Workshop on Integrated Machine Tool
Simulation & Verification
April 9-10, 2002
Cypress, California
Workshop on Integrated Machine Tool Simulation & Verification
Agenda
First Day – April 9th:
08:30 – 09:30 Introduction to IS&V and its
architecture
09:30 – 10:00 IS&V demonstration
10:00 – 12:00 Machine tool builder application
12:00 – 13:00 Setting for machine tool simulation
13:00 – 14:00 Lunch
14:00 – 17:00 Workshop - building your machine
tool model
Second Day – April 10th:
08:30 – 09:00 Review & Discussion
09:00 – 09:45 Machine tool driver philosophy
09:45 – 10:30 Using S&V Commands
10:30 - 11:30 Walkthrough driver examples
11:30 - 13:00 Workshop - building your machine
tool driver
13:00 - 14:00 Lunch
14:00 - 16:45 Continue workshop
16:45 - 17:00 Summary
Workshop Objective
Our Objective:
To teach you the tools you need to model the machine tool
kinematics and its virtual controller. At the end of the workshop
we hope you could simulate a machine tool you built during the
workshop.
Your Objective:
To give us your feedback, any feedback, about the system during
the workshop and after… good or bad.
IS&V Highlights
 Fully integrated machine tool simulator.
 New machine tool builder application.
 In process machine tool and controller considerations:
• Close loop control
• From Postprocessor to Machine Tool Driver.
 ‘Close to Reality’ simulation:
• Controller plug-in option.
• Accurate simulation for controller dependent events.
 Customizable Virtual NC controller based on Manufacturing
Output Manager (MOM).
 Utilization of UG technologies: Assembly modeling and dCade
toolkit library (e.g. collision library).
 Library managed machine tool, fixtures and devices.
Current Architecture
Events
Events
Mfg. Output
Manager
Events
Events
Cutting Tools
Cutting Methods
Part Materials
UG
CAM
Process
Data
Process Data
Machine
Machine
Tool
Tool
Statements
Statements
External
External Simulators
Simulators
CL File
Event Handler
G01 X3.4
G03 Y3.1 I3.3
Tool Materials
Feed & Speeds
Toolpaths
Toolpaths
Machine Tools
Tool Simulator
Material
Removal
Mfg.
Setup
Vericut
Machining
Machining
Filters
Filters
GraphicalFeedback
Feedback
Graphical
Unisim
IS&V Architecture
Mfg. Output
Manager
Events
Events
Events
Events
Machine Tool
Machine
ToolDriver
Driver
Cutting Tools
Process Data
Data
Process
Event Handler
Cutting Methods
Part Materials
Tool Materials
Feed & Speeds
UG
CAM
S&V
S&V
Commands
Commands
NC code
Virtual NC
Controller
Machine Tools
Fixtures
S&V Events
Machine Devices
Feedback
Feedback
S&V
Engine
S&V Events
Graphical
Feedback
Mfg.
Setup
External System
CL File
G01 X3.4
G03 Y3.1 I3.3
S&V Control Loop
Toolpath Events
Event
Generator
CEvents
G01 X3.4
G03 Y3.1 I3.3
Design
Parts
Machine Tool
Driver
NC-Post
UG
CAM
S&V Control
Loop
‘G Code’
Virtual NC
Controller
Mfg.
Resources
NC Controller
Plugin
Feedback
S&V
Commands
S&V
Engine
S&V Events
IS&V Building Blocks
Machine tool builder (MTB)
Machine tool configurator (MTC)
Machine tool simulation
Machine tool driver (MTD)
Virtual NC Controller (VNC)
Machine Tool Builder
New application to build a
machine tool or machine device.
Geometric model by Assembly.
Build Kinematics model.
Define Mounting model.
Animate axes for testing.
Edit model by Kinematics Tree
manipulations.
Machine Tool Configurator

Has similar functionality as
machine tool builder.

Active in Manufacturing
application only

Used for mounting
workpiece and fixtures on
machine tool.

Other future uses like
defining machine state.
Machine Tool Driver (MTD)
 Generates NC-Program and
Events
Events
emulates the NC controller.
 Motion control - accurate path
Machine
Machine Tool Driver
Driver
Process
Data
Process
Data
based on machine configuration.
 Handles specific machine tool
features such as macros, cycles,
subroutine call.
 Key role in machine tool simulation.
 Fully customizable as TCL program.
 Textual, graphical and audio
feedback triggered by events.
Post
Event Handler
CL File
G01 X3.4
G03 Y3.1 I3.3
NCcode
code
NC
Virtual NC
Controller
S&V
Commands
S&V
S&V Events
Events
S&V
Engine
NC Controller
Plug-IN
Machine Tool Simulation
Customizable user interface
Step through events in three different modes.
Continuos position and parameters display.
Step through NC program (G codes)
Flexible collision control
More ...
Collision
Customizable Simulation
Control Panel
Configuration
Simulation
Configuration
Current IS&V v19 Scope and Status
Focus: System architecture and Simulation
 Machine tool simulation for milling, turning and millturn .
 New application to build the machine tool model.
 Collision detection between all machine components.
 Close loop control architecture
 Machine tool driver architecture
 Library managed machine tool, machine
devices and fixtures.
 TCL based customizable virtual NC
controller.
 Plugin interface to machine tool driver.
 Customizable simulation dialog
 Closer Integration with CAM processor
Status:  done
 partially done
IS&V v20+ Proposed Features
Focus: CAM Processor Integration
 Closer integration:
 4-axis lathe programming and simulation.
 Machine state for each operation.
 Consider machine tool for collision and accessibility (e.g. variable
axis machining and hole making). Processor can be enhanced to
take advantage of it.
 Consolidate machine tool kinematics and data(e.g. used in post).
 Show machine state while programming. (e.g. show part moving
when applicable).
 CME integration
 Analysis tools for: material removal rate to adjust cutting
parameters, loads on cutting tools, forces on fixtures.
IS&V v20+ Proposed Features (Cont.)

Consolidate Visualize and Machine Tool Simulation.

IPW and gouge detection in machine tool simulation
context.

Material removal during machine tool simulation.

Machine tool simulation directly from ‘G’ codes.

Interface to commercial plugin (open controllers).

Special turning support (e.g., millturn and 4-axis lathe)

Generic inverse kinematics engine based on
machine tool kinematics.

Enhance post builder to build machine tool drivers.
More on IS&V
More information on IS&V can be found in:
 Visual requirement specifications (camsav200 project)
 Function specifications (camsav200 project)




Machine tool for Simulation functional spec
S&V Engine functional spec
Machine tool driver functional spec
dCade toolkit functional spec
 IS&V Help
 Examples of machine tool models and drivers.
Demonstration
Build it… Configure it… and Simulate…
Unisign Machine Tool
Sinumerik 840 Controller
Demonstration (cont.)