Bridging the Gap Between the Discrete

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White Paper to Factory Floor THINC for Yourself

• Bridging the Gap Between the Discrete Process
  Industries

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Innovation is critical to business success in
todays world. It is about taking what is there
and making it better as quickly as
possible. Jim McNerney
The Intelligent Numerical Control
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The Okuma Precept
The classic model of CNC design, implementation,
and use is obsolete.
The Intelligent Numerical Control is the next step
And why is that?
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Intelligent Numerical Control
Adapt to changing technology
Adapt to changing requirements
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Every control delivered on every machine tool was
obsolete and frozen in time the day it went into
service.
This model does not foster the development of an
adaptive environment It impedes this
development
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Caterpillar
GMPT
End users
John Deere
Controller manufacturers
Boeing
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Network Architecture
THINC - 2 Boards for all machines
Manufacturing Management System
Ethernet
Digital Caliper
Bar-Code Scanner
FD, CD-R Drive
USB
Camera
PCI bus
PC board
DeviceNet I/O modules
DeviceNet
Okuma Servo Link
Servo / IO board
Spindle / Axis drives and motors
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Software Architecture
Operating System Windows XP Reliable and
world de facto PC OS
Real time extension Volante Couples advanced
Windows applications and machine control with
reliable Hard real time control opens
application possibilities not previously possible
Standard API is available for communicating
between real-time process and Windows for
customers applications
Real time applications
Windows applications
Volante
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How is THINC Useful?
Partners in THINC
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Partners in THiNC
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Partners in THiNC

• What are the applications?
• Tool management (inventory management, tool
  offset adjustment, tool life management, tool
  identification)
• On-machine work measurement
• Real time adaptive control
• Speedy set up and reconfiguration plug and play
  industrial peripheral devices
• Machining optimization
• Shop floor data management paperless
  environment
• Operation enhancement (simplify user interface /
  reduce or eliminate human intervention)

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A Simple Application
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A Simple Application
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Kennametal/Zoller Tool Inventory and Data
Management
5. Job ID Setup Sheet with Tool Assembly
Requirements by USB Barcode Scan
1. Job ID Setup Sheet with Tool Assembly
Requirements
MC-V4020 P200
7. Tool Offset Tool Life Data Request and
auto update via Ethernet THINC-API
2. Job ID Tool Component Request
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Fanuc Robotics/Zeiss CMM Easy Connect and Direct
Tool Compensation
1. Job ID Setup Sheet with Program Select by USB
Barcode Scan.
2. Robot Load/Unload machine via plug and play
DeviceNet/Ethernet easy connect with easy
diagnostics.
4. Direct Tool Compensation via Ethernet
THiNC-API.
Captain L370 P100II
3. Robot Load/Unload CMM.
Fanuc Robotics M-16i
Zeiss CMM
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Applications
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Applications
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LT200 LNS Barfeeder Easy Connect
Easy Connect via Anybus DeviceNet bridge to
Barfeeder. Easy Diagnose/Setup via direct
controller communications.
Easy Connect and Diagnostics
LNS Barfeeder
LT200 P200
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Marposs Gauge SPC Simple, online process
control

• Online/Real time SPC with plug and play
  connection to Quickset Gauge enabling direct tool
  compensation.

LU300M P200
Marposs Quickset Gauge
RS232C
Marposs E9066 Industrial PC with QuickSPC
software for processing gauge data
RS232 Marposs to Okuma measure data and
compensation data converter (3rd party hardware)
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Applications
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Caron Engineering 3rd Party Value Added
Applications
Caron Engineering Three applications
demonstrating ease of integration by 3rd Party
value-added providers.

• TMAC7 Tool Monitor - PC based application that
  will run on the P200 control Caron real time
  processor for adaptive control.
• Tool Life Management Enhanced TLM application
  which stores TLM data to SQL database and
  provides custom report data. THiNC-API required.
• Machine Monitor - Machine production monitored
  and stored to SQL database. THiNC-API required.
• Is the machine in feedhold?
• Is the machine in cycle?
• Is the feedrate at 100? If not what is it?
• Is the machine I an alarm condition? If so what
  is the alarm?

MA-650 P200
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Applications
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Red Queen Hypothesis
The Intelligent Numerical Control
Red Queen Hypothesis For an evolutionary
system, continuing development is needed just in
order to maintain its fitness relative to the
system it is co-evolving with. (Leigh van Valen)
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Red Queen Inference
The Intelligent Numerical Control
Red Queen Inference Okuma sees a direct
correlation between biological evolution and
machine tool control evolution. As time
progresses, biological systems and control
systems must evolve more quickly to remain
competitive in the ecosystem. The CNC has reached
an evolutionary dead end. It is obsolete and
ready for extinction.
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Conclusions
The Intelligent Numerical Control

• With a true open architecture control, interface
  to peripheral devices both standard PC and
  industrial devices is simple.
• The next major step is to establish interface
  standards among devices on the factory floor
• OPC
• MTConnect