Software-based cell control technology targets the user experience

The roots of palletized cell controller systems have remained similar in nature for quite some time in terms of functionality and optimizing cell throughput. Most provide for scheduling what pallet goes into which machine and when, but older legacy systems typically involved macro-based programming for doing so, while today’s systems are now software based.

Software-based systems have opened the door for significant functionality enhancements, and during the past decade, many cell-controller enhancements have targeted the user experience. Through the incorporation of graphical user interfaces, machine tool manufacturers such as Mazak have made palletized cell controllers much more user-friendly and capable due to advancements in cell scheduling and setup, 3D simulation, and remote connectivity.

Introducing the PMC NEO

Mazak’s PMC NEO software-based control allows shops to further maximize output of the company’s modular, pre-engineered PALLETECH automation cell. The software helps shops create a schedule and prioritize jobs within that schedule. It’ll also look ahead within the schedule and check that all necessary requirements – such as tooling, material, and fixturing – for the jobs are in place, and will notify operators if anything is missing or needs attention.

The software’s display/navigation bar provides simple workability for data input. It allows users to easily refer to information, and it displays items required for data registration with red asterisks. In case of input errors, a caution message appears, prompting an input correction.

To streamline entered data searching and organizing, PMC NEO software provides a searching bar and sorting function. If the user wants to delete unnecessary data, they simply check the modified date, and the software records the date and time when that data was changed or used for automatic operation. This helps users decide if they should delete the data.

The PMC NEO’s touch screen also displays a 3D simulation of a shop’s PALLETECH cell. This allows users to manipulate the image, making the system layout more understandable for improved data input. With the PMC NEO’s Smooth Simulation function, shops can check machining progress and tool resources for up to one week in advance during automatic operation, which is beneficial for long-term unmanned operation.

For cell pallet setup and to ease operator burden, PMC NEO’s setup guide display provides a continuous 12-hour simulation based on actual operation and displays notices in chronological order of setup work at PALLETECH loading stations. A dedicated touchscreen shows when a pallet arrives at the station, then displays photos and instructions on how to load and fixture the job for that pallet. There’s also a feature that’ll notify the operator as to which pallet is coming next to the loading station so they can be prepared for it with any special tools or material.

Stay connected

When shops connect PMC NEO software to their enterprise resource planning system for instance, they can remotely schedule and control the PALLETEC cell using an office PC and view schedule information from a tablet or smart device.

When problems are found in the system, early detection and restoration is possible through the PMC NEO’s Notice application sending notifications to a smart device. The software’s Set-up Starting Time application shows when it’s time to start the next setup, allowing operators to perform the task promptly.

The PMC NEO Alarm Notification application notifies shops in the event of an alarm on the machine or system. This eliminates the need to constantly monitor the system because operators receive the alarm number on their smart devices.

Managing data, jobs

A growing number of shops are tying their cell controllers into larger enterprise-wide systems, reducing the need for highly skilled personnel on the shop floor adjusting cell schedules. Plus, one individual can schedule multiple pallet cells if needed.

In high-volume production of the same workpiece/job, the amount of input data when creating a schedule is relatively small, but in high-mix, low-volume production, the amount of input an operator must load increases significantly. Using the PMC Open Database Kit of the PMC NEO software and connecting to a host system, shops can automatically enter parts and schedule data normally entered manually.

In the past, when connected to a host system, cell software couldn’t retain pallet data if the pallet was removed from the system so it was deleted. However, with Pallet Management Outside the PMC feature, the PMC NEO system keeps such data even after a pallet is removed, eliminating the time and repetition of re-registering the data if a pallet is brought back into the system.

Additional features of the PMC NEO include a Tool Carry system and Material Supply function. Tool Carry is designed for oversized tools or exceeding a machine’s tool magazine capacity. The system automatically retrieves and returns these non-standard tools stored in a special stocker within a PALLETECH cell.

Material Supply is used for raw material management. Shops can store basket-type workpiece pallets within the PALLETECH cell, reducing the need for temporarily storing materials on the floor.

Automated palletized cell controllers continue to advance as machine tool original equipment manufacturers incorporate software-based technology. These controls improve the operator experience, making the job easier and less time consuming while also optimizing the efficiency and output of palletized cells.

Mazak Corp.
https://www.mazak.com