NC Express Programming Software
by Kyle Plass
Application & CAD/CAM Coordinator
FINN-POWER’s NC
Express CNC programming system is a user friendly, integrated,
and automated tool for managing FINN-POWER equipment in the most
efficient manner available. NC Express is a tooling, nesting,
and optimizing software package designed to easily integrate
into an existing manufacturing environment, taking full
advantage of the powerful CAM features and the FINN-POWER
machine tool product line.
NC Express is a scalable application – the
system may be used as a single part drafting and tooling program
or as a fully-automated machine tool management system. Either
way the results are the same – optimized automatic N/C code
creation.
The system utilizes several technologies to
create a fabrication environment in which individual parts or
assemblies of parts can be retrieved directly from the CAD
database and processed by NC Express for random part
Just-in-Time (JIT) production.
NC Express provides an easy-to-use
Windows-based Graphic User Interface. Drop down menus and icons
ensure easy interaction with the system and immediate
productivity. This user interface, combined with NC Express’
powerful automation capabilities facilitates optimum production,
maximizes the computer-controlled features of the machine tool,
and simplifies the effort required to design and program parts
for production.
With the rise in material costs, labor, and
short run jobs today’s demanding manufacturing market is
focusing more on ways to automate the fabrication of greater
quantities of parts in less time and with fewer people. NC
Express offers a complete programming package for FINN-POWER
machines that provides our customers the ability to obtain high
levels of automation for less user interface and more output.
Geometry
The first process in programming a component
file is the geometry creation. NC Express offers a full CAD
package for component generation.
 Alternatively,
geometry can also be imported from a standard DXF file format.
Open contours within a component file can be cleaned
automatically according to the set system tolerance. For open
contours or duplicate line segments outside the system
tolerance, NC Express will display where problem areas exist for
quick and easy cleaning.
Automation of importing of the geometry can be
done when using the MRP database (OMS). Through this process,
component files can be generated from a DXF file or by using
parametric scripting. During this process the geometry, tooling,
and storing of the component file is accomplished.
Tool Placement
NC Express’ Auto Tool will automatically place
optimal tool routines and tool placement in accordance with the
machines capabilities. Additional automation of robot placement
and last hit orientation for unloading is set properly for
sorting of components. Any section of tooling placed by the auto
tool function can be easily reorganized or replaced manually.
Tool placement features include:
-
Automatic and interactive tool placement
-
Automatic and interactive microjoint
creation
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Automatic and interactive destruct
-
Interactive cycling
-
Machine intuitive tool placement
Nesting
Nesting within NC Express can be done
statically or dynamically. During the nesting process parts can
be quickly moved by dragging and dropping to the necessary
location. For quick part revisions, a single component file can
be edited at the part level and once the nest layout is reopened
the change will be promptly updated for each part in the nest.
True Shape Nesting
True Shape Nesting uses the true boundary of
the part as it appears in the drawing. This allows a tighter fit
between parts as compared to rectangular nesting. True Shape
Nesting allows parts to be interlocked and provides
substantially higher material utilization.
-
Interactive part placement after auto nest
-
Automatically nest under or around the
clamps
-
Nests in zones to guarantee part accuracy
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Nest in holes to gain higher sheet yield
Rectangular/Shear Nesting
NC Express utilizes a rectangular nesting
algorithm to take advantage of the manufacturing features of the
FINN-POWER Shear Genius and Shear Brilliance punch/shear
Flexible Manufacturing Cell (FMC). Unique features include:
Optimization
 Optimization
is done automatically for all FINN-POWER machine types (punch,
shear/punch, laser/punch and laser). The Optimizer references a
pre-established tool library verifying that all of the necessary
tools to produce the parts are available for use in the
machine’s turret. Once confirmed, machine movement, punching and
forming operations, tool changes and sequencing are optimized
for efficient machine operations and throughput. Additional
optimization features:
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Automatic repositioning and clamp avoidance
-
Optimize index tooling based on angle
-
Automatic turret loading
-
Interactive optimization capabilities
-
Batch optimization for multiple nest
patterns
Simulation and Reporting
 Full
simulation of a nest will give the programmer detailed
information about how a job will run at the machine. A full
range of reporting options will offer the programmer and
operator ample information to setup the machine. The following
are some items listed within a report:
Key Features
The following is a description of a few
features that help obtain the high levels of automation within
NC Express.
Teach Cycles
Teach Cycles allows the ability to teach
tooling, or cycled functions/routines, to a specific geometry. A
Teach Cycle is applied when Auto Tool is run. The Teach Cycle
works off a given tolerance, material thickness, and symmetry
type. If geometry exists that has a Teach Cycle libraried, the
same tooling or routine will be applied through the use of Auto
Tool. The use for a Teach Cycle can vary among machine type.
To the right, a Teach Cycle is created to apply
a cycled order of hits for a round punch – extrusion – and a
tap. This cycle will only be used on material thickness 0.5 -
1.5mm (0.02” - 0.06”). The tolerance is 0.03mm (0.001”) for the
hole sizes. When a part would be Auto Tooled with the same type
of geometry the same exact tooling in the same exact order will
be applied throughout the part. This eliminates the repetitive
task of having to place each of the tool hits for each and every
hole on the part.
Automatic Form Avoidance
 During
punching only, NC Express knows when a form exists within a nest
to avoid smashing the form by a tool. Form protection areas can
be set for a special tool to inform NC Express of the formed
area on the nest. If a tool will cross the path of a formed area
within a nest NC Express will optimize the tool path so that the
ram will raise the tool completely up and then cross over the
formed area avoiding the possibility of smashing the form. No
additional axis moves are made in order to avoid the form.
In addition to the form avoidance settings, NC
Express allows the setup of an exit angle path to provide for
automatic ordering of a special tool when optimizing. This is
especially useful for a louver tool: time is saved during part
preparation and during optimization because no additional work
is needed to manipulate the tool path.
Orders Management System (OMS)
 NC
Express comes standard with an MRP/ERP interface to allow that
customers can control and track parts that have processed within
NC Express to be sent to the machine. The Orders Management
System is a database in which production requirements are
determined. The parts required for production, quantity,
material codes, priorities and due dates used to be processed
for JIT fabrication. From job shop to OEM, the OMS can benefit
the end user taking orders from the MRP/ERP and processing them
into nests.
Common Line Cutting
 For
punching, shear/punch, and standalone laser machines NC Express
offers fully automatic common line cutting features. Common line
activated in the nesting phase will help in reducing the scrap
rate between parts. Once a nest is created with parts and tools
in a common line the Optimizer will remove excessive hits in
order to avoid double punching hits or double laser paths.
Within the shear/punch environment the nesting engine will
common line symmetrical parts ignoring tooling overlapping from
notches. For non-symmetrical parts in the shear/punch
environment, the nest engine will check the tolerance set and
ignore tooling extending less than the grid nesting tolerance.
Component Stacking Management
 For
machine types requiring stacking of finished components on a
cassette NC Express is capable of automatically configuring the
stacking layout of the components on the cassette. During the
nesting process the user has options to determine the layout of
the cassette. The nesting engine will nest parts according to
the cassette layouts. This allows for NC programs to be loaded
within the machine
and minimal setup of cassettes by the operator when queuing the
NC files. The overall outcome of this feature is less setup time
by the operator at the machine.
For even more automation and time savings for
the programmer, if a robot exists on the machine the user can
take advantage of the automatic robot suction cup setup via Auto
Tool to automate more of the process.
Automation
Many different levels of automation can be
achieved within NC Express from the ability to Auto Tool a DXF
to the ability to automate the entire programming process. NC
Express offers parametric component scripting capabilities from
external Visual Basic scripting using NC Express Active X
control. External scripting can also activate many different
modules of the software allowing for complete external control
by the user.
PowerPlan software, made by FINN-POWER, can
also be purchased as an add-on to allow for a mini production
planning software allowing a company to setup an all-in-one cell
control management system. PowerPlan can elevate factory
automation to a new level. PowerPlan fits the pieces of the
production puzzle together by integrating: Order handling, Part
programming, Nesting, Tool management, Machine work queues
offline and Production reporting.
  
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710
Remington Road 
Volume
15 Issue 1 -
July 2005