Remote 3D reconstruction of CNC processing over IP

Rodrigo Gianasi Severino Hernandes Federal University of ABC, Brazil [email protected] range of future Internet Protocol(IP) architectures dedicated to industrial equipments.[1] In this section we will talk about the CyberOPC. The CyberOPC technology is an alternative to the others data exchange protocols based on the OPC technology and introduces streaming capabilities to gain high refresh rate on the remote control station. It means that the CyberOPC is a new open communication system for remote control of industrial CNC machines, making the transmission delay for time-critical control data shorter than other OPC-based solutions, and fulfilling cyber security requirements. A. OPC Technology Before we talk about the CyberOPC, we have to define the technology that it's based, OPC Technology. The OPC is a set of interfaces defined by the OPC Foundation, initially based on OLE/COM(Object Linking and Embedding/Component Object Model) and DCOM(Distributed Component Object Model) technology, for open software application interoperability between automation/control applications, field systems/devices and business/office applications. The basic principle of OPC operation is that an OPC client, like SCADA software, transfers data to/from PLCs/Devices using an OPC server(see Fig.1). The OPC client can operate either locally (the server is on the same PC) or via local network, and in this case the server accesses PLCs/Devices via drivers.[1]

Abstract- When we talk about the optimization of a process, the first step to achieve this objective is the knowledge of all parts of this process. Thinking about this, was proposed a lot of technologies that allow us to know some parts of industrial processes. The technologies that we study is the MTConnect and the OPC. Using a software based on OPC technology, the CyberOPC, we are doing a 3D reconstruction that allow us to know better of CNC process, and compare real-time how is the project of each piece and how is getting the real piece in a remote computer, using as communication protocol the IP on the KyaTera that have the bandwidth required to do the tests. I.INTRODUCTION Nowadays, we can to realize that entire scientifical society strives to obtain a process with high performance and reduce environmental impacts. This work aims to end helps with this problems on CNC process. The solution used to get informations about the process is the CyberOPC Client[1], and this project proposes a complement to this solution. To optimize the CNC process was done a 3D graph using the Microsoft Visual C# 2008 language and Windows Presentation Foundation(WPF) that allows to us some recurses to build this solution on 3D. Using this solution we can to do the remote 3D reconstruction of a real work of a CNC process. The main objective of the proposed scenario relies on the possibility to analyze energy consumption trough a 3D graph with the temperature data. This analysis can to give us information to optimize the CNC process and this implies into a energy saving and reducing the environmental impact. And this application toll should permit remote on line compare the effective 3D model with the estimated on softwares like AutoCAD. II.RELATED WORKS Everyday the search for a solution of problems in the industrial area, let us with responsibility to make softwares that allow the machines works better and with a resource economics. Thinking about this a lot of works has been done. Some emerging technologies in industrial monitoring and control, as OPC-UA[2] and MTConnect[3], design a wide

Fig. 1 General OPC communication diagram OPC is open connectivity in industrial automation and the enterprise systems that support industry. Interoperability is assured trough the creation and maintenance of open standards specifications. [4] The core of the OPC paradigm resides in its single database furnishing data: the OPC servers themselves are the database. Standard DCOM provides instant access to both clients and servers from any node. This way, OPC became the universal connectivity standard for manufacturing and factory/plant

floor devices and systems, allowing several devices and applications from multiple vendors to be tied together, thanks to its standard interface based on COM/DCOM. To extend the use of OPC over TCP/IP public networks, the OPC Foundation suggests adopting Web Services technologies.[1] And OPC UA is a platform-independent standard through which various kinds of systems and devices can communicate by sending Messages between Clients and Servers over various types of networks. It supports robust, secure communication that assures the identity of Clients and Servers and resists attacks. OPC UA defines sets of Services that Servers may provide, and individual Servers specify to Clients what Service sets they support. Information is conveyed using OPC UA-defined and vendor-defined data types, and Servers define object models that Clients can dynamically discover. Servers can provide access to both current and historical data, as well as Alarms and Events to notify Clients of important changes. OPC UA can be mapped onto a variety of communication protocols and data can be encoded in various ways to trade off portability and efficiency. [2] The OPC classic [1] and OPC-UA transport technologies were defined as general purpose technologies for industrial data exchange in wide range of industrial equipments. These technologies today include many transport protocol profile to cover the most IP application protocol as TCP and HTTP. However, the OPC Foundation currently does not provide optimized solutions for the essential correlation between the networks quality of service and the time critical requirements for process control. And the CyberOPC comes to propose a significant innovation related to this subject.[1] B. CyberOPC When the CyberOPC was conceived, it had as main objectives shorten the transmission delays for time-critical data and guarantee the security of the communication channel being used and the integrity and confidentiality of the messages transmitted. To achieve their objectives, the CyberOPC project provides a client/server software system composed of an HTTP Server and an HTTP Client library. The Fig.2 shows the software modules integrating the CyberOPC server/client. The block on the left represents the CNC tools or some other industrial equipment, the central block is the application server block produces the response and request message dispatched by the right block and collect data from device, the right block dispatches the HTTP messages, parse the JSON-RPC commands and forward the command message to the central block

With this module, we can understand how the services are defined in the CyberOPC specifications substitutes the weight of the Web Services processing based on SOAP-HTTP for the lightweight Web Services based on JSON-RPC over HTTP.[1] III.ARCHITECTURE The development of new machines tools for industrial quality parameters, such as: high speed, low prices, flexibility and quality, aim on intelligent CNC machine centers. Using common PCs and industrial computers instead of electrical dedicated hardware for operation spindles, axels and subsystems, machines increases accuracy of interpolation and movements, improve integration with external equipments and reduce costs. The fusion of sensors enables the machine to auto-detect eventual damages, and also control parameters in order to perform optimization of the manufacturing process.[5] To achieve this objectives, a lot of researches and practice have been proposed to develop a remote monitoring and maintenance system(RMMS), also know as Intelligent Service System. To develop a RMMS for machine tools application, a certain specific requirements are added in addition to primitive specifications: -Whenever a problem occurs with a machine tool, the operator must be able to notify the manufacturer immediately. Automatic notification during unmanned operation should be possible as well. -The manufacturer must be able to obtain the details of the situation from a remote location worldwide. -Access security must be guaranteed. It is not acceptable to allow malicious attack over the internet. -It must be possible to do quality analysis from collected machine tools' operating status. -The collected data must be available to customers so that they can make use of it in their production management system. -It must prevent as many potential breakdowns as possible of machine tools trough timely preventive maintenance.[6] A. Network The communication between the manufacturers and their customers' machine tools is the key to establishing a successful RMMS. Generally, machine tool manufacturers can use the customers internet connection installed at their factory.[6] But in our case, we have to monitor using a remote personal computer. To solve this problem the CyberOPC project proposes a new communication system for remote and monitoring industrial equipments, which are, in our case, CNC machineries fulfilling the time-critical and cyber security requirements. The network for experimenting the protocols and the methodologies applied to remote process control require high transfer rates with reserved bandwidth. The KyaTera network[7] from the FAPESP/TIDIA Program in

Fig. 2 CyberOPC Server and Client Arquitechture

Brazil fits the requirements for speed and bandwidth management. KyaTera is a public network research project in the state of So Paulo, Brazil, aiming to develop new web applications at near terabit/s transfer rates.[1] B. Data Communication Consider a consumer process reconstructing a transmitted digital signal to obtain the original analog signal. A consumer process consuming a periodically updated variable usually has to receive each volume within a maximum admissible interval that corresponds to the data lifetime. Periodic data transmission should, in theory, occur at fixed time instants; however, the real transmission instant, and this interval variation is known as a jitter. For a consumer process reconstructing an original digital signal, the maximum jitter allowed is represented by the sampling interval.[1] The information sent from the machine tools is represented in XML file format, in which each individual record is encapsulated by tags. The information includes operating status during the past sampling cycle, program number when the cycle start, alarm numbers when error, and operation status of major components, such as the spindle, ATC, turret, and so on.[6] The data needed to a 3D reconstruction is the time, the coordinates and the temperature at some point. IV.CONCLUSION AND FUTURE WORKS The objectives were partially achieved, to complete our objectives we will integrate this 3D reconstruction with the CyberOPC client, it means that this work will be another tool that will help to monitor and maintenance the CNC processes in real-time. The actual gain of this project is on the comparison of design of parts and the parts in real-time. REFERENCES [1] TORRISI, N. M.; OLIVEIRA, J. F. G. Remote control of CNC machines using the CyberOPC communication system over public networks. International Journal of Advanced Manufacturing Technology, v. 2007, p. 001, 2007. [2] OPC Foundation, OPC-UA Specifications, http://www.opcfoundation.org, DLA: 13/06/2010. [3] MTConnect Institute, MTConnect Standard V1.1.0, http://www.mtconnect.org, DLA: 13/06/2010. [4] OPC Foundation, OPC Specifications, http://www.opcfoundation.org, DLA: 13/06/2010. [5] BOTTENE, A. C.; FANA, T. V.; OMETTO, A. R.; TORRISI, N. M.; FILHO, A. G. Methodology to integrate the electrical energy consumption real-time monitoring and related environmental impacts assessment. In: 16th International Conference on Life Cycle Engineering, 2009, Cairo. CIRP - 16th International Conference on Life Cycle Engineering, 2009. [6] MORI, M.; FUJISHIMA, M.; KOMATSU, M.; ZHAO, B.; LIU, Y. Development of remote monitoring and maintenance system for machine tools. ANNALS- CIRP, V. 57, p. 433-436, 2008. [7] FAPESP Foundation, Kyatera Network, http://www.kyatera.fapesp.br. DLA: 13/06/2010.

[8] COELHO, R. T. ; ABACKERLI, A. J. ; OLIVEIRA, J. F. G. ; TORRISI, N. M. ; WATANABE, F. . Measurements and inspection with Machine Tools by remote control in micromilling operations A first investigation. In: MTTRF Machine Tool Technologies Research Foundation, 2008, San Francisco. The proceedings of MTTRF 2008 Meeting, 2008. p. 233-238.