WO2025170559A1

WO2025170559A1 - A system for cnc machines

Info

Publication number: WO2025170559A1
Application number: PCT/TR2025/050085
Authority: WO
Inventors: Muvaffak Amasya
Original assignee: Si̇skon Endüstri̇yel Otomasyon Si̇stemleri̇ Sanayi̇ Ve Ti̇caret Anoni̇m Şi̇rketi̇
Priority date: 2024-02-07
Filing date: 2025-02-04
Publication date: 2025-08-14
Anticipated expiration: 2026-08-07

Abstract

The invention relates to a system that collects real-time data from CNC (Computer Numerical Control) machines used in machining enterprises by utilizing Industry 4.0 communication protocols, predicts tool and equipment lifespan based on the data it collects, and determines machining parameters to increase the efficiency of tools and equipment.

Description

A SYSTEM FOR CNC MACHINES

Technological Field:

State of the Art:

CNC machines are production machines that shape raw materials such as metal, plastic, and wood by processing them using machining methods. CNC machines contain tools that remove chips from the workpiece. These tools have a certain service life. The system subject to the invention describes a system designed to increase the service life and efficiency of tools/equipment.

In the known art, each CNC machine brand has its own communication protocol. For this reason, it is difficult to manage CNC machines with different brands or communication protocols through a single system. For example, while the Siemens Sinumetrik 840D Power Line brand/model CNC machine uses a different communication protocol, the Fanuc 31 i brand/model CNC machine uses its own communication protocol. The data collected from these CNC machines do not belong to a specific standard. Data standardization is required to collect the data of CNC machines of different brands/models through a single system.

In the known art, there are certain systems that perform tool life prediction for CNC machines. In these systems, by analyzing the data collected from CNC machines, tool life prediction is performed through machine learning, and maintenance times are determined. For example, this situation is mentioned in the Chinese patent document CN111598251. However, in the relevant patent, the technique of creating a simulation with a digital twin, which is included in the invention subject to the description, is not used. In the Chinese patent, the tool life information is no more than a prediction. In the invention subject to the description, a simulation is prepared based on real-time data regarding the operation of the CNC machine, and the tool life is determined through the simulation. The determined tool life is more accurate and precise than the prediction in the Chinese patent. Additionally, by changing the tool operating parameters in the simulation, optimum machining parameters can be determined, thus extending the tool and equipment life or using them efficiently.

In the literature research conducted, although the Chinese patent documents numbered CN116125913, CN106647626A, and CN213043703 mention a system for collecting data from CNC machines, they do not provide tool life determination or parameter recommendations to increase the efficiency and life of tools and equipment.

As a result, there is a need for a new system in which the known state of the art is overcome and its disadvantages are eliminated to be used in enterprises where CNC machines are used.

Brief Description of the Invention:

The invention is a system for use in enterprises where CNC machines are used, which exceeds the known state of the art, eliminates its disadvantages, and additionally provides extra advantages.

The purpose of the invention is to introduce a new system that determines the equipment/tool life in CNC machines and increases tool life and efficiency in enterprises using CNC machines. Another purpose of the invention is to introduce a system that can collect realtime data from CNC machines independent of the communication protocol used.

Another purpose of the invention is to introduce a new system that visualizes and graphically presents the data collected from CNC machines.

The main purpose of the invention is to introduce a system that prepares a simulation by creating a copy of the data collected from CNC machines and determines the equipment and tool life through this simulation.

Another purpose of the invention is to introduce a system that prepares a simulation by creating a copy of the data collected from CNC machines and provides recommendations to improve the equipment and tool life through this simulation.

In the invention, data is collected from different brand/model CNC machines with data acquisition adapters connected to each CNC machine via an Ethernet cable. The data acquisition adapter uses MTConnect technology and converts the data into a standardized format. MTConnect defines production area data in a standardized format that can be understood by any MTConnect-compatible software application. Once the data has been defined by the MTConnect- compatible data acquisition adapter, there is no need to redefine the data within the system. In this way, data from different communication protocols can be converted into a single format and used.

In the invention, each data collected is copied in a system called the digital twin system. In this way, not only data security is ensured but also data loss is prevented. However, the primary function of the digital twin system is to generate an exact simulation of the CNC machine based on the copied data. Through the generated simulation, the tool life is calculated, and as a result of the calculation, the CNC machine operator is informed by the system. In this way, maintenance times, and tool or equipment change times can be calculated in advance, ensuring continuity in production. In addition, in the generated simulation, by changing the machining parameters it is possible to determine the machining parameters where the tool or equipment efficiency is maximized. The system, which provides these parameters as recommendations, is able to increase the tool and equipment life, i.e. efficiency.

The digital twin system in the invention is the section where the main function is performed. The benefits of the digital twin can be summarized as follows:

• Increasing the reliability of equipment and production lines,

• Improving OEE (Overall Equipment Effectiveness) through reduced downtime and enhanced performance,

• Increasing productivity,

• Reducing risk in several areas, including product availability, and market reputation,

• Reducing maintenance costs by predicting maintenance issues before they occur,

• Achieving faster production times,

• Being able to create new business opportunities such as mass customization, composite production, small batch production, and more,

• Providing improved customer service by enabling customers to remotely configure customized products,

• Offering improved product quality and enhanced insight into the real-time performance of products in applications and environments,

• Ultimately, ensuring higher profits. Description of the Figures:

The invention will be described with reference to the accompanying figures so that the features of the invention will be more clearly understood. However, this is not intended to limit the invention to these specific embodiments. Instead, all alternatives, modifications, and equivalents that fall within the scope defined by the appended claims are also intended to be covered. It is to be understood that the details shown are for the sole purpose of describing preferred embodiments of the present invention and are presented for the purpose of providing the most useful and easily understood description of both the embodiment of the methods and the rules and conceptual features of the invention. In the appended drawings:

Figure 1 is a schematic view of the system subject to the invention.

The figures which will facilitate the understanding of this invention are numbered as indicated in the attached drawing and are listed below along with their names.

Description of the References:

10.CNC machine

11. Operator

12.0perator panel

13. Ethernet connection

20. Data acquisition driver

21. Data acquisition adapter

22. Data publishing service

23. Data acquisition server

24. Database recording service

25. Database

30.Cloud database 40. Digital twin system

41. Simulation algorithms

42. Digital twin database

43. Digital twin server

50. Lifespan calculation module

60. Efficiency enhancement module

70. User device

Description of the Invention:

In this detailed summary, the system subject to the invention is explained only for a better understanding of the subject matter, with examples that do not have any limiting effect.

CNC machines (10) are production machines that shape raw materials such as metal, plastic, and wood by processing them using machining methods. They are controlled by an operator (11 ) through an operator panel (12).

The system described in the invention collects data from CNC machines (10) using data acquisition drivers (20) and a data acquisition adapter (21 ), which is connected to each CNC machine (10) via an Ethernet connection (13). The mentioned data acquisition adapter (21 ) uses MTConnect technology. MTConnect is an open and royalty-free standard based on the most common standards in the manufacturing and software industry, maximizing the number of tools available for its implementation and ensuring the highest level of interoperability with other standards and tools in these sectors at a reasonable cost. The collected data is thus converted into a standardized format. This collected data is published in a cloud database (30) or on a website or application through a data publishing service (22) located on a data acquisition server (23). The mentioned data publishing service (22) uses MQTT-based loT technology. This allows wired or wireless data transfer to a cloud database (30) or local database. Additionally, the data is recorded in a database (25) through a database recording service (24).

In the invention, the primary functional component is the digital twin system (40), the digital twin system (40) is positioned between the operator (11 ) or user and the CNC machine (10), and the operator (11 ) loses direct contact with the CNC machine (10). The management, monitoring and all necessary operations of the machine are carried out directly through the digital twin system (40).

In the invention, the digital twin system (40) directly copies all the data related to the CNC machine (10) from the database (25) or cloud database (30) and records them in the digital twin database (42). Having a copy of each data provides an additional security measure as it prevents data from being modified or lost. However, the primary function of the digital twin system (40) is to simulate the operation of the relevant CNC machine (10) using simulation algorithms (41 ) based on standardized data collected from CNC machines (10). In other words, in the digital twin system (40), a simulation of the relevant CNC machine (10) is generated by using simulation algorithms (41). Since this digital simulation is based entirely on real data, tool or equipment wear can be detected with high accuracy and precision. In the invention, the simulation algorithms (41 ) are operated on the digital twin server (43) and the generated simulations are recorded in the digital twin database (42). The simulation generated with simulation algorithms (41 ) includes a lifespan calculation module (50) and an efficiency enhancement module (60) operated by a digital twin server (43).

The lifespan calculation module (50) mentioned in the invention operates the simulation in accelerated time. For example, a year of real-time operation can be achieved in a 5-minute simulation. In this case, the end of tool and equipment life can be determined in a way that is equivalent to real-time operation. The detected tool life data is published on the application running on user devices (70) for transmission to the CNC operator (11 ) or authorized users. In the efficiency enhancement module (60) mentioned in the invention, however, the machining parameters are changed in the simulation of the CNC machine (10). Machining parameters can be listed as follows:

• Cutting speed (Vc)

• Spindle speed (n)

• Feed (f)

• Feed rate (Vf)

• Depth of cut (a).

The efficiency enhancement module (60) aims to extend the tool/equipment life by changing at least one of these parameters. For that, it determines the optimum parameters. The detected optimum parameters are published on the application running on user devices (70) for transmission to the CNC operator (11 ) or authorized users.

In the invention, the user devices (70) refers to devices that can be a phone, tablet, or computer. On these user devices (70) where the software application of the system subject to the invention is operated, users within the enterprise can access all collected data related to CNC machines (10), generate simulations, or follow the generated simulations.

The most important innovation of the invention is to determine the tool/equipment life in real-time by generating a real-time simulation through a digital twin system (40).

Another innovation of the invention is to provide data standardization using protocols such as MQTT, MTConnect, OPC UA.

Another innovation of the invention is the visualization of data through an application operating on user devices (70). Real-time data can be monitored by users through a dashboard application. This way, instant decision support mechanisms can be established, and production processes can be improved. In the invention, the digital twin system (40) has machine learning integration. Machine learning algorithms make predictions, enabling pattern recognition and predictive maintenance techniques for the early detection of anomalies and failures. Additionally, machine learning techniques ensure the continuous improvement of the digital twin system (40).

In the invention, the digital twin system (40) is the core component that performs the primary function. In the digital twin system (40), all the information and parameters related to the CNC machine (10) that the user wants to follow about the operation can be displayed on the user device, as well as performs information inferences, and provides warnings and recommendations for the life of the CNC machine (10) or components, remaining life estimation, and improving efficiency.

The digital twin system (40) performs the necessary calculations for the CNC machine (10) to operate more efficiently and with better performance and then generates the necessary driver/drive outputs to operate the machine accordingly. In other words, it has the authority to make changes on the CNC machine’s (10) operator panel (12). When an abnormal situation is detected, it can stop the operation of the CNC machine (10) or adjust the machining parameters to increase efficiency.

The digital twin system (40) not only stores the collected data from the physical system after cleaning and processing it and transforming it into usable information with the help of defined models but is also used to control the physical system. This way, the necessary operations can be carried out without any time loss. The location of the digital twin system (40) and its components is completely undefined. All its components can be on a single computer or mobile device, or they can be in different locations and computers on the cloud. The digital twin system (40) can provide the following outputs after the simulation:

• It alerts the operator by stopping the process before starting the operation.

• It sends commands to the real system by making the necessary updates to the parameters to increase efficiency.

• While operating the system, it provides useful information about expected situations and updated parameters based on simulation results about the operation.

A possible operation scenario for the digital twin system (40) is given below:

• The digital twin system (40) receives real-time data from the CNC machine (10) and receives initial information about the device’s status.

• The user accesses the user interface for the CNC machine (10). This interface is provided by the digital twin system (40) and the status of the CNC machine (10) is presented to the user. The user performs all kinds of operations through this interface.

• The user initiates an operation.

• The digital twin system (40) checks the status of the CNC machine (10) before starting the operation and, if necessary, performs a simulation on the numerical model of the digital twin system (40) and checks the results in advance.

• The digital twin system (40) provides recommendations regarding the operation parameters to the user if necessary (e.g. if part wear is at a state that the operation cannot be completed).

• If the simulation results are within the desired limits, the operation starts.

• During the operation, the digital twin system (40) continues to collect data from the CNC machine (10) and monitors the operation in real-time, transmitting information to the user interface.

• The data collected from the CNC machine (10) is stored in the permanent memory of the digital twin system (40). • The digital twin system (40) determines the remaining life of the machine and its components and reflects this information on the interface.

• The digital twin system (40) periodically analyzes the collected data and updates its models related to the CNC machine (10) by improving them through machine learning.

Claims

1. The invention is a system for use in CNC machines (10) in machining enterprises, characterized in that:

• including a data acquisition adapter (21 ) that collects data from the CNC machine (10) data acquisition driver (20),

• including a data publishing service (22) running on a data acquisition server (23) to publish the collected data by the mentioned data acquisition adapter (21 ) on a publishing platform (website, application) with a cloud database (30) or a local database,

• including a database recording service (24) that records the collected data by the mentioned data acquisition adapter (21 ) into a database (25) or a cloud database (30),

• including at least one digital twin system (40) that generates copies of the data recorded in a database (25) or a cloud database (30) and stores them in a digital twin database (42),

• including simulation algorithms (41 ) operated by the digital twin server (43) within the mentioned digital twin system (40), which generates simulations that simulate the operation of the CNC machine (10) in real-time using the copied data,

• including at least one lifespan calculation module (50) that determines the real-time depletion time of the tool/equipment life through the simulation generated by the simulation algorithms (41 ).

2. System according to claim 1 , characterized in that including at least one efficiency enhancement module (60) that determines the optimum machining parameters (cutting speed, spindle speed, feed, feed rate, depth of cut) through the simulation generated by the mentioned simulation algorithms (41 ) to improve the life or efficiency of the tool/equipment.

3. System according to claim 1 or claim 2, characterized in that including at least one digital twin system (40) that, based on the outputs determined by the mentioned lifespan calculation module (50) or efficiency enhancement module (60), modifies parameters through the CNC machine (10) operator panel (12), stops the CNC machine operation, or informs the operator (11 ).

4. System according to claim 1 , characterized in that the mentioned data acquisition adapter (21 ) having the MTConnect standard to ensure data standardization.

5. System according to claim 1 , characterized in that the mentioned data publishing service (22) utilizing an MQTT-based loT protocol for data transmission.

6. System according to any one of the preceding claims characterized in that including user devices (70) equipped with a dashboard application that enables the visual monitoring of all collected data and generated simulations.

7. Method for operating the system for use in CNC machines (10) in machining enterprises as defined in claim 1 , characterized in that:

• collecting CNC machine (10) data through data acquisition adapters (21 ) via data acquisition drivers (20),

• converting the collected data into a standardized format using the MTConnect standard,

• publishing the standardized data in a cloud database (30) or a local database via the data publishing service (22),

• identical copying the published data through the digital twin system (40),

• recording the copied data in the digital twin database (42),

• generating a real-time simulation from the recorded copied data using simulation algorithms (41 ) operated on a digital twin server (43), determining the tool/equipment real-time life using a lifespan calculation module (50) that operates the generated simulation in accelerated time periods.

8. Method according to claim 1 , characterized in that including at least one efficiency enhancement module (60) that identifies the optimum parameter values to increase tool/equipment efficiency and lifespan by modifying the machining parameters (cutting speed, spindle speed, feed, feed rate, depth of cut) through the generated simulation.

9. Method according to claim 1 , characterized in that the digital twin system (40) modifying parameters through the CNC machine (10) operator panel (12), stopping the CNC machine (10) operation, or informing the operator (11 ) based on the outputs determined by the mentioned lifespan calculation module (50) or efficiency enhancement module (60).