Sichuan Yibin Push Mold Co., Ltd. is a wholly-owned subsidiary of Push Group. Mainly engaged in injection molds, metal stamping dies, die casting molds, inspection tools, fixtures, R & D, design and manufacturing, products involved in automotive, home appliances, communications, daily necessities and other products of large and medium-sized molds and precision molds. The company covers an area of ​​about 100,000 square meters, and its fixed assets investment has exceeded 800 million yuan. More than 900 employees, the introduction of domestic and foreign senior management, technical personnel more than 100. In 2003, the company achieved a total production value of mold products of 100 million yuan; in 2004 the mold product output value of 130 million yuan, net profit of 11.42 million yuan; in 2007 the company completed mold product sales revenue 400 million yuan, completed profits and taxes indicators 37 million yuan. While introducing advanced equipment, mold companies also pay attention to the introduction of foreign advanced management concepts and models. On the basis of the implementation of total quality management, we conscientiously implement ISO9001, and in accordance with the ISO9004 and ISO14001 system requirements, establish and implement a sound quality management system. In 2004, the company successfully passed the qualification certification of suppliers of high-tech companies such as Audi and FAW. In March 2005, the company formally passed ISO9001:2000 and ISO14001:2000 quality system certifications. At present, the company has passed ISO16949. System Certification.
I. Background of the Dash System of Pushush Mould Network
The existing numerical control equipment of Pushi Mould Co., Ltd. is generally more advanced, and most of them have adopted a simple network sharing method to achieve code communication. However, the problems that still exist before implementing the DNC system are as follows:
1, there are still 15 devices through the RS232 interface, CF card, floppy disk copy data transmission, transmission means behind, restricting the improvement of production and management.
2. The existing CNC system in the workshop is not uniform. The communication programs used between the systems are different and the communication transmission parameters are not the same. Every program transmission requires technicians to move between the machine tool and the IT department multiple times. Each machine tool operates the machine tool panel to complete the transfer of the code file. Different systems require different connections and parameter settings, which results in incompatible machines.
3. Since this part of the equipment has not implemented network DNC, their on-line processing can only use the computer placed on site to temporarily solve the problem and does not comply with the 6S site regulations.
4. After the code is written, it is necessary to go through trial and error to correct the errors and optimize the code. The product's deformation design and product changes also require effective version control. At present, enterprises basically rely on technicians to distinguish different versions of processing documents. This document version management method is not standardized and it is difficult to form an orderly version management of the product. Over time, the problem will be very prominent.
5, the summary of product processing data is completed by hand, the workload is large, error-prone, and it is not easy to determine the scope of changes, affecting the efficiency of the work. The working status information of the machine tool cannot be fed back and collected in time, which is not conducive to the progress monitoring of the production tasks of the factory and the balance of production capacity.
Second, the demand for network DNC system
Taking into account the company's various problems in communications, summed up the company's demand for network DNC.
(1) Network transmission of processing codes/equipment parameters, etc.: Improve the effective working time of the machine tool;
Improve CNC transmission efficiency and accuracy;
Reduce unnecessary investment in fixed assets and consumable materials such as the number of computers, floppy disks, etc.
Solve the problem of parallel communication of serial control devices.
(2) Process management of documents such as code:
The code of equipment processing realizes transmission and management on the network;
Provides bidirectional and remote input and output functions of NC programs between CNC machine tools and DNC servers, and has a proofreading feedback function in the transmission process; version management of CNC machining related documents can be performed;
Provide on-site workshop code processing auxiliary functions to realize the rapid creation, editing, comparison, simulation, code conversion and NC standardization of NC programs.
Third, the program implementation
After combining the specific conditions of Push Mold Co., the CAXA Network DNC project team developed a set of implementation plans for the current status of Push Mold Co.
Project team approach -> implementation (integrated cabling, equipment installation) -> support debugging -> implementation is completed -> into the test run │ ↑
└--> User Training--┘
--> Making Completion Acceptance Documents --> Overall Project Final Inspection (Equipment Acceptance, Technical Acceptance) Both Parties Signed "Acceptance Report" and "Memo" --> Project and Documentation Cutover
The specific implementation can be implemented in steps according to the specific conditions of Push Mold Co., Ltd.:
The first step is to connect the existing CNC machine tools through the RS232 interface, and the remaining equipment is reserved for extended redundancy. The network cabling will strictly abide by the 6S standard, and the internal wiring of the machine tool will also strictly comply with the specified requirements.
Step 2: On the basis of existing networked machine tools, personnel training and processing codes of DNC online processing and management (versions, processes, permissions, etc.) of auxiliary documents (designs, processes, tools, etc.) are performed; processing procedures, production dispatch, Task load statistics, progress statistics, etc., unified data management;
The third step: Extend the effective data management system to the entire workshop, deepen the construction of digital workshops, realize the paperless production of the workshop, and integrate the DNC system with the entire ERP, PDM, and MES systems.
Machine Network Implementation Instructions:
Due to the use of the RS232 serial port for the transmission of CNC machine tools by Pushch Co., Ltd., direct serial port transmission is used in production and processing. There are many drawbacks in this method, such as limited serial port transmission distance (15M), line interference problems, frequent interface plugging, serial port parallelism, etc. In order to solve the above problems, the introduction of intelligent terminal equipment in the implementation, the serial port transmission conversion Ethernet port transmission. The intelligent terminal is a serial port server that increases a large number of serial port transmission functions and improves transmission stability and security. In this way, when the machine tool's request processing is transferred to the DNC communication software, the DNC communication software will quickly send the processing code to the smart terminal at a speed of 10/100 megabytes or more, and then the intelligent terminal and the machine tool will enter the new low-speed serial port for on-line processing. When the machine buffer is full, the entire link does not need to react. It is only the smart terminal response. In this way, the number of machine tools that can be processed in parallel by a single DNC communication server is greatly increased, and the network resource consumption is greatly reduced.
IV. Project Summary
Through the implementation of this project, the problems of communication transmission and numerical control processing programs and data management of CNC equipment of Pushchi Mould Co., Ltd. have been thoroughly solved, and some management confusion in the company has also been improved, and good results have been achieved. CAXA's DNC system has also provided assistance for the enterprise's informatization. It has made up for the previous part of the workshop that can not be reached by ERP, and provided powerful data for it. At the same time, CAXA's implementation of this project will also digitize the company's future construction. Manufacturing laid a solid foundation.
(1) Significantly increase the production efficiency of CNC workshops.
Due to the adoption of a unified and fast network transmission, all numerical control devices communicate with computer networks, especially the communication of numerically controlled machine tools using the RS232 serial port. Reduces the operator's loss time in obtaining code and process documentation. After the original site was placed on the desktop, the technician needed to go to the site to operate, that is, to transfer the code from the web server to the on-site desktop, and to complete the serial connection of the machine to transmit the NC code. There are many on-site operation steps and there are too many influencing factors, and the PC is placed in the workshop. The operation of unrelated personnel cannot be controlled. The network transmission of the network DNC system now solves the above problem of code transmission.
(2) Unified program management
Through the process, the NC process of the NC process data is controlled through the entire process, so that the NC code and related documents are saved in a unified manner and the latest version is maintained. In the NC machining workflow, the process designer uniformly transferred the NC code to solve the same CNC machining problem in different control system programming problems and the sharing of different machine NC codes, and also solved the frequent processing program due to the machine tool. Changes, various backward transmission methods take time, delay work hours. The DNC management system effectively manages the catalog and process management of parts and processing documents for different workshops. And can effectively back up a large number of important data, such as: backup of machine parameters, numerical control codes, etc., in order to deal with the occurrence of system disasters.
(3) NC code simulation, editing
With the aid of the DNC system, the NC code can be edited and simulated. The NC code can be post-transformed directly, and the NC codes of different CNC systems can be converted to generate NC codes suitable for different CNC systems.
(4) System Integration
Integrate the company's DNC system with PDM/MES system to create a digital workshop. Use DNC's data exchange interface to realize data exchange with MES, PDM, and ERP. The integrated production of numerically-controlled machine tools can reduce production costs, rationalize data flow, increase production efficiency, and drive work efficiency in related processes.
V. Conclusion
CAXA Network DNC is a powerful multi-level and multi-module enterprise CNC equipment management system. It plays a role in promoting production and improving the efficiency of CNC equipment in the projects of Push Mold Co., Ltd. The use of CNC machine tools networking system will give full play to the functions of existing CNC equipment, improve the workshop's production efficiency, and create more economic benefits for the company. To achieve low investment, high return to the intended purpose. According to the enterprise planning, the informatization solution of the DNC using CAXA network starts from the bottom layer networking, and then gradually expands to the data acquisition and statistical analysis of the application layer, and then provides the actual digital basis for the enterprise's production optimization. Therefore, the CAXA network DNC will become the enterprise. The best assistant.
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