United States Department of Commerce

United States Department of CommerceUnited States Department of CommerceNational Institute of Standards and TechnologyNational Institute of Standards and Technology

Manufacturing Engineering LaboratoryManufacturing Engineering LaboratoryIntelligent Systems DivisionIntelligent Systems Division

Case Study in the Challenges Case Study in the Challenges of Integrating CNC Production of Integrating CNC Production

and Enterprise Systems and Enterprise Systems

John Michaloski

NIST

ISA EXPO October 2005

NIST • Manufacturing Engineering Laboratory • Intelligent Systems Division

OMAC HMI Working Group Perspective OMAC HMI Working Group Perspective

Asset Mgt

MachineCapabilities

View Control

Human

OMACModel

(Data andEvents)

C ontro lle r

Machine ControllerHMI Subsystem

MachiningFeedback

Plant


ProblemProblem“Design Anywhere, Build Anywhere, Support

Anywhere” requires worldwide enterprise connectivity across design, manufacturing, distribution, and maintenance.

David Humphrey, ARC Advisory Group, commented, “… customers really want: real interoperability between production and enterprise systems with little or no integration.”

Can we realize real interoperability between production and enterprise systems with little or no integration, using OMAC and OPC concepts?


OPC Integration TechnologyOPC Integration Technology

Asset Mgt

MachineCapabilities

View Control

Human

OMACModel

(Data andEvents)

C ontro lle rO P C

S erver

Machine ControllerHMI Subsystem

O P CC lien t

MachiningFeedback

Plant


OMAC HMI OPC StrategyOMAC HMI OPC StrategyOPC does I/O based on item tags

OPC does not define application item tag names OMAC could standardize on required item tags List of needed OMAC HMI data items based on application

requirements

Strategy is to create named item tags since OPC provides communication mechanism, but no application layering

Item tags could be groups by purpose: DA, commands, machine configuration, maintenance/diagnostics, etc.


Axis Siemens Fanuc(methods)

Okuma

AxisAbsolutePosition $AA_IM[X]/Channel/MachineAxis/actToolBasePos

cnc_absolute OPC//Position/ActualPostion/ActualPositionAxisXX.Position

AxisDistanceToGo $AA_DTEB[X]/Channel/State/acDteb[x]/Channel/GeometricAxis/progDistToGo

cnc_distance OPC//Position/TargetPosition/TargetPositionAxisXX.Position

AxisFollowingError /Nck/servoDataFl32[1] N/A NA

AxisLabel $MN_AXCONF_MACHAX_NAME_TAB[n]/Channel/MachineAxis/name

cnc_rdsvmeter()label

OPC//Position/TargetPosition/TargetPositionAxisXX.Name

AxisLoad /Channel/MachineAxis/aaLoad[] cnc_rdsvmeter OPC/Position/TargetPosition/TargetPositionAxisXX.Load

Data Point MappingData Point Mapping


Mill

QCInspect

Rem ill

Assem ble

20 R ight W ing Parts23 Left W ing parts

Out of tolerance

Candidate App: Boeing LE Part AccountingCandidate App: Boeing LE Part Accounting

Real-time integration of cost data into ERP subsystems has been difficult, as traditionally, factory floor equipment have been "islands of automation."



GoalGoalTo do simple proof of concept part accounting, from

CNC to ERP. The project will attempt to determine if we can do this with minimal integration effort using OPC/OMAC.

CNC data will provide answers to the following questions: When is a new part being milled? – using part program

name. How long did it take to mill the entire part? – using cycle

start on/off as indication of milling/not milling How many pieces have been scrapped? Using count of

repeated parts


PlanPlan Use the backup machine, an Okuma MCV 4020 milling machine

that is managed by M&PT in the Boeing Renton lab, while the production 737 Leading Edge (LE) Panel project CNC machine is undergoing PM.

Apply Common Human Machine Interface (HMI) concepts using OPC connectivity built on M&PT OKUMA CNC to output appropriate tags by the CNC to the ERP system (BAAN) and provide the cost data on demand via the web front end.

Use Okuma OPC connectivity to output desired tag information that will then be enabled to send tag data to an upstream ERP system to provide cost data of making 737 LE panels.

2 MONTH TIMEFRAME!


DeliverablesDeliverablesDemonstrate connectivity of production equipment

using OPCDevelop an interface document that would identify

right variables /tags to upload the manufacturing information to the ERP system.

Record part accounting data to reflect machine activityDocument issues involved in “seamless” integration


Okum a MCV 4020 CNC+ OPC Server

Baan ERP

OPC Client

737 LE panels

Tim estam ped Data

System ArchitectureSystem Architecture Systems

Okuma MCV 4020 CNC Okuma PC-Based P100 Controller Ethernet Network

Software Okuma OPC Server Microsoft VB.Net and COM/DCOM Baan Erp

Machine.CycleStart

Program.ProgramName

Program.PartCount


Idyllic System ArchitectureIdyllic System Architecture Systems

Okuma MCV 4020 CNC Okuma PC-Based P100 Controller Ethernet Network

Software Okuma OPC Server Microsoft VB.Net and COM/DCOM Baan Erp

CNC + OPC Server

ERP

737 LE panels

Machine.CycleStart

Program.ProgramName

Program.PartCount

Tim estam ped Data


OPC ServerOPC Group

OPC Item1

OPC Item2

OPC Item5

OPC Group

OPC Item2

OPC Item4

Automation/VB Scripting

Custom/C++

•DA

•Events

•History

•Browse

CNC

OPC ArchitectureOPC ArchitectureIO Items

OPC Item1CycleStart

OPC Item2Program

OPC Item3Ready

OPC Item4Alarm

OPC Item5PartCount

OPC Item6Ready


Actual Production Test ArchitectureActual Production Test Architecture Systems

Okuma MCV 4020 CNC Okuma PC-Based P100 Controller

Software Okuma OPC Server Local Visual C++ OPC COM Application logging part accounting to .CVS file Visual Basic Scripting to Excl

M achine.CycleStartProgram .Program Nam eProgram .PartCount

CNC + OPC Server

OPC C lientSaves to

.CVS to F ileSystem

737 LE panels

Tim estam ped DataExcel VBS Excel

F ile


CVS FileCVS FileLine Number, Start Time (Y),End Time (Z),Setup Time (min),Machining Time(min),Install Time,Total Time

(min),Part Count,Burn Rate,Shop Cost,Panel Cost,Total Cost1803-L01.MIN,Tue Aug 30 03:09:29 2005,Tue Aug 30 03:14:55 2005,1.03,4.39,3,8.42,1,10,21.05,30,41.051803-L02.MIN,Tue Aug 30 03:17:31 2005,Tue Aug 30 03:22:16 2005,0.17,4.59,3,7.76,1,10,19.4,30,49.41803-L03.MIN,Tue Aug 30 03:23:52 2005,Tue Aug 30 03:29:53 2005,1.24,4.77,3,9.01,1,10,22.525,30,42.5251803-L04.MIN,Tue Aug 30 03:32:02 2005,Tue Aug 30 03:36:29 2005,0.1,4.36,3,7.46,1,10,18.65,30,518.651803-L05.MIN,Tue Aug 30 03:38:53 2005,Tue Aug 30 03:43:23 2005,0.07,4.44,3,7.51,1,10,18.775,30,48.7751803-L06.MIN,Tue Aug 30 03:45:40 2005,Tue Aug 30 03:50:16 2005,0.42,4.17,3,7.59,1,10,18.975,30,48.9751803-L07.MIN,Tue Aug 30 03:53:44 2005,Tue Aug 30 03:58:08 2005,0.15,4.26,3,7.41,1,10,18.525,30,48.5251803-L08.MIN,Tue Aug 30 04:00:29 2005,Tue Aug 30 04:05:35 2005,0.12,4.97,3,8.09,1,10,20.225,30,40.2251803-L09.MIN,Tue Aug 30 04:06:38 2005,Tue Aug 30 04:10:57 2005,0.08,4.24,3,7.32,1,10,18.3,30,48.31803-L10.MIN,Tue Aug 30 04:12:38 2005,Tue Aug 30 04:16:57 2005,0.07,4.24,3,7.31,1,10,18.275,30,4W8.275


Excel FileExcel FileLine Number Start Time (Y) End Time (Z) Setup Time (min)Machining Time(min)Install TimeTotal Time (min) Part Count

1857-L01.MIN Tue Aug 16 15:26:55 2005 Tue Aug 16 15:27:51 2005 0.58 0.35 3 3.93 11857-L02.MIN Tue Aug 16 15:27:51 2005 Tue Aug 16 15:28:27 2005 0.24 0.35 3 3.59 11857-L03.MIN Tue Aug 16 15:28:27 2005 Tue Aug 16 15:44:48 2005 16.01 0.35 3 19.36 11857-L04.MIN Tue Aug 16 15:44:48 2005 Tue Aug 16 15:45:26 2005 0.28 0.35 3 3.63 11857-L05.MIN Tue Aug 16 15:45:26 2005 Tue Aug 16 15:45:59 2005 0.19 0.35 3 3.54 11857-L06.MIN Tue Aug 16 15:45:59 2005 Tue Aug 16 15:46:30 2005 0.17 0.35 3 3.52 11857-L07.MIN Tue Aug 16 15:46:30 2005 Tue Aug 16 15:47:01 2005 0.16 0.35 3 3.51 11857-L08.MIN Tue Aug 16 15:47:01 2005 Tue Aug 16 15:47:32 2005 0.17 0.35 3 3.52 11857-L09.MIN Tue Aug 16 15:47:32 2005 Tue Aug 16 15:48:00 2005 0.12 0.35 3 3.47 11857-L10.MIN Tue Aug 16 15:48:00 2005 Tue Aug 16 15:48:34 2005 0.21 0.35 3 3.56 11857-L11.MIN Tue Aug 16 15:48:34 2005 Tue Aug 16 15:49:13 2005 0.3 0.35 3 3.65 11857-L12.MIN Tue Aug 16 15:49:13 2005 Tue Aug 16 15:49:46 2005 0.21 0.35 3 3.56 11857-L13.MIN Tue Aug 16 15:49:46 2005 Tue Aug 16 15:50:15 2005 0.12 0.35 3 3.47 11857-L14.MIN Tue Aug 16 15:50:15 2005 Tue Aug 16 15:50:44 2005 0.12 0.37 3 3.49 11857-L15.MIN Tue Aug 16 15:50:44 2005 Tue Aug 16 15:51:13 2005 0.14 0.35 3 3.49 11857-L16.MIN Tue Aug 16 15:51:13 2005 Tue Aug 16 15:51:59 2005 0.4 0.35 3 3.75 11857-L17.MIN Tue Aug 16 15:51:59 2005 Tue Aug 16 15:52:34 2005 0.24 0.35 3 3.59 11857-L18.MIN Tue Aug 16 15:52:34 2005 Tue Aug 16 15:53:10 2005 0.24 0.35 3 3.59 11857-L19.MIN Tue Aug 16 15:53:10 2005 Tue Aug 16 15:53:45 2005 0.23 0.35 3 3.58 11857-L20.MIN Tue Aug 16 15:53:45 2005 Tue Aug 16 15:54:22 2005 0.28 0.35 3 3.63 11857-L21.MIN Tue Aug 16 15:54:22 2005 Tue Aug 16 15:55:00 2005 0.28 0.35 3 3.63 11857-L22.MIN Tue Aug 16 15:55:00 2005 Tue Aug 16 15:55:33 2005 0.19 0.35 3 3.54 11857-L23.MIN Tue Aug 16 15:55:33 2005 Tue Aug 16 15:56:17 2005 0.38 0.35 3 3.73 11857-R01.MIN Tue Aug 16 15:56:17 2005 Tue Aug 16 15:56:53 2005 0.26 0.35 3 3.61 11857-R02.MIN Tue Aug 16 15:56:53 2005 Tue Aug 16 15:57:30 2005 0.26 0.35 3 3.61 11857-R03.MIN Tue Aug 16 15:57:30 2005 Tue Aug 16 15:58:03 2005 0.17 0.37 3 3.54 11857-R04.MIN Tue Aug 16 15:58:03 2005 Tue Aug 16 15:58:42 2005 0.3 0.37 3 3.67 11857-R05.MIN Tue Aug 16 15:58:42 2005 Tue Aug 16 15:59:22 2005 0.31 0.35 3 3.66 11857-R06.MIN Tue Aug 16 15:59:22 2005 Tue Aug 16 15:59:56 2005 0.21 0.35 3 3.56 11857-R07.MIN Tue Aug 16 15:59:56 2005 Tue Aug 16 16:00:27 2005 0.17 0.35 3 3.52 11857-R08.MIN Tue Aug 16 16:00:27 2005 Tue Aug 16 16:01:01 2005 0.21 0.35 3 3.56 11857-R09.MIN Tue Aug 16 16:01:01 2005 Tue Aug 16 16:01:33 2005 0.19 0.35 3 3.54 11857-R10.MIN Tue Aug 16 16:01:33 2005 Tue Aug 16 16:02:06 2005 0.19 0.35 3 3.54 11857-R11.MIN Tue Aug 16 16:02:06 2005 Tue Aug 16 16:02:37 2005 0.17 0.35 3 3.52 11857-R12.MIN Tue Aug 16 16:02:37 2005 Tue Aug 16 16:03:15 2005 0.28 0.35 3 3.63 11857-R13.MIN Tue Aug 16 16:03:15 2005 Tue Aug 16 16:03:47 2005 0.17 0.35 3 3.52 11857-R14.MIN Tue Aug 16 16:03:47 2005 Tue Aug 16 16:04:24 2005 0.28 0.35 3 3.63 11857-R15.MIN Tue Aug 16 16:04:24 2005 Tue Aug 16 16:05:03 2005 0.3 0.35 3 3.65 11857-R16.MIN Tue Aug 16 16:05:03 2005 Tue Aug 16 16:05:43 2005 0.31 0.35 3 3.66 11857-R17.MIN Tue Aug 16 16:05:43 2005 Tue Aug 16 16:06:23 2005 0.3 0.37 3 3.67 11857-R18.MIN Tue Aug 16 16:06:23 2005 Tue Aug 16 16:07:02 2005 0.28 0.37 3 3.65 11857-R19.MIN Tue Aug 16 16:07:02 2005 Tue Aug 16 16:07:37 2005 0.24 0.35 3 3.59 11857-R20.MIN Tue Aug 16 16:07:37 2005 Tue Aug 16 16:08:07 2005 0.14 0.35 3 3.49 11857-L09.MIN Tue Aug 16 16:08:07 2005 Tue Aug 16 16:08:41 2005 0.23 0.35 3 3.58 11857-R14.MIN Wed Aug 17 14:50:13 2005 Wed Aug 17 14:50:33 2005 0.33 0 3 3.33 1


PortabilityPortabilityThis works! Now the bigger test…Is the application code portable across CNCs and OPC

technology providers as promised?Replace Okuma with GE/Fanuc 16i and Use KEPWare

OPC Server.


CNC Connectivity with OPC Demonstration Location: Booth #1210October 25-27, 2005

Sponsors: ISA and Open Modular Architecture Controller (OMAC) Users Group

Taking the Next Step in CNC Technology

E vo lu tion o f N C M ach ines

Util

ity

Paper Tape NC

CNC

Fully Integrated CNC

Hardw ired NC


Demo “Highlights”Demo “Highlights” “Same” OPC Application Software

to run on GE/Fanuc 16i simulator – demonstration in ISA Booth 1568 Boeing/NIST tested same OPC

client on different OPC Servers – different OPC tags via ini file

Show ease of access and connectivity

Promote better/easier CNC-Factory Floor integration

OPC widely adopted Industrial “Standard”

Potential for new Apps is Wide Open


“Lessons Learned”“Lessons Learned” Networks don’t

XP/SP2 and DCOM security don’t mix. File sharing immune

.Net not ready for prime time Nothing is ever easy…

Okuma midnight resetting of PartCount. “Unsolicited” (Asynchronous) DA – necessary but non-trivial Enum issues,

e.g., Auto Mode: Okuma=0, MDSI=2, 840D=1 Variant issues

Empty versus Zero problem. No alarm returns empty variant. BSTR “0” <> 0

Thankful for loads and loads of OPC utilities


Next StepsNext StepsOMAC HMI will be further promoting CNC-ERP open

connectivity Porting to other CNC vendors and OPC technologyActively seeking collaboration partners among the

OPC, ERP and CNC vendors and end-users


Questions?Questions?Thank you.

Documents

United States Department of Commerce