I. Overview At present, China's shipbuilding industry is in an unprecedented period of vigorous development. The shipbuilding industry is experiencing the development of agile shipbuilding from traditional manual and mechanical shipbuilding to computer digitization and rapid response manufacturing. Database, network and computer software application systems are the foundation of digital agile shipbuilding and the core technology for digital agile shipbuilding.
In the fourth quarter of 2006, FastCAM China selected a representative large-scale shipbuilding company for a two-week on-site practice and two months of follow-up guidance, from the design department to the DXF/DWG file format nesting Drawings and detailed design of the parts drawing, part drawing optimization, automatic programming, automatic nesting, code conversion, database management, statistical reports, and cutting production planning management, to CNC cutting machine on-site cutting, to solve various cutting quality problem.
The two-week on-site guidance not only solves the efficiency and quality problems of programming nesting and CNC cutting in time for shipbuilding enterprises, but also provides practical and specific application cases for the application of FastCAM nesting software in shipbuilding enterprises. Shipbuilding enterprises provide effective technical guarantees for effectively improving the production efficiency of programming nesting and improving the cutting quality and cutting efficiency of CNC cutting machines.
Second, the application case analysis 1. Application Case 1: Optimization of nesting diagrams, automatic programming and transcoding to improve programming efficiency and cutting quality
At present, China's shipbuilding enterprises generally adopt a professional collaborative production mode. The ship design department or the design company directly provides the nesting DXF/DWG format nesting drawings (see Figure 1) to the shipbuilding enterprise for programming and cutting. The production department, after simple NC programming and code conversion by the programming nesting department, is handed over to the cutting department for CNC cutting.
Using the DXF/DWG format nesting files for programming and CNC cutting, the main difficulties and problems faced by the company are as follows:
First, automatic programming is difficult. Because DXF/DWG files often have redundant entities that are unrecognizable to the naked eye, overlapping curves, or curves that are not closed, there is no automatic programming or programming error, such as multiple lead-in and repeated cuts.
The second is the code conversion problem. The company has several CNC cutting machines from different years in the Ship Research Institute and Shenzhen Bolichang. It uses Fagor, EDGE, Lynx and other brands of controllers. The code formats are different, and it is very cumbersome and difficult to convert between them.
Figure 1 DXF/DWG format nesting diagram
The third is the quality of cutting. The first is to introduce the lead point to burn over the scar; the second is that the cut section is not smooth, there are many wave patterns.
Fourth, the cutting efficiency is low and the plasma cutting nozzle is wasteful.
In response to the above difficulties and problems, we help companies analyze the causes of problems, and guide users to use FastCAM nesting software and solve them one by one.
(1) Use the CAD removal function of FastCAM software to optimize the DXF/DWG file (see Figure 2), remove redundant and overlapping entities, compress small lines, and make the nesting diagram consisting of 282 entities. After optimization, the number of entities is reduced to 218, which effectively reduces the amount of program, avoids runaway and repeated cutting. At the same time, compressing small entities can directly improve the quality of the cutting section, avoid wave pattern and cutter jitter, and effectively improve Cutting quality and cutting efficiency.
Figure 2 CAD clear compression function
(2) Using the FastPATH automatic programming function (see Figure 3), setting the cutting mode, introducing the lead wire type, the kerf compensation method, the contour gap and selecting the plate border, and automatically programming, you can get the cutting code program and make it The closed curve is automatically closed; at the same time, the quality problem of introducing the lead point over the burned scar is solved.
Figure 3 automatic programming function
(3) Use FastCAM software to achieve fast conversion of different codes. FastCAM software provides a variety of controller code conversion functions (see Figure 4). Controller code types include: ESSI, Messer cutting machine ESSI format and general EIA format, including common EDGE, LYNX, FastCNC , FAGOR, START and other controller types.
(4) Using efficient cutting programming skills, especially for plasma cutting, using the bridging function provided by FastCAM software to achieve bridging and continuous cutting of multiple parts, effectively reducing plasma perforation, saving plasma cutting nozzle and improving cutting efficiency.
Figure 4 Multiple controller conversion types
2. Application Case 2: Automatic Extraction and Automatic Nesting of Parts Drawings <br> At present, China's large and medium-sized shipbuilding enterprises have their own ship design institutes, from the structural design of the hull, the segmental design of the hull to the detailed design of each section. Has considerable design and development strength. However, after detailed design, there are still many technical problems to be solved in the programming nesting and CNC cutting production departments. For example, how to quickly extract the same thickness of parts from the detailed design drawing, organize the generated part cutting list, and carry out automatic nesting to avoid repeated drawing, thus effectively avoiding manual finishing of the cutting parts list and avoiding manual nesting and programming. It is the key to realize paperless and digital programming nesting, effectively improve the efficiency of programming nesting, and improve the quality and efficiency of CNC cutting.
FastCAM nesting software provides shipbuilding manufacturers with a mature and professional integrated automatic extraction, automatic nesting, automatic programming techniques and methods. The operation flow is described below.
The first step: using the CAD compatible function of FastCAM software, read the detailed design of the hull section of the DXF/DWG format (see Figure 5, the ship company has already carried out the different thickness parts in the detailed design of the hull section. Classification, plate thickness 10 ~ 45mm can be divided into a variety of specifications), and then processed separately according to different plate thickness. For example, a 20 mm thick part is first removed from other thick parts and a frame, leaving only a 20 mm thick part set (see Figure 6). Then use the CAD clear compression optimization function described above to remove redundant and overlapping entities, avoid repeated cutting, compress small line segments, optimize DXF/DWG files, and reduce the original 233 entities to 183 entities, effectively improving the numerical control. Cutting quality and cutting efficiency.
Figure 5 Detailed design of the hull section
Figure 6 20mm plate thickness cutting parts set
Step 2: Using the CAD extraction of the FastCAM software to extract the sorting function, not only can you easily extract any part drawing, save it as a DXF/DWG or CAM file, but also automatically extract the part name. The most important function of this program is to automatically break up parts, automatically extract part names, store parts sequentially, and automatically sort and automatically generate a part cut list (see Figure 7, Figure 8) to prepare for automatic nesting.
Figure 7 automatic break sort function
Figure 8 automatically generates a list of cut parts
Step 3: Use the automatic nesting function of FastCAM software to directly read the automatically generated list of cutting parts for automatic nesting (see Figure 9); use automatic and manual interactive nesting and automatic programming in the FastNEST nesting software. Method, optimize nesting and programming results; use multi-controller conversion function to generate NC cutting files required by different cutting machines and controllers for CNC cutting.
Figure 9 Part set of 20mm plate thickness
3. Application Case 3: Automatic identification and cutting code conversion of Tribon.Gen nesting diagram
At present, a small number of large and extra-large shipbuilding enterprises in China have built a world-class shipbuilding enterprise to meet the market needs of ship export, and invested heavily in the purchase and use of the internationally renowned Tribon hull design software for hull structural design and detailed design of sections. And the sheet metal parts of the parts, so that the ship design technology level has reached the international advanced level.
However, in the CNC cutting production department, there are still problems in the automatic identification and cutting code conversion technology of Tribon.Gen nesting drawings. Since the nesting file provided by Tribon software is a special file suffixed with GEN format, CNC cutting production department The Tribon.Gen file needs to be converted into a common nesting file, and then converted to the corresponding cutting code file according to the requirements of different CNC cutting machine and controller code formats.
The following is a brief introduction to the TriCAM universal conversion software developed by FastCAM for Tribon's ship design software (see Figure 10). It directly reads the nesting file in Tribon.Gen format and automatically identifies the cutting layer and the powder marking layer of the nesting part. And the text labeling layer is automatically saved as a common CAM file format (see Figure 11), and then using the automatic programming function of FastCAM software and multi-controller conversion function, according to the type of CNC cutting machine and controller used by the enterprise, directly Different CNC cutters output different cutting codes or cutting programs.
Figure 10 TriCAM conversion software
Figure 11 Converting Tribon.Gen files to CAM files
4. Application Case 4: Digital Information Management of CNC Cutting Agile Manufacturing Execution System and CNC Cutting Production Process
When the shipbuilding enterprise develops to a certain scale, informatization construction becomes an indispensable infrastructure for shipbuilding enterprises, especially when the shipbuilding enterprise applies CAD, CAPP and other product design software, Tribon and other ship design software, PDM product data management system, After the implementation of ERP, that is, the enterprise external resource management information system, the information management of the internal production process of the enterprise, especially the computerized information management of the steel CNC cutting and cutting production process should be put on the agenda.
At present, most of China's shipbuilding enterprises have made gratifying progress and achievements in enterprise informationization, especially in ship design software and ERP systems, not only with large capital investment, but also with strong technical strength. However, in the information construction of the internal production process of the enterprise, especially in the information management and construction of the steel CNC cutting production process, it is still relatively backward, and there are information faults and information islands. For example, due to the lack of statistical data on cutting production and steel consumption, the ERP system can not play its due statistics and decision-making role; the technical information of the hull design department includes the data of the PDM product data management system, and it cannot directly serve the CNC cutting production. The information of the management decision-making layer of the shipbuilding enterprise, the ship design technology layer and the steel cutting and welding production layer are out of line, and there is still a phenomenon that the CNC cutting production management is disordered, the cutting efficiency is low, and the steel waste is serious.
Based on this, FastCAM has launched the FastMES agile manufacturing execution system in due course.
China's shipbuilding enterprises are no strangers to the MES system. According to the definition of MES by the Manufacturing Execution System Association (MESA), MES brings together hardware or software components in the shop to manage and optimize all activities from the order to the completion of production. Use accurate manufacturing information to respond quickly to real-time events in the shop's production activities, while providing important information about the production activities to the enterprise decision support process. Therefore, simply speaking, the MES manufacturing execution system is a production management and optimization operation technology for the shop floor; it is a management information system located between the upper production plan and the bottom industrial control of the enterprise and facing the shop floor. However, most of the discrete manufacturing enterprises in China conduct information transmission and processing between the information in the ERP and PDM information systems and the production site through “manual methodsâ€. The "manual approach" causes informational faults between the planning and production process control layers. The role of the MES system is to link up and down in the enterprise information system, establish a bridge of information communication between the production process and management, respond to the production process in a timely manner, and use the accurate data to control and adjust the production process.
Due to the different product structure and material supply in different industries, the production process and production process are very different. Therefore, different industries need different MES manufacturing execution systems. For the CNC cutting and cutting production process, FastCAM developed the FastMES agile manufacturing execution system based on the FastCAM nesting software, which is specially applied to the information management of steel CNC cutting production process.
The FastMES agile manufacturing execution system provides an information management platform for shipbuilding companies, from hull design, production planning, programming nesting, CNC cutting to steel storage, enabling system integration of production processes and production processes (see Figure 12). Integration with CAD, CAPP, Tribon, Hudong and other hull design software, as well as ERP, PDM and other systems.
On the one hand, the FastMES agile manufacturing execution system solves the real-time control and accurate digital management of the CNC cutting production process, effectively improving the production efficiency of the CNC cutting of the shipbuilding enterprise; on the other hand, solving the steel in the steel procurement, warehousing and cutting management process Waste the problem and effectively improve the economic benefits of shipping companies.
The following table is the MES application effect survey statistics made by the US MESA Association:
Third, the implementation and application of the FastMES agile manufacturing execution system (1) system integration with the hull design department, the establishment of a paperless multi-user product data management system, the establishment of a cutting parts database according to the ship order and the tree structure of the hull segment; The steel storage management department conducts system integration, establishes a steel and residual material storage management system, and optimizes the steel and residual material storage structure.
(2) According to the hull segment welding and assembly process, the production planning and process department develops the cutting production plan, coordinates with the steel procurement, storage management and other related departments to carry out steel procurement budget, fixed-board calculation, and steel inventory. Inquire, do a good job in cutting production planning and scheduling.
(3) System integration with FastCAM nesting software, according to the cutting production plan, realize dynamic, real-time programming nesting and numerical control cutting of cutting parts database, sheet residual material database and FastCAM nesting software, accurately control and dispatch cutting production process.
(4) Integrate with the ERP system to submit the real-time and accurate data of the CNC cutting production process to the ERP system to realize the comprehensive digitalization and information management of the shipbuilding enterprise.
IV. Conclusion FastCAM has a history of 30 years of CNC cutting software development, and has rich software development and application technology and experience in the field of shipbuilding. FastCAM Company advocates a new CNC cutting concept and technical method, through the use of FastCAM nesting software and FastCNC numerical control system to achieve full-time cutting, automatic cutting, high-efficiency cutting, high-quality cutting and high nesting rate cutting of CNC cutting machine, through the efficient cutting Programming nesting techniques and techniques effectively reduce preheating perforations, improve flame and plasma cutting efficiency, reduce plasma torch loss, and save steel.
FastCAM's FastMES agile manufacturing execution system, which is the first in the field of steel CNC cutting production, will effectively improve the information management and integration level of shipbuilding enterprises, and effectively improve the CNC cutting production efficiency and economic benefits of steel use.
Square Shower Drain,Shower Grates Drain,Square Gold Shower Floor Drain,Square Gold Floor Drain
Kaiping City Jinqiang Hardware Products Co.,Ltd , https://www.kimpowerdrain.com