Digital twins for CNC job preparation

SinuTrain for SINUMERIK 828D and 840D sl, and Run MyVirtual Machine /Operate for SINUMERIK ONE mean that an exact image of the CNC is also available during job preparation. The virtual CNC contains the same NC kernel and the same user interface as the real CNC. CNC programs can thus be created in exactly the same way as on the machine. Personnel can therefore be flexibly deployed on the shopfloor and in the programming office. Program runtimes, i.e. machine assignment, can be determined exactly. This is an important prerequisite for preparing quotes in CNC contract manufacturing. CNC programs from CAM systems can also be checked for syntax errors. Demanding CNC programs, for example parameterizable programs, can be created stress-free in the office. New operators can be trained offline in the use of the CNC. 

SINUMERIK ONE opens up a new chapter with Run MyVirtual Machine /3D. This add-on option for the virtual SINUMERIK provides an exact image of the real manufacturing environment, in other words the machine room, clamping devices and tool holders. This allows realistic, stress-free testing and optimization of CNC programs, which significantly reduces changeover times, especially for complex machines. It is also possible to verify the manufacturing feasibility of jobs in advance, for example with compact 5-axis machining centers. This is a great benefit, especially in job order production. The integrated collision detection function determines at the job preparation stage whether the tool will collide with the component, the workholder, or with the machine itself. The risk of unexpected machine failures is therefore significantly minimized. Last but not least, operators can be trained not only offline in the use of the CNC, but also in the handling of the machine itself.

The creation of CNC programs with CAM systems can also benefit from the digital twin of the SINUMERIK. While many CAM solutions now offer simulations with the virtual image of the machine room, the simulation takes place on the basis of internal CAM data. This is not the case with NX CAM. There, the simulation takes place after the post-processor run, i.e. with the CNC program already created. This helps to maximize process reliability.