THE MICROTECHNOLOGY INFORMATION PORTAL/THE SHOW
15.12.2017
A - Machines
INDUSTRY 4.0 – HOW TO TAKE ADVANTAGE OF IT WITH TISIS
There are many ideas and much information about this concept and how it can meet our actual requirements. In this article, we want to present practical applications in today’s production that can be realised thanks to Tornos TISIS software. Why Industry 4.0? On the whole, the advantages achieved by a turn towards the digital economy are the flexibility of production and the individualisation of the products that takes any conceivable parameters into account. The concept helps to create personalised mass products while stream-lining production. The ultimate goal is to deliver to the customers increasingly customised products and solutions at prices and with deadlines that are satisfactory for both the vendor and the customer. One of the consequences is the required programming flexibility.
A comprehensive range of services
The TISIS program is offered as an option that allows to manufacturers to program the complete range of Tornos products. It is available for rather simple machines working with ISO programs but also for more complex machines such as the machines of the EvoDeco type. The software allows machines to be programmed but also allows us to communicate and interact with them using a simple tablet computer or smartphone.
Connectivity Pack – an industrial PC as interface
To be able to link the world of production with the current concepts of Industry 4.0, the machines must be equipped with more intelligence. Against this background, the machines of the various Tornos series have and industrial PC that serves both as data server and storage server.
TISIS – programming and much more
TISIS is offered in several versions: the light version allows programming while the comprehensive version includes programming, set-up and data management support functions as well as an optional CAD/CAM system that enables complex shapes to be easily programmed. The Connectivity Pack enables production tracking via TISIS Tab (mobile version for Android and Apple peripherals) and includes the optional TISIS i4.0 production tracking function and set-up support function via camera system.
Six simple stages
With TISIS, the overall production can be divided into six simple stages: programming, tool selection, data transfer to the machine, set-up, real-time production monitoring and tracking and finally, efficiency evaluation. In the following, we would like to study these stages in detail.
1 – programming
The programming wizard enables the comprehensive documentation of all workpiece data; by means of the mobile TISIS Tab application, it allows the registration and the visualisation of drawings and photographs that have been made or taken directly during set-up. When the program is restarted later on, any operator can thus directly check all parameters and characteristics in the programming software. As far as actual programming is concerned, numerous refined functions simplify the operator’s life. For instance, he can opt for highlighting certain parts by colors and decide to register recurring operations in a directory that can be called on request. An ISOcode data base is available at any time and thus enables the operator to always have the right code at hand. The various channels can be directly viewed on one single screen. With a 2D simulation system, the tool paths can be directly reviewed during programming which ensures considerable time savings. Talking about time savings, it should also be noted that the cycle display (by GANTT chart) enables the tool paths and thus the cycle times to be optimized.
1 – programming of complex workpieces with TISIS CAM
Depending on the geometries to be programmed, the ISO code system is difficult to use (and for certain operations, it cannot be used at all without modifications). For such cases, TISIS comprises a CAD/CAM module that enables programming based on a 3D model. The program can thus be optimized where required by means of the TISIS editor and the GANTT chart.
2 – tool selection
The directory of the available tools is synchronized with the machine configuration. The arrangement of the tools in TISIS exactly corresponds to the tool layout in the machining area The software directly shows the position of the tools and thus avoids any risk of interference. Any assembly errors or incompatibilities are avoided from the very beginning.
3 – data transfer to the machine
Once the program has been carried out (and documented), it is transferred to the machine via a simple USB flash drive or directly via the company network. This connectivity is bidirectional and allows the stage described below.
4 – set-up
Based on tool selection and arrangement in TISIS, the actual tool set-up is simplified; just follow the virtual wizard (from stage two mentioned above). However, in certain cases, especially when machining very fine workpieces, the tool set-up may require special skills. For such situations, an optional macro camera is available that can precisely display the workpiece and the tools. A direct workpiece measuring system is offered as well.
5 – real-time production monitoring and tracking
Real-time tracking of the production enables the operator to view the production progress in real time and thus to determine the deadlines and the availability of the machines as realistically as possible. With this tracking function, it is possible not only to view the detailed machine parameters, especially the spindle and axis loads as well as the respective temperatures, but also to monitor the entire workshop. The connectivity ensured by TISIS Tab includes a function to immediately inform the user of unexpected events (or e.g. of the series end) directly via his smartphone.
6 – efficiency evaluation with TISIS i4.0
The efficiency of each machine and of the entire workshop (OEE) can be requested permanently. It can be displayed most easily and the display gives a quick overview. The efficiency display is based on certain parameters that can be selected as desired – the efficiency can thus be viewed per machine or per machine group, per day, per week, per month or per year. The system is comprehensive and fully autonomous and the history of each machine is saved permanently. The analysis is thus considerably simplified. With TISIS, TISIS Tab and Connectivity Pack, the user of a Tornos machine can work more efficiently and is better informed about the production status of the machine; in addition, however, the built-in intelligence helps to maintain consistent quality because all data are documented. While, normally, a change of the operator might affect the production quality, TISIS minimizes such risks. A TISIS evaluation software version can be downloaded from the Tornos website under http:// store.tornos.com/en. If you wish further information, do not hesitate to contact Patrick Neuenschwander, Tornos’ Software Manager, under neuenschwander.p@tornos.com or your distributor.
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