Application of DNC System for Workshop Information Construction
As the most basic application in the construction process of the workshop information system, the DNC system has become an indispensable tool for the workshop CNC programmers, technicians and CNC machine operators. The DNC system helps shop floor technicians solve the most fundamental program transfer and management problems, shorten production lead time, improve programming accuracy and efficiency, and lay the foundation for a comprehensive digital production.
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I. Overview
Xi'an Xidian Switch Electric Co., Ltd. (referred to as Xikai Electric) is the core enterprise of China Xidian Group. Its predecessor Xi'an High Voltage Switchgear Factory was founded in 1955 and is one of the 156 key projects of the country during the first five-year plan of China. . After the completion of the three phases of the "Seventh Five-Year Plan", "Eighth Five-Year Plan" and "Ninth Five-Year Plan", a series of transformations have been carried out. It has introduced, digested and absorbed the technology of sulphur hexafluoride switch from Mitsubishi Electric Corporation of Japan and the 500kV GIS product technology of ABB of Switzerland. Xikai Electric now has GIS products high-strength aluminum profile shell welding and cold flange technology, insulation epoxy casting technology, arc chamber manufacturing technology, high-strength aluminum alloy casting technology, large-scale aluminum-copper silver plating technology, product assembly Core process manufacturing technologies such as technology, intermediate testing and high voltage testing. In recent years, there have been more than 40 new product projects independently researched and developed, and more than 140 scientific research projects.
Founded in the 1980s, Xikai Electric Machine Shop is specialized in the machining of high-pressure parts and components. Since the 1990s, the workshop has introduced advanced CNC equipment for the production of high-precision, high-complexity parts and products. From the beginning of development to the present, the CNC equipment occupancy rate of the workshop has reached 80%. In the past two years, with the increasing demand for mechanical processing, the company has also introduced high-precision production equipment such as flexible manufacturing units.
The gradual increase in equipment will inevitably bring about problems related to management and application.
By summarizing and summarizing the problems, companies are now facing the problems shown in the table. Many of these problems can also be said to be common problems in the discrete machining industry.
How to solve these problems, through the understanding of informatization construction and the study of advanced production enterprises at home and abroad, the high-speed start-up workshop has created a road of informatization of the workshop in line with the development status of the west start-up workshop. The workshop implemented the first DNC ​​system in 2005, and the existing old CNC equipment in the workshop was networked. The method of applying a single serial port server on the machine side realized the networked and distributed machine tool communication function. Due to the earlier implementation time, the application of the WINDOWS folder is applied in the aspect of program management, and the function of automatic transmission is basically realized in operation. From 2008 to 2009, the workshop introduced several small giant MAZAK equipments. As the advocate of digital factory, the biggest difference between MAZAK equipment and other machine tool manufacturers is that they not only have their own unique technology in machine tool hardware, but also Supporting software also has a strong technological advancement. During the installation of the machine tool, the workshop also deployed the CPC Cyber ​​Monitor software system to monitor the machine status. Subsequently, the flexible manufacturing unit of Mori Seiki was also equipped with the corresponding transmission and monitoring software.
Such a complicated system parallel application brings a lot of troubles and inconveniences to the technicians in the workshop. Firstly, the transmission of the MAZAK device becomes a problem, and the USB and Ethernet sharing methods have been tried, but the virus problem causes the application enterprise to give up. This unsafe transmission method. Secondly, although the transmission problem of Mori Seiki can be carried out through its own transmission software, the program management has this inconsistency.
Through the analysis of the current state, the company decided to adopt a new way - the DNC system to re-plan the entire network. At that time, it coincided with the relocation of the new workshop, so the application of the new DNC system was also integrated into the planning and construction of the new plant.
Second, the overall program
First of all, the new DNC system should ensure absolute consistency in program transfer and program management. It can realize the communication functions of the old equipment, the new MAZAK equipment and the new Mori Seiki equipment in one software, and can guarantee the The management method of transferring NC programs is also the same. All of them are managed by professional NC program management software, and have functions such as process auditing, version management, and attribute management.
The application functions and structure of the new DNC software are roughly as shown.
It can be seen from the figure that the new DNC system adopts the unified DNC communication and management software, and the three types of machine tools are connected in a unified way, which solves the problem that the previously existing program transmission is not uniform, and also solves the problem that the program is not stored. The unified problem has fully realized the standardization and scientific management of the program, and realized the unified distribution of program tasks and centralized archiving. At the same time, it also realizes the full utilization of MAZAK software and Mori Seiki software, as well as real-time monitoring and data acquisition of machine status.
After the application of the new system in the workshop, the original workflow has also undergone certain changes, from an experience-driven approach to a data-driven model.
In the past, if the production plan was issued, arranged, and coordinated with the corresponding production preparation materials, it was issued by experienced personnel, even if it was based on some data, it was relative evaluation data, not actual data. For example, before the production execution plan of the MIS system needs to be arranged, it is necessary to know the status of WIP in the workshop in time, and this situation is often that the plan is not as fast as the change, so the new scheduled production task and the actual workshop processing status are caused. There are certain conflicts, and the production plan and corresponding preparation data need to be revised repeatedly, thus greatly prolonging the preparation time before production.
Also, changes to the machining program become especially important when machining parts that are basically shaped but slightly modified. The original mode is that the operator directly modifies the existing machining program on the machine tool and modifies the direct machining. There are many unstable factors in this mode. The first thing that the operator stores on the machine tool may not be the program that has been basically fixed. The result is that the operator modified the program according to his own wishes and processed the parts. When the inspection is performed, the dimensional tolerance is problematic, and the repair is light, and the workpiece is scrapped. For example, when the workshop had a batch of urgent production tasks in 2009, after receiving the task list, the workshop process and related technical personnel analyzed the product parts and found that it was basically the same as the batch of parts processed half a year ago. There are only minor size modifications. Then, because the MAZAK machine that stored the machining program at that time emptied the memory for some reason, the processing program at that time was completely lost (because it was not a fixed product, so it did not make a full backup, and later only found some programs in the computer). The craftsman and the operator worked together to compile the program. It took almost a day to compile the NC program and process the check. The workers finally worked overtime to deliver the basic on-time delivery. This incident also made us realize that the unified platform is distributed. The importance and necessity of DNC systems in the workshop.
After implementing the unified DNC system, these problems will be solved very well. Firstly, the NC library is unique, so that the common management is achieved in the calling and saving of the program. The management of the NC program will also adopt the structure tree. - Refinement management in the form of a version, and then restrict the operator through the corresponding rules and regulations, can not directly use the in-machine program (can directly clear the existing program in the machine), and finally realize the uniqueness and reliability of the NC program data source. The NC program will be stored as a company's knowledge resources, just like drawings and craft files. In addition, through the realization of the online monitoring and collection functions of MAZAK and Mori Seiki system, and the creation of the whole plant acquisition system in the later stage, the real-time degree of the underlying processing information will be greatly improved, and the mode of “taking data to speak†will also be realized. It is not entirely judged by human experience. The machine shop will also create a workshop information platform based on the distributed DNC system.
Third, the conclusion
The construction of a unified DNC system is an urgent problem that our workshop is currently facing. After the completion of the system, it will completely solve the problems of the original program transmission and management of the workshop, and improve the details of the workshop management. Improved related specification processes. At the same time, the construction of DNC hardware network will also provide a good foundation platform for the realization of a comprehensive digital workshop in our workshop.
Through the construction and planning of the new DNC system, the informatization planners of our workshops also fully understand that the construction of grassroots informatization needs to start from the point, gradually build the surface, and finally establish the enterprise information model through the face.
Problems with failing factory relays, connectors/terminals and fuse contacts are also common when excessive load is placed on them.
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