obtaining high accuracylevels (in the order of a micrometre) and thereliability required by grinding operations.

SOLUTIONS

Moreali produces 100,000gears per monthwith Num CNCs!

The development ofa professional HMI

facilitatesautomatic

production andflexibility

7num information No 41

Totally enclosed, the Vegamachine offers excellentsafety. Furthermore, itsHMI allows the operator tofind familiar terms andrepresentations on thedialogue screens and 3Ddisplays

The Vega machining centermeets all the needs forjoinery and timber frames(maximum section: 300 x450 mm – width: 650 mmand optionally 1200 mm).

The position of the toolhead, above the part to bemachined, facilitates theevacuation of waste, inparticular during sawingoperations. This Sytecbrand tool head iscontrolled by a Num AxiumPower CNC, coupled withHP Drive digitalservodrives.

Almo uses its metal cutting know-how for aninnovative woodworking machine!

W hen Michel Loyet took over at Almotwo years ago, he knew how to makeuse of the company’s knowledge andskills with flexible and industrial

machines to diversify into the constructionjoinery sector. This is how the Vega 5-axismachining center was born. Intended for carpentersand joiners, this machine is notable for thejudicious transfer of technology …

Machining an entire construction frame“With the Vega, we meet every need in terms ofcutting timber joints and wooden frameworks’’explains Miguel Gomez, Technical Director atAlmo Technologie. “The m/c’s originality liesin the fact that it is based on true metalworkingphilosophy. Thus, the perfectly rigid portalframe structure, usually reserved for machiningmetal parts, is ideally suited to intensive, highspeed operations. Likewise, the multi-directional18,000 rpm tool head allows machining at anyangle, even on the ends of the beams.Combined with a feed rate of 60m/min, we areentering the realms of high speed machining.This is why we have also worked in co-operationwith tool makers to take account of all theaspects of high speed machining. Taking allthese imperatives into account is quite naturalwhen machining metal, but less so in the caseof wood”.The position of the tool head, above the part tobe machined, facilitates the evacuation ofwaste, in particular during sawing operations.The Sytec brand tool head is controlled, likethe entire machine, by a Num Axium PowerCNC, associated with HP Drive digitalservodrives. It automatically selects the toolaccording to the machining to be performedand optimizes cutting speed.‘’Several applications were developedspecifically for this machine”, adds FranckStrugareck, Sales Engineer at Num. “Thus, thehead positions itself automatically according tothe degree of incline required by the tool andthe arrangement of the part. We have alsodeveloped, with the help of dynamic operators,algorithms that either allow accuratelysynchronizing the loading and unloading

clamps, or on the contrary, managing themindependently during the machining phases, toeliminate any possibility of collision. Finally,thanks to a measuring system located at theloading system, the blank (section and length)is identified and the CNC can then launch theappropriate program”.

Automating the constructioncarpenter’s tradeThe Vega machining center has a completelyenclosed machining area. This is another legacyof Almo Technologie’s experience in the metalworking sector. “In the automotive industry’’states Miguel Gomez, ‘’we had to follow verystrict safety rules.We thought it would be usefulto replicate them on the Vega, especially sincethis favors compliance with noise and duststandards”.With Vega, the objective of the Almo Technologieteams was to industrialize the constructioncarpenter’s profession. Objective attained, since3 machines have been sold already. ‘’We plan tomarket 50 machines per year,’’ concludes MichelLoyet, ‘’twenty of them for export, for a priceranging from 300,000 to 350,000 euros”.Especially since other functions are yet to beimplemented, like remote maintenance viaAxium Power’s TCP/IP link. Other businesssectors are interested by this type of machine. Itsflexibility and characteristics allow it to be easilyconfigured for machining composite materials,light alloy profiles and models.

Almo Technologie has launched a machine capable of performing all the machiningand jointing operations on wooden frames, entirely automatically, with a 5-axismachining center controlled by an Axium Power CNC.

Industrial machining of Timber Frames

num information No 418

SOLUTIONS

D esigning and building a bottling linerequires perfect synergy betweenmechanical engineers, productspecialists and micro-biologists.

Their close collaboration yields systems thatare increasingly compliant with thestringent organic, chemical, physical and micro-biological characteristics required today.Having based its production on its capacityto unite these trades, Alfatek whose headquartersare in Albano Laziale, near Rome, succeededin imposing its systems on the national andinternational markets in the last ten years. Itscore business is the installation of winebottling lines but it has increasinglydiversified into all food liquids, oil, liqueurs,milk etc.

"It was precisely to meet the needs of thesenew applications that we made new investments."says Francesco Scarano, plant manager."We had to improve flexibility, productivity anddelivery lead times".This policy led notably to the acquisition ofa Maut MME3 boring/milling machine, as wellas five vertical machining centers and tennumerical control lathes.The boring/milling machine is equipped withan Axium Power CNC system and Num HPDrives, enabling it to reach traverse rates of 40m/min and machining speeds of 20 m/min.Thanksto its 18 kW "built in" Num Motorspindle©, thetool can rotate at 7,600 rpm, while the X axistravels up to 6 m (1 m for the Y-axis and 1.8

Alfatek has improved the quality and flexibility of its production thanks to a Maut boring/milling machineequipped with an Axium Power system!

m for the Z-axis). Furthermore, the machinefeatures a bi-rotational head (A inclined at 45°,driven by B) and uses the "inclined plane"function of the CNC system to execute cyclescommon to a three axis machine with anyinclination of the toolhead.The CNC calculatesall the translations to perform for the rotationof the toolhead, simply on the basis of the anglesformed by the new plane with the axes of themachine, taking into account the tool length andradius corrections. Finally, the automatic toolchange system, with forty available stations andrandom management, completes the equipment."Before having this machine" explainsFrancesco Scarano, "certain mechanical partssuch as the bases or more generally large sizeparts, could not be machined in a singleoperation. This reduced the precision of thefinished part and considerably increased leadtimes.The manufacture of large size parts hadto be outsourced which limited the autonomyof the company".

Goal Reached!Since its implementation in May, the Mautmachine was especially used to produce steelbases for batches that varied from one to tenitems. "Availability, in CNC, of macro-commandsfor drilling, rigid tapping, boring and slotting,greatly facilitates the production of partprograms" says Francesco Scarano."Furthermore, rigid tapping integrated in theCNC enabled us to use spindles with no axialcompensation system, guaranteeing bettermachining quality and reducing tool costs"."Another important asset", he concludes,"is that this machine can manufacture a widerange of different parts, notably those normallymachined on our CNC machining centers.This provides our production with significantflexibility and enables us to adapt more easilyto the current and future requirements of ourmechanical designers. Finally, the selection ofthe Axium Power PC-based system facilitatedthe connection of the CNC to the companynetwork with obvious benefits in terms ofproduction management".

Boring/Milling Machine

"Before having thismachine" explains

Francesco Scarano,"certain mechanical

parts could not bemachined in a single

operation. Thisreduced the precision

of the finished partand considerably

increased lead times".

Num contributes to the development of High-techBottling Lines

9num information No 41

A Service "Pro" Chooses Num !

For several years,TTB Engineering hasbeen producing 5 or 6-axis tool shar-pening centers for the production ofsmall size tools (12 to 0.02 mm Ø).

Called TGC (Tool Grinding Centres), thesemachining centers are designed for production,and feature up to 5 wheel spindles, each ableto hold 3 grinding wheels. This innovativesystem permits cylindrical and shape grindingfrom A to Z without unclamping the workpiece.In addition to time savings, this process is alsohighly precise. The Swiss manufacturer hasannounced results of roughly 0.5 µm!But TTB’s strategy is not limited to thesupply of recognized, high performance grindingcenters.This company, located near Lugano, hasdecided to differentiate itself through a veryservice-oriented approach to customer needs.

Downtimes less than a day long!Like many machine manufacturers, TTB isconfronted with diverse and varied requests;the imperatives of the automotive industryare not the same as those of the medical,watch making or electronic industry. Thusthe TGC feature a modular design enablingthem to adapt to the different specificationsof users. It is here that TTB wants to make adifference. "We have broken the machinedown into several functional blocks that aretested before and during machine assembly"explains Roberto Vassalli, company Director.‘’But above all, we have decided to keep someof them in stock in order to respond nearlyinstantaneously to any failure notified by ourclients. Thanks to this anticipation, we areable to repair a machine in less than one day,and saving a day of production can be vitalfor a manufacturer. This is what led us tomonitor our inventory of spare parts withsuch precision", he continues, "and in ourwarehouse we store parts that are no longermanufactured by our supplier but that weknow are still used by our clients".This method enables TTB to optimize itsassembly times. "We are capable of setting upa machine, complying with client specifica-tions, in about 15 days!" announces RobertoVassalli.

Num, A Partner up to Standard"It was initially the renown and success of theNUMROTO software that attracted us toNum." confessed Roberto Vassalli. "In the

sharpening sector, NUMROTO has a veryextensive installed base, in many countries.Furthermore, its scalability, like for example itscompatibility with the most varied measuringsystems, make it a truly universal system.Moreover, Num quickly demonstrated itscapacity to meet our particular needs" headded.To meet TTB’s requirements, Num developeda specific fluid-cooled synchronous servomotor.This servomotor, reaches speeds of over10,000 rpm, and is available in severalversions (self-contained and housed for axisapplications, and as separate parts for spindleapplications). In addition, to its major asset(compactness) its multiple applications capa-bility facilitate its placement in the inventory."Today, Num mounts complete systems forus, CNC/Drives/Motors" affirms RobertoVassalli. And having the same philosophyregarding customer satisfaction is certainly aexcellent way for us to get along!

When choosing a machine, technical performance is certainly one criteria. TTBEngineering also decided to include quality of service and Num has followed it inthis approach.

Tool Grinding

Mounted on a turntable,the wheel spindles can beequipped with 3 grindingwheels each. Associatedwith the 4-axis work-holding device, this multi-wheel spindle canperform a cylindricalgrinding operation with notool change.

TTB Engineering produces 5 or 6-axissharpening centers for the production ofsmall size tools (12 to 0.02 mm Ø).

num information No 4110

APPLICATION

In the machine-tool environment, machiningcenters have customarily competed withrotary or linear transfer machines. Theformer were generally used for small and

medium size batches, while the latter, built forspeed and precision, were reserved for largescale production. Transfer machines arecomposed of several stations. A part ismachined by undergoing partial treatment ateach station, which always executes the sameoperation. While the borderline betweenmachining centers and transfer machines wasfairly well defined for a long time, it has nowbecome much less clear. There is a trend towardgreater operating flexibility to allow thelaunch of smaller batches with a greaternumber of part variants.In these conditions, changeover times becomesparamount. Likewise, flexibility anduser-friendliness are decisive characteristics inthe selection of this type of machine. That iswhy CNC systems are an excellent solution forreplacing the fixed, rigid solutions that havelong driven the basic design of transfermachines.

A New Concept for Transfer MachinesA transfer machine supports the most diversemachining processes: turning, drilling, milling,grinding, measuring, etc.The CNC system mustbe able to manage a great number of axes, andwhen that number is very high it must bepossible to link several CNCs in a way that is

How to allow the intuitive use of a machine with more than100 axes?As transfer machines evolve, they reveal new control needs. Num offers a solution toimprove yield.

totally transparent for the user. Users must befreed of any concern specific to a particularCNC such as the name of fixed axes, thedesignations of the channels, etc. They mustbe able to focus on the proper terms of theirmachine, like the name of the station and theoperations performed there.Based on its Axium Power CNC system, Numhas developed an application that drives a simpleor complex machine and illustrates it on theCNC panel as it appears in reality.This application can be adapted to themachine’s configuration. An Axium Powerkernel can drive a maximum of 8 stations fora total of 32 axes, with at most 9 axes perstation. For the largest transfer systems,several CNC kernels can be connected inparallel (see figure 1).This yields machines withover 40 stations and more than 100 CNC axes.The turning, milling, grinding, measuringstations, etc. are combined at will accordingto need. The many stations of larger systemscan be combined into "modules". The Numsolution takes into account this type ofconfiguration and allows the user to focus onthe stations of a particular module. Station andmodule names can be freely defined. Eachstation can thus be easily identified by the user.Likewise, whatever the operating mode of the

Transfer Machines

Flow chart of Num system. Operator-side, use isparticularly simple and intuitive.

Shop network(e.g. Ethernet)

EthernetPLC

PCsystem

CN

C k

erne

l 1

CN

C k

erne

l 2

CN

C k

erne

l n

Axi

s 1

Axi

s 2

Axi

s n

Num’s solutionwith integrated PLC

11num information No 41

CNC system, each station or module can beselected.The assignment of part programs andother CNC machining data to the differentstations is automatic, releasing the operatorfrom this distribution.This is also the case forthe backups.When part programs are created,their assigned station is clearly indicated.Particularly transfer machines with a lot ofstations can have a considerable number of tooloffsets. These offsets can be assigned to aparticular station to facilitate their managementand use. Users can simply choose to show allthe tool offsets or just those corresponding tothe station selected.With these complex machines, an operatingproblem like de-synchronization can havedisastrous effects. In the event of a failure, itis essential that error messages are as clear andaccurate as possible. The Num applicationinforms users of possible errors, while theunaffected stations continue to run normally.These error messages indicate the physical CNCkernel and the CNC channel concerned.Thisinformation facilitates trouble-shooting on thephysical components. Furthermore, the errormessages are recorded in a fault log.

A nearly limitless system…To make best use of the features of alltransfer machines, the Num solution is notlimited to the previously mentionedpossibilities. It also allows specific developmentseither by the machine manufacturer or thesystem supplier. These adaptations are

possible both for the HMI (Human MachineInterface) and the real time CNC kernels.In conclusion, the new Num applicationsimplifies transfer machine use and reducesthe risk of operating errors, yieldingimproved productivity and reduced setting times,and as a result, a reduction in part price.

A par t is machinedby undergoingpar t ia l t reatment at each stat ion,which alwaysexecutes the sameoperat ion(Precitrame's doc. )

Num goes to the Show...

Educatec

Paris / France

SPS/IPC/Drives

Nuremberg / Germany

March 2005

CIMT

Peking / Rep. of China

Industrie

Lyon / France

November 2004JIMTOF

Tokyo / Japan

September 2005

Automation

Paris / France

EMO

Hanover / Germany

November 2005

Educatec

Paris / France

FIMA

Valence / Spain

April 2005

LIGNA +

Hanover / Germany

May 2005

Scanautomatic

Göteborg / Sweden

October 2005

Published by Num SAImmeuble “Les Courlis”46 avenue Kléber92700 ColombesTel.: +33 (0)1 34 23 66 66Fax: +33 (0)1 34 23 65 49www.schneider-num.comUnited StatesNum Corporation (USA)603 East Diehl Road,Suite 115,Naperville, IL 60563Tel.: +1 630/505-7722Fax: +1 630/505-7754sales@num-usa.comwww.num-usa.comUnited KingdomNum (UK) LtdUnit 43 & 44, CentenaryBusiness Centre,Hammond CloseNuneaton CV11 6RYTel.: +44 (0)2476 387306Fax: +44 (0)2476 387316sales@schneider-num.co.ukwww.schneider-num.co.ukEditor: Laurence PetitguyotRealized by: AVANAOrléans (France)33 2 38 77 88 88ISSN 0248-73064th quarter 2004

num information

Axium Power CNC System

Num : CNC Complete Solutions

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From the combinationof a powerful industrialPC, a compact universalCNC, digital bus drivesand a wide range ofaxis and spindlemotors, Axium Powersystems are capableof meeting all needs,from the simplest tothe most complex.

QuickImplementation,ComputationalPower, Accuracyand Quality ofMachining areamong so manyreasons to chooseAxium Power! A

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