WorkCenter
Single Operation Mill Order (48
sec.)
Single Operation EDM Order (84
sec.)
Multiple Operation Order (67 sec.)
Batch (56 sec.)
Create an article (31 sec.)
CellManager
EDM-General (106 sec.)
EDM-Offset missing (106 sec)
EDM-Electrodes missing (124 sec.)
Milling-General (105 sec.)
Milling-Operation Sequencing (89 sec.)
Milling-Cutter Tool Monitoring (CTM), (104
sec.)
Milling-EDM (157 sec.)
Milling-Twin CTM (78 sec.)
WEDM-General (78 sec.)
WEDM-Twin (80 sec.)
WEDM-Triple (95 sec.)
It is generally thought that automated production is complicated to
introduce and that it can only be applied to long runs. The may be
true when the robot grips the workpiece directly, but hardly when
the workpiece is palletised.
The handling units in System 3R's automation programs are all
intended to move pallets between a magazine and predefined chucks in
one or more machines. When you work with pallets, the preparations
are the same whether you are producing 100 different parts or 100
parts of the same type.
When you have made the preparations for production in
WorkShopManager, the operation of lifting the pallet into and out
of the machine is not complicated at all.
WorkShopManager has been developed …
… to simplify the preparations for production in automatic
cells
… to maximise production capacity… to create the greatest possible
flexibility
… to ensure the security of the process.
WorkShopManager is equally useful for manual loading of pallets
in a single machine as for automatic production in a seven-axis
linear robot cell, since this software grows with the task. Start
with a single machine on the lowest level and then upgrade as your
business develops.
WorkShopManager secures the process
The core of the system is a central database. All clients, machines
and automation devices are in constant contact with the
database.
WorkShopManager links all machining processes together in a
controllable and clearly-arranged production system. All machining
data is available to the machines and can easily be transferred to
the right machine at the right moment.
• User-friendly - necessary data are entered quickly and in a
structured manner
• Quick, precise overview of the entire process chain
• Great flexibility - the order of priority can be changed at
any time
• Simpler, safer preparation of automatic cells. Information
about workpieces, magazine positions, offset values and NC programs
is always available.
• The risk of errors due to the human factor is
minimised
• Generates shorter lead times
• Increased process security
• Offers the possibility of automated one-piece production
The user-friendly procedure in WorkShopManager can be summarised
in three stages: preparation, execution and monitoring.
All information about the machining is brought together in
WorkCenter, which communicates with the database.
In the database, a manufacturing order is created. This may
contain:
• an operation list
• a NC program for the operation in question
• documents linked to the operations
• pallet identity
• offset values
WorkCenter does not produce its own data; it compiles information
for every machining operation.
The necessary information is fetched from the database and
transferred to the machines.
How the relevant order is executed depends on the type of
cell…
… manual creation of a batch with BatchBuilder, or
… automatic execution with CellManager.
A batch is a complete machining operation, containing several
manufacturing orders with their magazine positions. This type of
magazine loading can be regarded as static, since machining of the
entire batch must be completed before changes can be made in the
magazine.
With CellManager, each individual job is started according to a
priority list. Here, you can change priorities and magazine content
while the machine is working.
Job status and machining times are recorded and stored in the
database.
Reports such as machining time per workpiece can be generated and
transferred to a planning system.
Alarm messages from machines and robots can be transferred via
e-mail or SMS.
Order creation
In WorkCenter, manufacturing orders can be organised in
accordance with the company's standard order structure.
A manufacturing order covers one or more identical parts which may
be located on one or more pallets. The same pallet may also be
carrying different parts, each with its own manufacturing order.
This open structure offers great flexibility when creating a
manufacturing order.
Article register
The operation list can be saved as an article for use if the part
needs to be produced again. If a new order is created, based on an
article, every machining step and NC program will be present in the
new production order.
• Simpler and quicker
• Reduces the risk of data entry errors
Option -planning system integration
When information is imported from ERP/MPS, a manufacturing order is
created automatically.
What then remains to be done is to place the workpiece on its
pallet, to identify it and to fetch any offset values from the
measuring machine.
Up-to-date machining information is fed back to ERP/MPS for
evaluation and post-calculation.
Operation lists
In an operation list, the order of the various machining steps is
defined. One operation must be complete before the next operation
can start.
Documents
Documents - machining instructions, reports, images, etc. - can be
linked to every operation. This allows the operator to make use of
the information directly at the machine.
• No searching for information
• The information is linked to the right machining operation
• If the operation has been saved as an article, information from
previous occasions will be available.
Linked orders
For an EDM operation, electrodes need to be produced. Linking
electrode manufacturing with the EDM operation minimises the risk
of mistakes. As soon as the electrode blank has been identified on
its holder, the electrode and the EDM operation are linked.
• The right electrode for the right EDM operation
• High process safety
Status
The status - waiting / machining / ready - of every object in the
magazine is recorded in the database.
Identify
The next step is to link the physical objects with their
manufacturing orders.
The object is mounted on a pallet with a code carrier which is
recorded in the database.All information held in the database for
that object can now be fetched.
CCM integration
If required, a measuring machine can be used before
machining to determine offset values (X-Y-Z-C) for the workpiece on
its pallet.
The measurements are stored in a neutral format. They are then
adapted and transferred to the machine tool.
• Reduces the risk of data entry errors
Multi-pallet function
There is no need to measure objects on multi-pallets.
Every fixture on the pallet has a known position, and this
automatically gives the objects the correct offset values.
• With this function, users can create their own
multi-pallets
• Especially suitable for milling applications
Quality control
When the measuring machine has performed a geometrical inspection
of the object and sent the status to the database, the object can
be barred or released for further operations.
CellManager
CellManager, which requires the pallets to have an identification
system, manages the entire robot cell, handling all necessary data
automatically. The cell is controlled entirely from the
screen.
• Starts the robot's ID cycle.
• Manages the pallet ID codes and magazine positions.
• Displays the magazine content graphically.
• Creates priority lists.
• Automatically starts available jobs in the order of the priority
list.
• Updates the information in the database with the status and
machining times of individual orders.
Identification system
Whether you work with visual identification such as labels,
or an electronic system with inductive readers and ID transponders,
CellManager ensures the security of the process.
Chaotic magazine loading
On loading, the pallet is placed at the first available
free magazine position.
CellManager Multi
Manages a robot cell consisting of one robot and more than one
machine, regardless of the type and make of the machines.
Easy to change priorities
The order of priority of jobs can be changed while the machine is
working.
Easy to insert new jobs
Finished workpieces can be lifted out of the magazine and new ones
loaded into it, while the machine is working.
Manually loaded machines
Chaotic loading of a machine table with multiple
chucks.
After manual scanning of the machine table, a job list is created
in CellManager. The jobs are then done in the sequence in the job
list - one program at a time.
• The job sequence can be changed
• Automatic monitoring
Robot-loaded machines
Chaotic loading of the magazines
After automatic scanning of the magazine, a job list is created in
CellManager.The jobs are then done in the sequence in the job list
- one program at a time.
• The job sequence can be changed
• Automatic monitoring
• The magazines can be lifted out and loaded while the machine is
working.
Option - automatic electrode selection
(AES)
Automatically chooses the best electrode for the machining
operation. Used to limit the number of electrodes when producing
identical workpieces. However, for this function it is necessary to
make an estimate of the electrode wear with coarse, intermediate
and fine machining.
You can, for instance, choose to "downgrade" the electrodes after
the first bit. For the second bit you then use the first intermediate
electrode for the coarse machining, the first fine electrode for the
intermediate machining, and a new electrode for the fine
machining.
Option - Cutting Tool Montitoring
(CTM)
This function checks that all cutting tools that are needed for the
milling operatins are available before machining starts.
Option - RobotManager
Option for cells with industrial robot: CellManager handles
communication between the various units of the cell, coordinates
all activities, and monitors the status of every
operation.
BatchBuilder
BatchBuilder is a WorkCenter function for creating a
complete machining operation - en batch - made up of several
individual orders. You choose a number of orders and add magazine
positions. The function then generates a main program with
associated subprograms. The batch is transferred to the right
machine and when the machine is started, the individual machining
operations are executed - from the beginning to the end.
Batch ID
It is possible to use the ID system in combination with
BatchBuilder. The function is called Batch ID
and works as follows:
• Load magazine randomly
• Perform a magazine scan
• The available jobs with the corresponding magazine positions are
visible in the BatchBuilding window
• Select the job to execute
• Transfer the batch to machine and start machining
No risk of loading wrong magazine position
Magazine positions
The NC programs that were linked to the respective
operation do not include the magazine positions. This information
therefore must therefore be added when the batch is created. This
can be done manually or the information can be generated
automatically.
• Simplified NC-programming.
Loading list
When the batch has been created, you can print out a loading list
which describes the magazine positions of the objects.
• Less risk of loading at the wrong magazine position
Option - AlarmServer
Alarm messages from the machine and the robot can be
transferred via e-mail or SMS.
Transfer of NC programs
When creating the batch, you choose the machine or the
cell that you want to perform the machining operation. The complete
information is then transferred via the network. The magazines are
loaded according to the loading list and the machining operation
can start.
CellManager
CellManager maintains constant contact with the machines
and monitors what is happening in the cell.
• When a machining operation starts and ends
• What operation is being done
• What object is in the machine
• Messages coming from the maskin
WorkCenter
All information about the various operations is saved in
the database. WorkCenter makes it possible to use this information
wherever you happen to be.
Reporting
Reports such as machining time per part can be created and
transferred to a production planning system (PPS).
Status
WorkCenter keeps track of what is to be machined, and on
which machine, as well as monitoring the status of jobs.
Option -planning system integration
Up-to-date machining information can be automatically fed back to
ERP/MPS for evaluation and post-calculation.
WorkCenter
• Basic client/server package - SQL-server installation, WorkCenter
client & BatchBuilder machine licence
Options:
• Additional WorkCenter client - When more than one
WorkCenter installation is required
• Additional BatchBuilder machine licence - When more than one
machine is to be integrated into WorkShopManager
• Electronical identification - Opens the indentification function
for the entire WorkShopManager installation
• BatchBuilder Manual scanning software - For applications with
manually scanned magazine with Batch transfer. One per
machine
• BatchBuilder automatic Scanning software - For applications with
automatically scanned magazine with Batch transfer. One per
machine
• ERP/MPS interface - For integration on ERP/MPS systems
CellManager
• CellManager 3 - Handles jobs for one or more machines
with automatically scanned magazines
• Machine processor - For communication with the machine. Available
for most types of machines
• CellManager 3 Manual - Handles jobs for one or more machines
with manually scanned magazines or table chucks
• Machine processor for manual cell - Machine processor for
CellManager 3 Manual. Available for most types of machines
Options:
• Automatic electrode selection (AES) - CellManager automatically
chooses a suitable electrode for EDM machining
• Cutter Tool Monitoring (CTM) - Check that the cutting tools are
available before the job starts
AlarmServer
For transmission of messages from automatic cell via e-mail or SMS.
One AlarmServer covers the entire workshop
• Alarm Client WorkCenter - Each cell requires its own client
• Alarm Client CellManager - For advanced alarm function
• GSM Alarm Transmitter - For transmission of SMS. This requires a
GMS account and a SIM card
Hardware
• Code carrier - Available in two types - Trovan (3R
standard) and EM-Marin
• Hand scanner (HS) - Hand scanner for manual scanning
• ID reader with pistol-grip antenna - Reads Trovan. Also available
for EM-Marin
• Universal reader - Reads both Trovan and EM-Marin
• Magazine scanner (MS) - ID reader fixed mounted in a
rotary magazine
• Robot scanner ( RS) - The robot scans the magazines
• Loading station scanner - Fixed ID reader in every loading
station postion
• Quick Scanning (QS) - Fixed scanning at every level of a rotary
magazine
WorkShopManager is equally useful for manual loading of
pallets in a single machine as for automatic production in a
seven-axis linear robot cell, since it grows with the task.
Start with a single machine on the lowest level and then upgrade as
your business develops.
WorkCenter,
Option ERP/MPS
Application examples
Die-sinking EDM with CMM:
Electrode changer + table chuck
Electrode changer + WorkPal/WorkPartner/WorkMaster
Wire EDM with CMM:
WorkPal/WorkPartner/WorkMaster
Milling & Grinding:
WorkPal/WorkPartner/WorkMaster
WorkCenter
ID system
Automatic scanning software
Option ERP/MPS
Application examples
Die-sinking EDM with CMM:
Electrode changer + WorkPal/WorkPartner/WorkMaster
Wire EDM with CMM:
WorkPal/WorkPartner/WorkMaster
Milling & Grinding:
WorkPal/WorkPartner/WorkMaster
WorkCenter,
CellManager 3
ID-system
Machine processor for robot cell
AlarmServer
Option ERP/MPS
Option CTM
Option AES
Application examples
Die-sinking EDM with CMM:
WorkPartner/WorkMaster/WorkMaster Linear/Six-axis industrial
robot
Wire EDM with CMM:
WorkPal/WorkPartner/WorkMaster/WorkMaster Linear/Six-axis
industrial robot
Milling & Grinding:
WorkPal/WorkPartner/WorkMaster/WorkMaster Linear/Six-axis
industrial robot
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