# Presentation: 542912

## STEP-NC: E-ManufacturingUsing STEP

**David Loffredo**
**loffredo@steptools.com**
**STEP**** Tools, Inc.**
**216 River Street, Troy, NY 12180**
**(518) 687-2848 / (518) 687-4420 fax**
**http://www.steptools.com**

## Model Driven e-Manufacturing

**Direct control of machine tools from 3D data**
**Using ****STEP-NC**** specification under development in Europe and Far East for 3 years**
**Milling, Turning, EDM, Grinding, Bending **
**Extensions for Robotics and Assembly anticipated**
**Benefits**
**35% reduction in time for job shop to set up machining job**
**75% reduction in time for OEM to prepare data for job shop**
**50% reduction in computer infrastructure costs**
**Faster, safer, more adaptable machine tools**

## Current NC programming using ISO 6983

- %
- N05   G54
- N10   G00 Z10.000
- N15   G91 G0 Z200
- N20   T5 D1 WW
- N30   G90 M5
- N35   G00 X0.000  Y-150.000
- N40   G00 Z5.000
- N45   M08
- N50   S3183.000
- N55   M03
- N60   F1477.000
- N65   G00 X60.000  Y-150.000
- N70   G00 Z5.000
- N75   G00 X60.000  Y-150.000
- N80   G01 Z-0.500
- ...

- machine-specific part program with axis data generated by a postprocessor

- vendor-specific extensions of the original standard

- only primitive motion and switch commands

- no standardized data format for spline processing and sophisticated NC technology

**Courtesy WZL RWTH Aachen**

**STEP-NC**** replaces this with a**
**rich, integrated data format**

## STEP-NC Is Integrated

- workpiece

- machining_feature

- S[0:?]

- pocket

- plane

- region

- hole

- 1

- S[0:?]

- machining_operation

- workplan

- machining_workingstep

- L[0:?]

- plane_milling

- side_milling

- drilling

- 1

- tool

- technology

- strategy

- L[0:?]

- cutter_contact_trajectory

- parameterised_path

- cutter_location_trajectory

- 1

- toolpath

*geometry*

*geometry*

*geometry*

**Courtesy WZL RWTH Aachen**

## Use Cases for STEP-NC (ISO 14649)

**STEP-NC enables direct control of NC machine tools from 3D data.**

**Courtesy WZL RWTH Aachen**

## .

**STEP**** Tools, Inc.**
**216 River Street**
**Troy, NY 12180**
**info@steptools.com**

**Model Driven Intelligent Control of Manufacturing**

- Function
- Design

- Mfg
- Design

- Process
- Capture

- AP-203
- AP-214

- AP-224
- AP-xxx

- AP-213, PSL
- ISO 14649
- ISO 13399

- Intelligent
- Controller

**STEP-NC**
**Database**

**Intelligent**
**Interface**

**.**

**.**

**“****Super Model”**

**Electro-Mechanical Integrators**
**Honeywell**
**Liberty Consulting**
**RPI**

## MDICM Industrial Review Board

**GE Fanuc**
**CNC Data (MASTERCAM)**
**CADKEY**
**Alibre**
**Boeing**
**General Electric**
**General Motors**
**Gibbs and Associates**
**Hurco Companies Inc.**
**Lockheed Martin**
**IBM**
**Monarch Machine Tools **
**NASA (GSFC)**
**NASA (JPL)**
**NCMS**

**Unigraphics Solutions**
**NIST Intelligent Systems**
**Lawrence Livermore**
**Chrysler**
**Watervliet Arsenal (Benet)**
**General Dynamics**
**The Design Edge**
**RMC Associates**
**Fala Technologies**
**Cambridge Valley Maching**
**Allied Signal**
**Bridgeport Controls**
**Liberty Consulting**
**RPI**

## Software tools to make implementing and using the STEP ISO standard easy.
Forerunners in STEP technology since 1991
Founders working on product data since 1978
First commercial software tool kit
First solid model data exchange using STEP
First STEP Repository
Contributors to STEP and STEP-NC meetings
Owner of Parts 14, 21, and 24 of STEP
Owner of Parts 3 and 51 of STEP-NC
300+ customers use our tools to define and implement STEP and STEP-NC

**Forerunners in STEP technology since 1991**
**Founders working on product data since 1978**
**First commercial software tool kit**
**First solid model data exchange using STEP**
**First STEP Repository**
**Contributors to STEP and STEP-NC meetings**
**Owner of Parts 14, 21, and 24 of STEP**
**Owner of Parts 3 and 51 of STEP-NC**
**300+ customers use our tools to define and implement STEP and STEP-NC**

**Who We Are**

## End User Benefits

**The supplier creates the production process from a**
**3D product model instead of paper drawings**

**Measured by Lockheed Martin**

## End User Benefits

**50% of total process plan effort is composing visuals.**
**STEP-based system using to produce process plan visuals.**
**Projected 75% reduction in man hours spent in visuals preparation (25 hours vs. 100 hours).**

**GOAL: Reduce manufacturing costs**

**End User Benefits**

**STEP is used to automatically prepare visuals for process plans.**

**Measured by Raytheon**

## The Super Model Solution

**CAD**
**System 1**
**STEP Interface**

**STEP Interface**
**Supplier A**

**STEP Interface **
**Supplier B**

**STEP Interface **
**Supplier C**

**STEP Interface **
**Supplier D**

**“****Super Model****” = STEP +++ database on the Internet**

**CAD**
**System 2**
**STEP Interface**

**CAD**
**System 3**
**STEP Interface**

**CAD**
**System 4**
**STEP Interface**

**CAM**

**CAPP**

**NC Milling**

**NC Turning**

**Ford**

**GM**

**Boeing**

**Lockheed**

**STEP Interface**
**Supplier 1**

**STEP Interface **
**Supplier 2**

**STEP Interface **
**Supplier 3**

**STEP Interface **
**Supplier 4**

**One database replaces hundreds of PDM files**

## MDICM Year One Pilot Project

- Controller

**MDICM Year One Pilot Project**

- FBMACH

- EASYMILL

- Virtual
- Gibbs

- CAD

- Process Planning

- Benet Laboratories
- Watervliet Arsenal
- Demonstration

- General Dynamics
- Land Systems
- Demonstration

- Bridgeport
- Controller

- Work Plan

- STEP-NC
- Database

- Tool Path
- Generation

- Milling
- Machine

- AP-203

- STEP-NC AIM

- XML ISO 14649-11 Work plan

- CADKEY

**STEP-NC AIM has**
**not yet been given**
**an AP number by**
**ISO STEP**

## Year One Pilot in Detail (1 of 3)

**Enhanced FB Mach CAM system to write STEP-NC data for holes, pockets and slots**
- Developed the STEP-NC AIM model
- Reviewed by ISO STEP
- New Work Item being submitted to get an AP number
- ST-Developer**TM** and ST-ACIS**TM** are STEP programming tools developed by STEP Tools

- CADKEY

- FBMACH

- Work Plan

- AP-203

- STEP-NC AIM

**ST-ACIS**

**ST-Developer**

## Year One Pilot in Detail (2 of 3)

**Work Plan generator**
- Bridge between STEP and XML
- Feeds XML data to EASYMILL shop floor programming system
- An application of the STEP Tools database product ST-Repository**TM**

- Bridgeport
- Controller

- Work Plan Generator

- EASYMILL

- STEP-NC AIM Database

- XML Work Plan

**ST-Repository**

## Year One Pilot in Detail (3 of 3)

**STEP-NC Controller**
- Modified EASYMILL to read XML Work plan
- Put Controller and EASYMILL onto PC
- Working with General Dynamics Land Systems for second demonstration

- Bridgeport
- Controller

- EASYMILL

- XML Work plan

**ST-Developer**

- ST-Repository+

## Consequences of STEP-NC

**No more post processors!**
- Every tool reads the same instructions
**New market for CAM software!**
- Every controller needs tool path generation software
**More efficient CAD!**
- Less tedious process planning
**Self correcting manufacturing!**
- Every work plan includes the nominal geometry of the part
**Faster, safer, more intelligent machine tools!**
- Verify set up
- Dynamic optimization