1: The Xpanel promotes the machine control panel to a command panel for enhanced productivity. Alternating with the control view, a second screen page becomes the information center on the machine: the operator receives exactly the information that best supports the current work.
2: An integral part of Xpanel is the 18.5" touchscreen, to which numerous rotary and tip switches have been moved from the machine control panel. Its high resolution makes it suitable even for 3-D simulations.
3: Xpanel can provide useful information such as set-up sheets or tooling lists while operating the control. They are displayed on a second screen page, which the operator can switch to by pressing a button.
4: The entire user and machine documentation is available as background information in Xpanel already when the machine is delivered. This includes both the operating and programming instructions as well as the complete set of circuit and hydraulic diagrams, which previously have been shipped on a separate DVD.
5: In connection with an industrial PC installed in the control cabinet, Xpanel offers more capabilities for the production process, for example, "Virtual Machine on Board." Various simulation modes coupled with or independent of the current machine operation–help ensure high process reliability.
INDEX now supplies all machines–single and multi-spindle machines as well as turn-mill centers with the Xpanel operating system. It allows easy set-up and control of the INDEX machines as usual. In addition, even in its standard version, Xpanel offers extensive added user assistance through complete integration into network structures. Drawings, set-up sheets, user manuals, circuit and hydraulic diagrams, etc. are available directly on the machine without additional hardware. Xpanel features an additional industrial PC installed in the control cabinet. This allows the user to run 3-D simulations coupled with the machine in real time or even create complex programs using a CAM system. There are almost no limits to data communication.
"Workpieces are becoming more and more complex. To produce them economically, the machines must be powerful and very flexible in most cases," said a company spokesperson. "For lathes, this means multiple toolholders and a variety of axes. This increases the demands on programmers and operators. To ensure a smooth production process, they need plenty of information and, for safe processes, ideally a reliable 3-D simulation directly on the machine. The Xpanel operating system is designed to meet these needs."
It focuses on the optimal control of the machine for the effective machining of workpieces with maximum productivity. But the operating system also provides a direct connection between the machine control and the operations organization within the company. Besides job and set-up information, the operator also receives drawings and quality requirements or even own documents on the control panel screen. Xpanel thus creates the conditions for the use of INDUSTRY 4.0.
Network-Integrated Control Technology, High-Resolution Touchscreen
Before the idea of such a control system could be implemented in detail, the necessary basic conditions had to be created: INDEX made the step to a network-integrated control technology already with the C200 sl control generation, which has been on the market for more than a year and is now standard for all new, Siemens-controlled INDEX machines. It is based on the Siemens Sinumerik 840D sl (solution line) control, Sinamics drives, 1FT7servo motors and the ET200S ProfiBus peripherals. Another fundamental component is the 18.5" touch-sensitive wide-screen monitor that initially does not require a Windows PC. The user interface works with a separate controller, running INDEX's proprietary software among others.
With the control panel concept of the C200 sl, INDEX has included not only the ABC keyboard but also many non-safety-related rotary and tip switches from the machine control panel directly on the touchscreen. This creates space for the 18.5" monitor with WXGA resolution (1,366 x 768 pixels), 16:9 aspect ratio (widescreen) and LED backlight with 300 cd/sq. m brightness. These characteristics make it possible to use the monitor for high-resolution simulations on the machine itself. Due to the latest capacitive touch technology, the screen can be operated even with gloves. A touch is sufficient to activate the desired function.
Due to the eliminated hardware elements, the machine control panel located under the monitor has become significantly leaner and clearer. The remaining keys have been provided with LED backlight and are protected against accidental operation. If they are operational by the current machine status and the associated movements are allowed, they are selectively backlit, while invalid keys remain dark. Flashing keys must be enabled by the operator, directly guiding the operator and preventing errors.
More Applications
The touchscreen has a separate controller. For this mini-computer with an 8 GB memory card and USB port, INDEX developed its own software, which lays the functional foundation for the Xpanel concept. By using the integration with the corporate network, it provides the machine operator with useful information for his or her current activities.
With Xpanel, INDEX primarily wanted to make the machine operator's and set-up engineer's jobs easier as well as increase the productivity of the machines. The practical orientation of this system prepared for Industry 4.0 is already reflected in the start page. After starting up the machine, the familiar control screen appears with the information of axis positions, etc. On the right side, where hardware keys used to be, there is now a vertical, differently colored control strip that contains the ABC keyboard, number pad, cursor keys and some other touch buttons. One of them is the "i4.0-ready" button that is used to launch "Xpanel Industry 4.0." Its use is not absolutely required, but it is merely a support option provided by INDEX. If it is not pressed, the operator sees the usual control environment.
By touching the i4.0-ready button, the control strip on the right edge of the screen changes to an activity-driven display. It contains the preselectable areas of Production, Setup, Programming, Maintenance, General and Diagnostics, which are associated with additional function keys labeled with intuitive icons. They enable operators, set-up engineers or maintenance personnel to obtain additional information on the screen of the machine.
Screen with a Second Face
The Xpanel software developed by INDEX allows the user to open a second view on the screen. Pushing a special button on the touch-monitor, the user can toggle between the "normal" control view and this "second page" at any time. For example, if the user selects the icon for the workpiece name in Xpanel Industry 4.0 mode, it will be displayed on the second screen page, and the user can then navigate to it repeatedly by pressing a button. Other buttons allow the user to retrieve and view also job or quality requirements, and always return to the control page.
Similar assistance is also available for setting up tools for a new job. Here Xpanel can provide set-up sheets and tooling information on the second page. Full-page display of PDF formats in combination with extensive and intuitive navigation and zoom functions on the touchscreen enable safe transfer of all information.
However, before retrieving the documents, e.g. DNC of the NC program, they must be stored in the workpiece folder provided–for which mostly other departments are responsible (another change of the organization structure is not required). When the program starts, Xpanel then searches these folders for stored information and, if it finds any hits, enables the corresponding button. If nothing can be found, the button remains gray.
The entire user and machine documentation is available as background information in Xpanel already when the machine is delivered. This includes both the operating and programming instructions as well as the complete set of circuit and hydraulic diagrams, which previously have been shipped on a separate DVD. So, the user no longer needs to look for the proper DVD and a PC workstation. Everything is available directly on the machine.
Xpanel offers an editor, which allows the machine operator or programmer to add notes to the workpiece job. If the workpiece program is used again at a later time, the documented empirical values help to get back to an error-free production in the shortest possible time. This function is very helpful also for passing information during a shift change.
Additional PC Allows 3-D Simulation on the Machine
All of the above-mentioned functions are included in the standard version of Xpanel. But many more possibilities open up with an optionally available industrial PC, the VPC Box, installed in the control cabinet. It can be connected with the operating panel via an Ethernet interface and also uses the second page of the control screen.
Touch functionality and wide-screen view of Xpanel then allow the use and consistent operation of Virtual Machine (VM) developed by INDEX, which previously could be used only on a separate PC outside the machine. "VM on board" now takes 3-D simulation directly to the machine control panel. Based on the new technical capabilities that the Siemens Sinumerik 840D sl provides, INDEX has developed additional functionality in the VM. For example, the virtual NC core can now be run coupled with the real machine. This enables collision monitoring in a completely new dimension.
INDEX offers different operating modes for VM on Board. Crash-Stop and RealTime use coupled operation with the NC core of the real machine. CrashStop allows the advance simulation of workpiece programs on the machine. In case of a virtually detected collision, the function triggers a timely machine stop to prevent the real collision. Using RealTime, the machine program can be simulated on the operating panel simultaneously, thereby enabling real-time analysis of the machining sequence in difficult-to-access work area situations. VM on Board is useful also for creating and testing new NC programs, for which direct connection with the machine is not required.
Programming Assistance, Openness for Customer Applications
Xpanel offers also useful assistance for machine programming via INDEX's proprietary VPro ProgrammingStudio that can be used with the VPC Box, not only as part of VM on Board, but also directly on the machine control. Self-contained machining operations are generated with VPro as NC code by repeated sequential selection of individual technology steps. The functionality of the machine and control equipment is taken into account at every step. The generated NC code can be viewed and also edited manually.
The VPC Box even allows the use of the NX-CAM system with an INDEX postprocessor directly on the machine under the "CAM on Board" button. Other CAM systems and other customer-specific applications can be used as well. INDEX has opened the industrial IPC for access by the user's IT department for this purpose. The open system allows the customer to adapt Xpanel to specific user needs and to integrate its own applications and functionalities.
For more information contact:
INDEX Corporation
14700 North Pointe Blvd.
Noblesville, IN 46060
317-770-6300
sales@index-usa.com
www.indextraub.com
Southwest
N. TX
Hillary Machinery, Inc.
1825 Summit, #207
Plano, TX 75074
972-578-1515
www.hillaryinc.com
S. TX
PD Browne South
440 Brenmar
Houston, TX 77060
281-405-9378
www.pdbrownesouth.com
OK
Gage Machine Tool
10668 Widmer Road
Lenexa, KS 66215
913-894-1233
www.gagemachinetool.com
Southeast
AL, GA
Applied Machine Solutions, Inc.
2200 Airport Industrial Dr., Suite 300
Ball Ground, GA 30107
678-880-0893
info@appliedmachine.com
www.appliedmachine.com
NC, SC, VA
Advance Machinery Sales, Inc.
416-C Gallimore Dairy Rd.
Greensboro, NC 27409
336-665-9114
www.am-sales.com
FL
Arthur Machinery
5903 Johns Rd.
Tampa, FL 33634
813-887-4455
www.arthurmachinery.com
Northeast
DE, MD, E. PA, NJ, NYC, Long Island
Automation Solutions, Inc.
2 Hagerty Blvd., Ste. 300
West Chester, PA 19382
610-430-3670
inquire@asi-pa.com
www.asi-pa.com
N. NY
Britton Machinery Sales
P.O. Box 709
Pittsford, NY 14534
585-924-9335
www.brittonmachinery.com
W. PA
Marcus Machinery
106 Bellefield Court
Gibsonia, PA 15044
412-862-0803
info@marcusmachinery.com
www.marcusmachinery.com
MA, CT, RI, ME, NH, VT
Northeast CNC, LLC
36 Bartlett Rd., Unit 1
Gorham, ME 04038
207-775-5510
sales@necnc.com
www.necnc.com
Midwest
KS, W. MO
Gage Machine Tool
10668 Widmer Rd.
Lenexa, KS 66215
913-894-1233
www.gagemachinetool.com
E. WI
Iverson & Company
441 North 3rd Ave.
Des Plaines, IL 60016
847-299-2461
sales@iversonandco.com
www.iversonandco.com
MI
Methods & Equipment Associates
31731 Glendale Ave.
Livonia, MI 48150
734-293-0660
sales@methods-equipment.com
www.methods-equipment.com
MN, IA, ND, SD, E. NE, W. WI
Hales Machine Tool, Inc.
2730 Niagara Lane North
Plymouth, MN 55447
763-553-1711
sales@halesmachinetool.com
www.halesmachinetool.com
West
OR, WA
Ellis Machinery & Equipment, Inc.
6225 20th Street E.
Fife, WA 98424
253-926-6868
sales@ellismachinery.com
www.ellismachinery.com