INDU 411

Computer Integrated
Manufacturing

Lab01

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Labs
6 Labs

Attendance is Mandatory

Lateness will not be tolerated

Switching lab sections is not permitted

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Lab Structure
1st Lab
Introduction & Safety
NC Codes
Project Description
2nd Lab
Introduction to NC Milling programming
Lab assignment #1
Project Progress Report #1
3rd Lab
Introduction to NC Lathe Programming.
Lab assignment #2
Project Progress Report #2

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Lab Structure
4th Lab
Robots Introduction
Robots Pick and Place Programming
Project Progress Report # 3
5th Lab
Introduction to CIM Manager
Production Run Simulation
Project Progress Report # 4
6th Lab
Project Run
Production optimizing
Final Report Preparation

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Lab Safety
1) No Food / Drink in either Lab
2) Safety Glasses must be worn when in proximity of the
equipment
3) A lab instructor or technician is required to be present to
operate any equipment in the lab
4) Call 3717 for any emergencies
5) Notify technician or lab instructors of any personal or
equipment accidents / incidents
6) Only one team may be in proximity of a machine or robot
while in operation

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Lab Assignments & Project
There will be two lab assignments during the semester
Lab assignments are to be done individually as exercises to be
marked by your lab instructors
Each Session is divided to 5 teams consisting of two students.
Each team will work on one selected Chess Pieces which are
King, Rook, Queen, Bishop and Pawn with appropriate base
design
The pieces will be assigned to each team by the instructor.

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Lab Assignments & Project
Each lab group must give project Progress report and
Final Report Submission on April 13th,2017, e-submission
through moodle
The moodle submission must contain the full report including
all programming codes and simulation optimization methods
and comparison.

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 OPEN CIM INTRODUCTION
CIM LAB OBJECTIVE
a fully computerized manufacturing system that covers
transformation of raw materials to finished parts/products

The lab components includes

Three robots (two ER-9 and one ER-5)
3-axis CNC mill (ProLight Machining Center)
2-axis CNC lathe (ProLight Turning Center)
Automated storage and retrieval system (ASRS)
Closed loop continuous conveyor
Quality control center

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OPEN CIM INTRODUCTION
Stations
OpenCIM cell is composed of a set of stations located around a
conveyor
ASRS Station
Machine Station
Assembly Station
QC Station

Each station is controlled by a Station Manager PC

A CIM Manager PC coordinates the activities of all stations
Station devices are Robot, Robot Controller, Station Manager, and
machine.
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OPEN CIM INTRODUCTION
Material Flow
Primary Material Handling: transportation of parts between stations
Conveyor

Secondary Material Handling :handling of parts within a station

Robot

Material Flow Components

Templates

Conveyor and Pallets

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OPEN CIM INTRODUCTION
Robot and Controller (To be updated with a new controller)

move parts within a station (secondary material handling) and perform

assembly operations

Robotic programs inform the robot what path

to follow and what task to perform once it
reaches a destination.

The controller (ACL) provides the power

supply to the robot and moves the robot by
controlling the power to the motors inside the
robot.

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 OPEN CIM INTRODUCTION
Communication Interface
Sendcommands from the CIM Manager to
Device Drivers (e.g. data such as part ID #)

Sendreal-time production status messages from

Device Drivers to the CIM Manager

AllowDevice Drivers to retrieve process

programs (e.g. G-code) stored on the server

Sendreal-time production status messages to

the Graphic Tracking software

TransferCIM messages between different

device drivers

TransferCIM messages between devices and a

user application running on a networked PC

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 OPEN CIM INTRODUCTION
Device Drivers
A device driver translates OpenCIM messages in two directions:
OpenCIM instruction messages into a set of commands understood by the target
device.
A response from the device into an OpenCIM status message.

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 OPEN CIM INTRODUCTION
CIM MANAGER
CIM manager is used for operating the open CIM system and production

Real Mode : communicates with all device drivers, whether or not hardware is in use

Simulation Mode : is not communicate with device drivers

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 OPEN CIM INTRODUCTION
Production Operations
Supplied parts (raw materials) are loaded into storage locations.
Manufacturing orders are generated by the CIM Manager
Parts are removed from the ASRS and transported on the conveyor to
production stations.
Robots take parts from the conveyor and move them to various
production machines (e.g. CNC machines) at a station (machine
tending).
Typical production tasks include:
Processing in a CNC machine
Assembling two or more parts
Quality control tests
Robots return processed parts to the conveyor for transportation to the
next station.
Finished products are removed (unloaded) from the cell.

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OPEN CIM INTRODUCTION
Part and Machine Definition
A product is manufactured from a group of subparts (bill of materials) that
are put together according to a specified set of machine processes

The process name enables the CIM Manager to determine which machine is
capable of performing the specific process required to produce a part (as
defined in the Process field in the Part Process Table in the Part Definition
form).

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OPEN CIM INTRODUCTION
Real Time Monitoring
The Device View is a complete list of every robot and machine (including
QC devices) in the CIM cell and a description of the current action being
performed by each

The Leaf View provides a detailed description of the production activities of

the CIM cell, describing the current operation being performed on each item
and the operation that will immediately follow

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 NC PROGRAMMING
G Code

NC programming generally incorporate two types of instructions: those

which define the tool path (such as X, Y and Z axis coordinates), and
those which specify machine operations (such as turning the spindle on or
off).
An NC program is composed of blocks (lines) of code. An NC word is a
code made up of an alphabetic character (called an address character) and
a number (called a parameter)
Each block of NC code specifies the movement of the cutting tool on the
Machining Center and a variety of conditions that support it

N0 G90 G01 X.5Y1.5 Z0 F1

N0: This is the block sequence number for the program

G90: This indicates absolute coordinates are used to define tool position

G01: This specifies linear interpolation

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NC PROGRAMMING
G Code

N0 G90 G01 X.5Y1.5 Z0 F1

X.5: This specifies the X axis destination position as 0.5

Y1.5: This specifies the Y axis destination position as 1.5"

Z0: This specifies the Z axis destination position as 0". The cutting tool will move to the
absolute coordinate position (0.5, 1.5, 0)

F1: This specifies a feed rate of 1 inch per minute, the speed at which the tool will
advance to the specified coordinate points

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NC PROGRAMMING
G Code

The Units Group

G70 : Inch Unit

G71: Metric Unit

If the code is placed at the beginning of the program before any tool motions are made,
that unit of measure is assumed for the entire program. Otherwise, it affects the rest of
the program following the code.

The Wait Group

G04 (wait):Pause between motions on all axes for the number of seconds specified by the
F code, then continue the program

For example: G04F10; //Wait for 10 seconds

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NC PROGRAMMING
G Code
The Programming Mode Group

G90 : Absolute Programming Mode

G91: Incremental Programming Mode

Programming mode G codes select the programming mode, absolute (G90) or

incremental (G91). These codes remain in effect until superseded by each other. With
absolute programming, all X, Y and Z coordinates are relative to origin (0, 0, 0) of the
current coordinate system. With incremental programming, each motion to a new
coordinate is relative to the previous coordinate.

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NC PROGRAMMING
G Code
Preset Position Group

G28 Set reference point: This code moves the machine to its home position. The G28
code performs an automatic calibration of the axes.

G92 Set position: The X, Y and Z coordinates following a G92 code define the new
current position of the tool.

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NC PROGRAMMING
G Code
Linear and Circular Interpolation
G00 Rapid linear motion (no cutting)

G01 Linear movement (accompanied by Z, Y, or X coordinate)

G02 Circular interpolation clockwise

G03 Circular interpolation counterclockwise

The end point is defined by Z, Y, or X coordinate. The center of the arc is defined by
I, J, and K coordinate. The radius of curvature can be defined with R

interpolation using center point:

G03 X0Y1 I0J0 F2; CCW

interpolation using the arc radius

G03 X0Y1 R1 F2; CCW

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 NC PROGRAMMING
G Code
Cutter Compensation Group

G40 Cancel cutter compensation.

G41 Invoke cutter compensation left. compensation compensation

left right
G42 Invoke cutter compensation right G41 G42

D Specifies the offset number from the Offset Table (D1, D2, D3,).

Without
Active the compensation programming
command before any movement with cutter
compensation
to the desired path
G41 D3; active cutter compensation left with offset number 3 commands
G00 X2 Y1 coordinates are
obtained from
G01 Z-0.063 F5 offset contour
G01 X4 Y5 F10
G02 X5 Y6 R1
.
.
G02 X2 Y1 R1
G00 Z0.1 Cancel cutter compensation after
G40` retracting the tool away from the
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part
NC PROGRAMMING
F Code

Feed Rate

Specify the rate of speed at which the tool moves (feed rate) in inches per minute (ipm).
For example, F3 equals 3 ipm..

Feed Rate Formula

To determine the Feed Rate use the following formula:

fm = ft nt N
ft = Feed per tooth in inches per minute (IPM). Use a ft of 0.010 for Acrylic.
nt = Number of teeth
N = Spindle speed in RPM

Plexiglas recommended cutting speed (CS) is 300 feet per minute.

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 NC PROGRAMMING
The cardinal rule in machining is to remove as much material as possible within the limits of
machine capability. That is, to machine as quickly as possible. It is not so much a question of
minimizing time wasted machining, but one of maximizing cutting tool life.

Feed rates that are too low produce excessive heat which may cause premature failure of the
cutting edge.

Feed rates that are too high may cause the cutting edges to fracture or cause more catastrophic
failure.

Cutter speeds outside the recommended range may cause the cutting edges to experience
buildup, wear excessively, crater, chip, or produce poor work piece surface finish.

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