1. STEP-NC Solutions
Martin Hardwick
David Loffredo
info@steptools.com
STEP-NC Manufacturing Center
Watervliet Arsenal, Building 20
Metal Processing Manufacturing Division
Watervliet, New York 12189
(518) 687-2848 / (518) 687-4420 fax
http://www.steptools.com

2. Slide 2M. Hardwick
Introduction
“4 CAM’s – 2 Controls – 0 Postprocessors”
AB Tool Tilt
BC Table Tilt
AP-238

3. Slide 3M. Hardwick
AP-238 Functionality
Benefit
Functionality
TCP
Lines
& Arcs
Drilling
Cycles
Toleranced
Splines
Feature
parameters
Feature
tolerances
Other Models
Turning (in AP-238 ed1)
EDM
Contouring
Inspection
Robotics
Parametric
Operations
Probing
Workingsteps
Toleranced
Surfacing
Conditional
Operations
Better Process
Control
Better Process
Monitoring
Flexible
Manufacturing
Today
Tested during
research phase
Product
Geometry

4. Slide 4M. Hardwick
Smart Process Control
• Base level configuration
– Eliminates post
– Enables faster operator prove-out
– Creates pathway for on-machine optimization
Converter
dll
Control HMI
Motion
Controller
TCP Motion
Codes
New components
CNC Vendor components
CAM
Writer
dll
AP-238
File
Expresso
Data check
STEP-NC
Simulator
Subs
bi-directional

5. Slide 5M. Hardwick
Smart Process
Monitoring
Monitor
dll
Control HMI
Motion
Controller
CNC
Loader
• Process Monitor configuration
– Allows customer to verify correct operation of the control
– Timings, operational parameters
– Feature, operation and tool id for each workingstep
New components
CNC Vendor components
TCP
Code
Block
Number
Customer
ReportCAM
Writer
dll
AP-238
File
Expresso
Data check
STEP-NC
Simulator
Subs
bi-directional

6. Slide 6M. Hardwick
Smart
Manufacturing
Interpreter
dll
Control HMI
Motion
Controller
CNC
Loader
Subs
CAM
Writer
dll
AP-238
File
Expresso
Data check
STEP-NC
Simulator
• STEP-NC Interpreter configuration
– Execution flow depends on sensor values
– Sensor values are connected to NC Variables of the program
– Executive tells Interpreter when to start and stop
TCP
Code
Block
Number
Customer
ReportExecutive
Sensor value
Sensor value
Run
WS1-N
Program
Status
System Integrator component

7. Slide 7M. Hardwick
Application
s
• Smart Process Control
– CNC Operator needs to change a speed for all pocketing operations
– Converter identifies all workingsteps that use this feed.
– CAM operator guided to operations that need to be edited
• Smart Process Monitoring
– Motion control records maximum Z tool tip position
– Monitor dll adds data about workingstep and feature id
– OEM checks hole feature has required depth.
• Smart Manufacturing
– CAM creates program including probing operations
– Executive relates probe value to STEP-NC Variable
– Interpretation of program decides how to adjust finish allowance

8. Slide 8M. Hardwick
The Dynamic
OEM
Shop
CNC Vendor
ISO Standard
“Accept jobs defined
by AP-238 so I will
know how they are
machined”
“I need AP-238 so I
need to upgrade my
controls to include the
TCP option.”
“Put the AP-238
dll’s on my TCP
controls”
“Here are dll’s
to read and
write STEP-NC
data”

9. Slide 9M. Hardwick
Current Status
• Can machine NAS 979 CDS part with 5 axis cone
– 3 and 5 axis tool paths, lines and arcs
– Machine functions and technology
• Draft International Standard in review
– A few EXPRESS errors being found
– Some scope for data compression
– Enhancements for process monitoring
• Writer and Converter dlls ready for Beta use
– Stage 1 – replace RS274D but keep same procedures
– Stage 2 – optimize procedures using new intelligent data

10. Slide 10M. Hardwick
Conclusio
n
• AP-238 delivers rich data to the control
• The benefits are well known
– Design anywhere, build anywhere
– Cross enterprise re-use of CNC programs
– Fewer operational errors
– Faster machining
• The post was always in the way
– Delivering low level machine codes
– No connection between a feed and the reason for the feed
• The combination of Open Controls, TCP
Programming and AP-238 eliminates the barrier.