OpenCNC[R] v6.5 enables manufacturers to integrate off-the-shelf hardware and software technologies. Set of lathe macros helps saves programming time, while hand-wheel feed feature lets user hand feed job stream up to programmed cutting and traverse speeds. Software also provides compiled HTML help menus, lead screw compensation for rotary axes, and Sercos SoftSERCANS support. With winPlot, users are provided with clear, 2D plot of machine moves.

Manufacturing Data Systems, Ann Arbor, MI, announces the release of OpenCNC[R] Version 6.5 with a host of features that saves programming time and improves usability across a wide range of machine tools.

OpenCNC software, the first production-proven, unbundled, software CNC built on an open control architecture, enables manufacturers to save cost and keep up with rapidly advancing technology by integrating off-the-shelf hardware and software technologies. It was introduced to the market in 1990 and is installed on thousands of machines across a range of industries.

OpenCNC Version 6.5 enhances the productivity of the software through several new features:

o New set of lathe macros, including profile definition, finishing, grooving, roughing, and tool definition saves programming time, delivering the maximum machine motion for minimum programming time.

o The new Hand-Wheel Feed feature allows the user to hand feed a job stream up to the programmed cutting and traverse speeds. Handy for debugging programs, this feature allows the user to control machine motion and watch the machine tool follow a programmed path and avoid potential collisions or misfeeds in the program.

o Help menus are now compiled HTML allowing for easier searching and navigation.

o Improved lead screw compensation for rotary axes reduces complexity in set up, saving programming time and contributing to machining accuracy due to improved positioning.

o A low-cost assist for analog servos, a new driver for Sensoray526 card also will be included in the new OpenCNC release. The Sensoray526 card is an economical reader of an encoder input used to run a servo.

o Broadened Sercos SoftSERCANS support with the addition of drivers that will run more variations of Sercos drivers in use on machines today, making OpenCNC even more widely applicable to more different machine tools.

SERCOS (SErial Real-time COmmunications System) is an open, fiber-optics-based, CNC-to-digital drive interface standard. Interfacing a completely open, all-software CNC with an open digital communications standard allows the power and tuning of a servo drive to be managed entirely in software from a single PC, with just one fiber optic cable and a passive communication card between the PC and the drive.

The benefit of the OpenCNC SERCOS interface for machine tool builders and end-user manufacturers is enhanced servo performance, improved part finish, and the cost savings associated with using standard digital interfaces and non-hardware-based open solutions for communications to the machine tool versus using proprietary digital or analog drives.

Other new features include:

o The new winPlot feature allows users to display the machine coordinates during operation for diagnostic and prove-out purposes. The feature provides a clear, two-dimensional plot of machine moves.

o The winSevView feature makes it easy to search and view specific patented Significant Events / files. Significant Events are time-stamped events stored in the control in order of occurrence. With this new tool users can quickly review significant events from any time in the machine's operating history.

Unlike proprietary CNC controls, OpenCNC requires no proprietary hardware or motion control cards. Combining a soft CNC and soft PLC in a single application, OpenCNC is well suited for new equipment as well as machine control replacements and allows the easy and regular installation of software updates. OpenCNC also provides essential software tools and diagnostic features for customizing servo, spindle, ATC and other hardware interface options.

"In an industry dominated by proprietary hardware CNC solutions, MDSI has proven that high-end, multi-axis CNC machine tools can be controlled entirely from software-without any motion control cards, proprietary hardware, or embedded firmware," said an MDSI spokesperson.

OpenCNC provides a common control technology across a full range of machine tools: single- and dual-turret lathes, single- and multi-spindle precision drills, routers, mills, grinders, gear hobs, dial index machines, and gantry machines-all from a single operating system, running from a single processor.

MDSI's OpenCNC[R] and WinMotion[R] open architecture machine control solutions improve machine tool productivity, and permit users to easily upgrade hardware, software, and peripheral components without having to reengineer existing machine logic. MDSI is a subsidiary of Tecumseh Products Company, a $2 billion global manufacturer of compressor, gasoline engines, and pumps. MDSI supplies open architecture factory automation solutions that increase flexibility and enable agile manufacturing for the CNC and general motion control markets. MDSI software has logged millions of hours of successful metalcutting production in the aerospace, construction, agricultural and machine tool industries.

Designed for HyPerformance(TM) Plasma systems and FASTLaser(TM) processes, Automation CNC v6.0 provides HPR interface with full-screen diagnostics, configurable Watch Windows, and ability to create custom cut chart databases. HPR130 auto gas console features allow users to setup plasma supply operations. Along with facility for determining focal position, software offers Dynamic Pierce Control, auto process control, and laser marking capabilities.

Hanover, NH, USA - Automation CNC v6.0 software from Hypertherm, Inc. is now available for metal fabricators seeking greater productivity from mechanized HyPerformance(TM) Plasma systems and FASTLaser(TM) processes. CNC v6.0 is especially designed for applications of HyPerformance Plasma.

Newly released by Hypertherm Automation, CNC v6.0 is a performance upgrade that will be standard on all future shipments of Hypertherm CNC controllers including all EDGE[R], MicroEDGE(TM), Voyager(TM) and Mariner(TM) models. The company recommends that current CNC users contact their Hypertherm representative for specific information about system compatibility and available software upgrades to CNC v6.0.

The CNC v6.0 HPR (HyPerformance) interface is the most complete ever offered by Hypertherm Automation. It features full-screen diagnostics, configurable HPR Watch Windows, and the ability to create custom cut chart databases. HPR130 auto gas console features allow users to setup plasma supply operations by selecting material type, material thickness, process current and process gases.

The new CNC release also enhances FASTLaser software tools. Using Hypertherm's patent-pending process monitoring, it provides an automatic adjustment feature for determining focal position. The new automated focal position calibration routine simplifies the process of finding the spot where the laser focal position meets the material surface. It can be used whenever a shift in focal position occurs as with lens installation or resonator maintenance. Additional laser enhancements in CNC v6.0 include time saving Dynamic Pierce Control (DPC), auto process control and laser marking.

"Hypertherm is committed to being the supplier of choice for all our customers' thermal cutting needs," wrote Tate Picard of Hypertherm Automation in a recent Field Facts newsletter. "By actively soliciting feedback from our customers about software enhancements they'd like to see, we've been able to dramatically improve CNC v6.0 user interface screens and functionality. Additional requests from our customers promise to make CNC v7.0, already underway, even better."

Since 1968, Hypertherm has been the industry leader in plasma arc cutting equipment and service. Now, with its entry into the plate-laser cutting market, Hypertherm expands its technology leadership commitment. By continually delivering breakthrough advances in metal-cutting productivity and precision - first in plasma, now also in laser - Hypertherm reaffirms and extends its position as the world's leading supplier of advanced high temperature metal cutting technology. Hypertherm serves a wide range of industrial metal cutting needs from its headquarters in Hanover, New Hampshire, with subsidiaries, sales offices and partner representation worldwide.

Hypertherm, HyPerformance, FASTLaser, EDGE II, MicroEDGE, Voyager and Mariner are registered trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries.

Designed to optimize CNC machining process, VERICUT v6.0 can simulate multiple setups in single session. Collision checking monitors spindle states, enabling program to catch programming errors with spindle and cutting tool usage. With in-process model of simulated workpiece, inspection and process documents accurately reflect state of workpiece at any stage of process. Model Export creates CAD models from in-process cut model generated by simulating NC program.

(Chicago, Illinois - Wednesday, September 6, 2006) - CGTech showed the latest version of VERICUT CNC machine simulation and optimization software at IMTS in booth D-3035. VERICUT 6.0 has many new features designed to increase the ability of CNC manufacturing engineers to analyze and optimize the entire CNC machining process in order to increase manufacturing efficiency.

"Due to global competitive pressures on our customers CGTech is increasingly challenged to simulate more complex processes and more complex machines," said Product Marketing Manager Bill Hasenjaeger. "VERICUT 6.0 ties these complex processes together with the ability to simulate multiple setups in a single simulation session."

VERICUT 6.0 also includes enhanced collision checking that monitors spindle states for milling and turning simulation, enabling VERICUT to catch common programming errors with spindle and cutting tool usage. Additionally, significantly enhanced simulation of complex cutting tool shapes commonly used in production processes shows the NC programmer or manufacturing engineer exactly what will happen when using the tool.

"The result of this work is a tightly unified environment for simulating complex mill/turn multi-function machining centers for production processes," said Hasenjaeger. VERICUT 6.0 leverages the results of simulating these complex processes with the ability to create inspection instructions, CNC inspection programs, and automated process documentation using the simulated workpiece. Because of VERICUT's accurate feature-rich in-process model of the simulated workpiece, the inspection and process documents utilize and accurately reflect the state of the workpiece at any stage of the process.

To ensure VERICUT's simulation is as accurate as possible, CGTech has partnered with many key machine tool builders, control manufactures and CAD/CAM companies. CGTech's Technology Partner Program establishes a cooperative working relationship with a goal of helping mutual manufacturing customers maximize their success and productivity.

"IMTS is a fantastic show for us because not only do we get a chance to meet with many current and future customers, we can meet with most of our partners under one roof. No other show is that productive," said Hasenjaeger.

Some of the new and improved features users will find in VERICUT 6.0 include:

Multiple Setups in a Single Session

With the new Project Tree in VERICUT 6.0, the manufacturing engineer can organize all his NC process steps in one place and the workpeice(s) transition from setup to setup automatically during the simulation. Each setup has its own CNC machine, fixtures, tools, NC programs and simulation settings. The cut stock moves from setup to setup, with automatic orientation. Once a user selects the CNC machine configuration, the stock, fixture and design component information is attached to the machine, ready to simulate the entire set of machining operations.

Simulate Machines with Multiple Synchronized Tools

VERICUT 6.0 now offers the capability to synchronize up to 32 machine "channels" or machines with multiple synchronized CNC controls. VERICUT's virtual machine is organized into multiple sub-systems that can all synchronize together seamlessly.

New Tool Manager Speeds NC Program Optimization

VERICUT's NC program optimization module--OptiPath[R]--is easier to implement thanks to a redesigned Tool Manager. OptiPath tooling data is now stored inside the Tool Manager. This simplifies the implementation by placing all relevant tool information in one place. Creating new tools has also been simplified. The new tool assembly wizard allows the user to create a new milling tool in one simple panel by answering a few questions.

Model Export Enhancements

Model Export creates CAD models from the VERICUT 'in-process' cut model generated by simulating an NC program. The model includes machined features such as holes, fillets, corner radii, pocket floors and walls - exactly as it is cut on the CNC machine. In VERICUT 6.0, Model Export outputs features where possible and also "synthetic features" when individual features are not possible or desirable (such as "scallops" created by a ball endmill).

Create CNC Probe Programs and Inspection Sequences

VERICUT is an ideal place to create probing routines because of the 'in-process' model which is not available anywhere else in the CNC manufacturing process. Rather than having to create additional "manufacturing" CAD geometry that "hopefully" represents the as-cut workpiece, using VERICUT's simulated in-process feature geometry to create the CNC probe program makes on-machine in-process inspection a practical reality. In addition to on-machine probe programming, VERICUT 6.0 allows the creation of customizable inspection reports in HTML or PDF format for use by machine operators or quality control staff.

"A journey of a thousand miles starts with a single step."

This ancient Chinese proverb is good to keep in mind when thinking about how a factory begins to move toward a plant-wide electronic production monitoring system. The vision of the future destination may be luminous and compelling, but turning this vision into reality is no hop, skip and a jump. It has to be taken earnestly and carefully, step by step.

In the end, plant managers will be able to access the system and get instant, up-to-the-moment reports summarizing the OEE (Overall Equipment Effectiveness) rating of the whole plant, separate production lines or even individual machine tools. Analysis of the collected data used to calculate this rating will pinpoint where problems or opportunities for improvement appear.

Here is an example of what is to come when a production monitoring system is in place: Managers are alerted to a report showing that a certain machine in one of the machining lines needed an average of 3 minutes cycle time during the last shift when it should have been closer to 2 minutes at programmed feed rates and spindle speeds. Reviewing the log of events that occurred during this shift shows that a grinding wheel was not cutting as aggressively as intended and had to be replaced at 50 percent of its expected life as a result of excessive wear. A recent change in wheel grade is recorded in notes entered by the manufacturing engineer. At the start of the next shift, a message to the cell operator gives instructions to install a harder grade wheel. Cycle times monitored during the day show a return to the required output. Problem solved.

This vision is not new. It's been talked about and dreamed about for years. In fact, the software and hardware to make it happen not only exist, but they also have a proven track record. What is becoming clear is that making the transition to this future state will be neither quick nor effortless. The first steps are the toughest, but that is where the journey begins, as the proverb reminds us.

Tecumseh Products' compressor plant near Tupelo, Mississippi, has taken those first steps, and the benefits are already clear and substantial. The plant has installed software-only CNCs on several "bottleneck" machine tools and is running key portions of a bidirectional production monitoring system that integrates the CNCs with the plant's existing computer network and ERP software. Plant management is taking the results of these initial installations as proof that these steps are definitely moving in the right direction.

Under Pressure

Although Tecumseh Products is best known for its small engines found on leading brands of lawn mowers, snow blowers and similar products, the company is a major producer of compressor motors for refrigerators and air conditioners. Consumers are not likely to be aware that the reason these products run so quietly and efficiently is the unseen presence of a Tecumseh-built compressor inside, yet the reliable performance they enjoy is dependent on the quality of those compressors. Because many of the major brands of refrigerators and air conditioners have moved production offshore, Tecumseh has had to redouble its efforts to maintain profitable operation of its compressor plants in the face of the cost pressures brought on by the severe contraction in U.S.-based appliance manufacturing.

In Tupelo, Tecumseh operates three main machining lines that feed an assembly line on which the various compressor models are built in a mix that is determined by a schedule of firm customer orders. This plant houses about 100 active metalcutting machine tools. A shop control system that relies on manual data entry allows managers to monitor production, but the information is at least 1 day old by the time it is available for analysis and response. The system tells managers basic information about labor input, machine output and scrap rates. This gives them a somewhat sketchy picture of where the bottlenecks are and when part shortages may affect the assembly line. It is adequate to tell them how to react but rarely helps them anticipate and avoid shortages that hamper the assembly line. It can't tell them what is happening inside each machine to reveal the causes of bottlenecks.

"What we have in place is now the framework for a much more capable production control and communications system," says Joe Kulovitz, a manufacturing engineering manager.

The system will eventually supplant the existing one and provide a much more detailed picture of machine performance in real time. The new system has two main elements, both from Manufacturing Data Systems, Inc. (MDSI) in Ann Arbor, Michigan. One is OpenCNC, an open-architecture machine control that replaces OEM-installed CNCs. The other is MaximumFactory, a suite of software modules that collect and analyze real-time data generated at machine control units. This software suite is tailored for the ability of OpenCNC to extract data, but the software can also be interfaced (although less conveniently) with proprietary legacy CNCs.

The company has added enhancements to its Mastercam Version 9 products for design, machining, turning, wire EDM and routing operations. Users gain immediate production benefits from the Version 9 upgrades, and new users quickly acquire CAD/CAM capabilities, according to the company.

Mastercam Mill Version 9 delivers high speed pocketing and increased machining options, including full trochoidal machining: moving the tool in small circles that can "nibble" out the entire pocket so the tool is never buried.

To save runtime, the trochoidal machining feature also allows users to set the percentage of tool contact, speeding successive passes because "nibbles" are only taken when the tool would be buried in left material. When combined with Mastercam Solids, the software can automatically detect and program drill holes on solid models.

Precision production of shops' complex designs is simplified by enhancements to 3D and Multi-axis functions at the most advanced level of the software. The Finish Project Toolpath function is said to deliver a consistent finish that follows the natural curves of unlimited surfaces or solids. Toolpathing with Custom Plunge Roughing lets users machine in any pattern, and new Hybrid Remachining changes cutting strategies with model slope changes in a single toolpath.

One new five-axis resource, broad-based Tool Containment, cuts difficult internal areas. Other new features allow cutting unlimited surfaces in five-axis and adding cuts to steeply angled areas of five-axis parts.

Mastercam Lathe Version 9 is said to deliver new toolpaths based on proven industry needs and add new verification tools for quick reference. More than 16 new programming and automated operational features cut programming and turning time as production quality increases.

Mastercam Wire Version 9 combines new wirepaths with easy new interfaces for faster programming. It features new tools, such as fast land programming, easier rough/skim/tab cut control, and either automatic or click and drag tab positions.

With Mastercam Solids Version 9, users can now sew an unlimited number of surfaces into a single solid model; create sheet solids that can be thickened, shelled and more; trim solids to multiple surfaces using sheet solids; create "disjoint" bodies; and much more. Its Solid Feature Recognition component identifies entities such as fillets and holes on imported solids and adds them to the history tree as fully editable features.

Enhancements common to all Mastercam Version 9 products ensure that you can open and edit virtually any CAD file. Support for AutoCAD, DWG, DXF and Inventor files plus updated SAT and Parasolids translators are included. Catia and Pro-E translators are also available.

Other enhancements include the new Work Coordinate System, which smoothes the progress of the user's work on a model by reorienting the view, construction and tool planes, then it transfers the new planes to the user's G-code. The new Entity Attributes Manager controls how specific entities will be created and sorts incoming entities as files are imported.

Mastercam is a Windows-based CAD/CAM software for two- through five-axis milling and turning; two- and four-axis wire EDM; 2D and 3D design, surface and solid modeling; and 2D and 3D routing. The software runs under Windows 2000 and Windows XP and is compatible with all other CAD/CAM systems.

The company says it has developed techniques that will improve the three most important areas for an NC programmer: ease and flexibility in programming any tool path; the toolpath calculation speed; and toolpath output.

The company has released version 5.1 of its MachineWorks CNC simulation and verification technology. One of this version's major developments is feature based picking across all the software's geometric engines. Feature based picking enables CAM packages to accurately report the coordinate of a point on the actual cut surface rather than the faceted representation of the cut surface. The surface normal and the surface type (plane, cylinder, sphere) are also given.

Another improvement lies in the visualization of results from a target part comparison. Version 5.1 now features an option whereby unmachined areas can be ignored.

The software's handling capabilities are said to protect applications from problems experienced when making calls to the software's libraries.

The software now returns full details of the faces involved, including the point of self Intersection, the plane equation of the face, the number of vertices in the face loop and the vertex position in the face loop.

Enhancements specific to the Visicut Machine-Works geometric engine include enhanced support of complex tool shapes. Previous restrictions on the definition of 2D tool profiles have been removed so that the profile can be non monotonic in Y. This allows tools with concave ends to be properly simulated in plunging operations, whereby an 'island' of material remains. Closed profiles (toroidal tools) are now also supported.

Ray-traced target part comparison now supports transparency improving the visualization of gouges or areas of rest material. Additionally, the performance of ray-traced target part comparison has been improved, particularly when large stock models are used.

Wire EDM support has been enhanced to support the simulation of different XY/UV and XY'/UV' planes.

Enhancements specific to the Rapidcut Machine Works geometric engine include the fact that holders can now be attached and detached from selected tools at any time. This removes the previous restriction that the bolder must be attached before the tool is positioned.

Target part comparison has been enhanced such that the results can be filtered so that false gouges or undercuts are not displayed.

Enhancements specific to the Pixelcut Machine Works geometric engine include performance gains in speed and memory usage, particularly when using complex solids.

Manufacturing Event Monitoring--MEM is a modular software system designed for real-time acquisition and storing of manufacturing event information and for viewing and analyzing that information across an enterprise. The information provided by the system is said to allow managers to better understand their manufacturing resource utilization and, with that information, to determine changes in processes to increase machine and operator efficiency.

A typical implementation involves the company meeting with designated stakeholders within the customer's organization to determine the optimal combination of data collection and reporting requirements. Once those needs have been identified, the software can combine existing modules to produce a cost-effective solution that meets the client's needs, the company says. Custom additions, if requested, can generally be provided quickly and at minimal cost, according to the company.

The system supports data collection through a combination of one or more interfaces, including HSSB (high speed serial bus), Ethernet, remote I/O devices, PC I/O cards or serial interfaces. The approach recommended to a client is based on data requirements, machine capabilities and budget considerations.

The data collected can range from simple to the complex. Some examples are machine cycle time, machine cutting time, feed hold time, spindle on/off, feed rate override, coolant on/off, lube pump on/off, tool utilization, tool breakage and alarm states. The software also provides a variety of operator and status inputs such as shift start, shift end, job start, job end, setup status, parts count and more.