Olympic Runners with Sinumerik and ShopMill Olympic Runners ...

motion world
Systems and Solutions for Machines and Plants
6 th edition February 1|2007
Parallel Kinematics
in the Wind Tunnel:
Dynamic Models
Modular Laser Cell
used for Flexible 3D
Material Machining
Olympic Runners with
Sinumerik and ShopMill

2 CONTENT
6 10
14
W. Geyer
P. Koerber
Sinumerik 840D and ShopMill gave the
runners of the World Champion bobsled
a new edge
Parallel kinematics lends never-before-seen
dynamics to the Model Positioning
Mechanism (MPM) during aerospace tests
The new TruLaser Cell
Series 7000 from Trumpf
relies on Sinumerik and
Simodrive
3 EDITORIAL
4 NEWS
TRENDS
Bobsled Racing
6 When Slimmest Margins Count
“Olympic” runners developed
with Sinumerik and ShopMill
CASE STUDIES
Machining Centers
9 Twice as Productive
Mach 1 machining center from
Honsberg equipped with Sinumerik
840D and Weiss spindles
Test Facilities
10 Dynamic Models
Parallel kinematics with 1FN3 linear
motors for aircraft wind tunnel testing
otio
Laser Machining
w
14 Dynamic and Flexible
Modular laser cell for flexible 3D
material machining
Machining Centers
17 Turning and Milling
from “X” to “Z”
British machine tool manufacturer
turns to Sinumerik
Cover photo:
W. Geyer
motion world 1/2007

EDITORIAL
3
A. Kradisch
Dear
readers,
Trumpf
17
The turning and milling centers of the British
tool maker XYZ Machine Tools are equipped
with Sinumerik
XYZ
As a result of its universal design architecture, our
Sinumerik 840D has literally become synonymous
with performance and innovative solutions for
lathes and milling machines. However, the fact
that Sinumerik equipped with linear drives was
installed in a wind tunnel to test the motion of the
new Airbus and other plane models is really
something special – particularly so, considering
the solution employs innovative parallel
kinematics actually developed for machining
centers, as the article on page 10 explains.
SOLUTION PARTNERS
Machining Simulation
16 Test Run – As Close As It Gets
First Sinumerik Solution Partner in Scandinavia
norld
18 SHORT LIST
CNC Design, Australia
Volvo, Sweden
H&H Machine Tools, Australia
19 DIALOGUE
The article on the CNC milling solution for the
bobsled runners of Olympic gold medal winner
and world champion Sandra Kiriasis provides
a winterly backdrop for our Sinumerik control
(see page 6). It also offers a good example of
the team effort of Sinumerik along with leading
technological partners, and of the performance
and innovative capabilities present in Germany –
while also making a contribution to professional
sports.
Just as the top athletes, we also want to play in
the pro leagues, in the international “Champions
League” – with superior technical concepts and
smart solutions designed to secure your
competitive advantage.
The fact that renowned global market research
institutes recognize our continuous efforts to
improve customer value, performance and simplicity,
is both a source of motivation and responsibility
for us. In a recent study on the CNC market
conducted by ARC, our Sinumerik was once again
cited as the leading system worldwide – and
Siemens as the market leader. With a mix of
courage, inventive spirit and the appropriate dash
of passion that characterizes winners, we will
continue to work at securing the top spot together
with you.
I wish you a prosperous new year and, as always,
hope you enjoy the articles.
Bernd Heuchemer
Head of Marketing Services
Siemens A&D Motion Control, Erlangen
motion world 1/2007

4 NEWS
More Productive Heavy-Duty
Machining
High-strength materials such as titanium
can now be machined more productively.
The Siemens-owned subsidiary Weiss
Spindeltechnologie has developed motor
spindles with integrated gears which, similar
to conventional gear spindles, are capable
of achieving torques of over 3,000 newton
meters. Consequently, improved machine
tool values can be attained even during
heavy-duty machining: motor spindles enable
higher rotational speeds, machining
rates and workpiece accuracy levels than
conventional gear spindles.
Two model types are available. Both are
based on a work spindle, a planetary gearing
system and an steplessly variable electric
drive. In the first version, the planetary
gearing system is situated between the
spindle and motor. As a result, the motor
spindle is slender yet relatively long at 1.6
meters. In the second version, the gearing
system is located between the bearings. The
shaft of the spindle extends through the
hollow shaft. The bearings of the work spindle
are situated in front of and behind the
drive motor, thereby reducing the overall
length by as much as one-third. The spindles
the only factory to not only win the Best Factory/Industrial
Excellence award of the
French management school INSEAD and the
chair of the production management faculty
of the German Technical College for Comhave
already been successfully tested at the
Waldrich Coburg machine tool factory. The
Hessapp company is currently already utilizing
the new high-performance spindles in
a vertical lathe.
More information:
www.weissgmbh.com
Weiss GmbH
A&D Electronics Plant Erlangen Named Factory of the Year 2006
The Siemens
Automation
& Drives (A&D)
Electronics Manufacturing
Plant in Erlangen, Germany
(Gerätewerk GWE) is the 2006 winner of
the “Factory of the Year/Global Excellence
in Operations” award. The jury members of
the management consulting firm A.T. Kearney
and the trade journal “Produktion” based
their decision on the efficiency GWE achieved
as a result of the outstanding mobilization
of its employees. The plant’s success was
attributed to a good management system
in the form of an integrated production
system and an effective program to continuously
improve productivity and the
plant’s cost position. Among experts, the
Factory of the Year/GEO competition is regarded
as one of the most demanding
benchmark competitions for manufacturing
operations.
The GWE is part of the Siemens A&D Motion
Control Systems (MC) division. With a
staff of over 900 employees, the factory produces
CNC controls and drives for machine
tools, crane systems and production machines
in the power range of between 0.7
kilowatts and 1.5 megawatts. To date, it is
Simpler Handling
and Reduced Overall
Length
Highly dynamic, compact and assembly
friendly – these are the basic characteristics
of the new 1FT7 synchronized servo
motors. As a result, they are clearly designed
to meet the technical and economic
requirements of the demanding
motion control applications in today’s machine
tool and production machine manufacturing
operations. The new servo motors
offer a number of additional advantages,
particularly when operated together
with the Sinamics S120 drive system:
• clearly reduced overall design length –
up to 30 percent at comparable torque
• robust and long-lived – sensors are connected
via special coupling and can be exchanged
without parameterization
pany Management, but also the Factory of
the Year/GEO competition.
More information:
www.siemens.com/motioncontrol
• simple installation due to cross-profile
• higher speed control range during use in
field weakening operation
With the overall design length reduced
by up to 30 percent, the new high-performance
servo motor is markedly more compact.
Already in the self-cooled model, an
overload capability of four times the standstill
torque M 0 is available.
While designing the new top model, special
attention was given to continuity with
the 1FT6 motors, which have been wellestablished
in the market for a number of
years: the assembly, connection and characteristic
compatibility is ensured, enabling
a simple direct exchange for a servo motor
of the new generation.
More information:
www.siemens.com/motioncontrol/motors
motion world 1/2007

5
“Manufacturing
Excellence” Award
for DaimlerChrysler
From left to right: Prof. Dr. Ing. Raimund Klinkner, Gildemeister AG, Volker Stauch,
Günther Pauler, Volker Albrecht, Heinz-Werner Marx, all from DaimlerChrysler,
Dr. Olaf Rathjen, Siemens, and Prof. Dr. Ing. Frank Straube, TU Berlin
DaimlerChrysler was presented with the
Manufacturing Excellence (MX) award
in the process innovation category for its
“future-oriented maintenance service as
a champion of company success.” Volker
Stauch, a member of the production board
for Powertrain at DaimlerChrysler, accepted
the award at the Manufacturing Excellence
Conference in Berlin at the beginning of November.
According to the jury’s argumentation,
DaimlerChrysler efficiently translated
the total cost of ownership (TCO) approach
in its production operations. With
its concept of future-oriented maintenance,
the company set the stage for efficient,
highly available and productive manufacturing.
The prerequisites for success also
include the condition monitoring system
that DaimlerChrysler introduced to production
in a development partnership with
Siemens A&D.
“In the automation of production lines,
an integrated approach, and thus a compliance
with TCO, is one of the key elements
for more effectively managing production,”
as Dr. Olaf Rathjen, division manager of
Siemens A&D Motion Control Systems, explained
during the conference. The Manufacturing
Excellence award is designed to
promote the cross-sector industrial and in-
ternational cooperation, and to create a
communications platform for scientific and
professional experts.
More information:
www.mx-award.de
TU Berlin
Customized Milling Spindles
Flexibility with milling spindles need not
necessarily be expensive: the new preferred
spindle series from Weiss is suitable
for applications in all types of industries,
thereby assisting manufacturers of milling
machines in bridging the gap between competitive
pricing and high quality.
The new milling spindle of the preferred
“F150S.18.29” series, equipped with an
HSK-A63 interface, for example, features an
Spindles of the Weiss preferred series can be modified to meet applications
of any industry. Thereby, performance is continuously improved,
as with the new preferred series, whose outer diameter was reduced
from 170 millimeters to 150 millimeters. As a result, the spindle is more
dynamic and enables machine productivity to be increased
Weiss GmbH
outer diameter of 150 millimeters while
achieving 18,000 revolutions per minute
with lifetime lubrication. The synchronous
motor has a power output of 29 kilowatts
and 35 newton meters. Until now, an outer
diameter of 170 millimeters was required
for comparable power. Thanks to its more
compact design, the spindle is more dynamic,
and machine productivity higher.
The preferred spindle types offer users a
great deal of flexibility in terms of modifications.
A range of basic preferred types
cover all of the customary requirements in
terms of dimensions, rpm ranges and nominal
power. The specialists in Schweinfurt,
Germany also offer machine tool manufacturers
support during the planning and
commissioning stages of the spindles.
More information:
www.weissgmbh.com
motion world 1/2007

6
TRENDS
Bobsled Racing
“Olympic” runners developed with
Sinumerik and ShopMill
When Slimmest
Margins Count
The new
runners for the
winning bobsled
of Sandra Kiriasis
were developed at
Iscar with the help of
Sinumerik and a great
deal of expert know-how
All pictures: W. Geyer
motion world 1/2007

7
Effective October 1, 2006, only
standard runners made of the same
type of steel are permitted in international
bobsled racing. For the
German Olympic champion Sandra
Kiriasis, it meant taking leave of the
runners she had been accustomed to.
In order to retain the tried-and-tested
runner geometry of the winning
bobsled from Turin 2006, the shape
and the curvature of the last runner
had to be scanned and new sleds
manufactured on the basis of the
digital data thereby gathered. In
cooperation with a team of competent
partners, Siemens mastered the
challenge on a milling machine
equipped with a Sinumerik 840D CNC
control and ShopMill HMI.
In bobsled racing, a few hundredths of a
second frequently separate the winner
from the next-placed finisher. The sled’s
aerodynamics and its runners play a particularly
important role. With her previous
runners, Sandra Kiriasis took silver at the
2002 Olympic Games in Salt Lake City. From
2003 to 2006, she captured the overall World
Cup Championship four
times in a row. After two
silver medals in 2003 and
2004, she was crowned
World Champion in 2005.
The absolute highlight of
her sports career, however,
was the Olympic victory in
Turin in 2006.
Bobsled runners have repeatedly
given rise to speculations
ranging from prohibited
machining practices
to illegal lubricants. At every
competition, FIBT inspectors
therefore had to check
for compliance with no fewer
than 40 of the international
bobsled organization’s
rules and regulations.
As of the 2006/2007 season,
this issue has been put
to rest as a result of the fact that the FIBT
only permits one standard type of steel for
the runners. This will enable non-destructive
tests to be conducted.
Calls for help from the ice chute
“Given the fact that we can no longer use
the same runners with which we regularly
captured the World and European as well as
the World Cup titles and even the Olympic
gold medal since 2001, we are in need of a
service provider who can assist us in manufacturing
new runners from a standardized
material,” as Sandra Kiriasis described
the problem she faced in the “Industrieanzeiger”
back in the middle of August. Although
the previously so successful runners
were now useless for competition, they
were to serve as a template for the new
ones.
Karsten Schwarz, head JobShop project
manager for Sinumerik at Siemens, discovered
the article by coincidence. Immediately
interested, he mobilized a competent
group of partners to solve the demanding
task together with control and
CAD know-how. Due to previous cooperation,
good contacts already existed with
Iscar Germany, a specialist for machining
tools. Kurt Brenner, CTO (Chief Technology
Officer) at Iscar in Ettlingen, was also immediately
enthusiastic: “Bobsled racing already
fascinated me as a child. If we can
help manufacture the new runners and
thereby support bobsled racing, we’re happy
to do our share.” Renishaw, a specialist
Using two reference holes, the runners were exactly
aligned by ShopMill in the inching mode via setup
and measurement functions
for industrial metrology, scanned the old
runners and generated one data file each
for the outer runner contours and the running
surfaces: for the outer runner con-
tours – a simple geometric form of straight
lines and circles – a DXF file (drawing exchange
format), and a data set in IGES format
(initial graphics exchange standard)
for the mold part corresponding to the running
surfaces.
The runners were manufactured on a
milling machine at Iscar in Ettlingen, which
is equipped with a Sinumerik 840D CNC
control and ShopMill workshop operator
interface. The DXF file can be converted into
a ShopMill readable format via the software
CAD reader, and machined directly afterwards
via the operator interface. From the
IGES file (3D model), a CAD/CAM program
must first be created for the Sinumerik.
This was handled by Sescoi, software specialist
for tool and mold making, using the
Work\NC software. The CAD/CAM program
can be transferred to the control via USB or
network.
Personally on hand in Ettlingen
The actual milling process was performed
October 12 at Iscar in Ettlingen, with Sandra
Kiriasis on hand to personally evaluate the
machining.
First, the DXF file was translated into a
machine-readable format using the CAD
reader. Afterwards, it was possible to machine
the runner’s outer contour directly
via the workshop operator interface. With
the help of integrated setup
and measurement functions,
the runners were aligned exactly
in the inching mode on
the basis of two reference
holes. Using sequencer programming,
the machine operator
defined the program sequence
of the 2.5D machining
tasks. On the runner contour,
it was also necessary to adjust
the rounding of the transition
radius corners and chamfers
for the scanner values. This
task was handled quickly with
the integrated contour calculator.
The programming of the
individual machining steps
such as roughing, finishing and
chamfering was performed
with powerful ShopMill cycles.
For the machining of the runner
contour, these included: path milling
on the contour with roughing, finishing
and chamfering; milling the circular pocket
1st hole, roughing and finishing; slot
motion world 1/2007

8
TRENDS
Bobsled Racing
Following the transfer of the CAD/CAM
program to the Sinumerik 840D, the program
parts for roughing the entire contour,
finishing the slopes of the runners and for
finishing the running surfaces were linked
via a main program, and then executed
directly from the hard disk
The Olympic
champion
Sandra Kiriasis
looks confidently
ahead
to the next
bobsled season
equipped with
new runners
based on the
tried-andtested
runner
geometry
It proved particularly advantageous
that even large programs
could be edited in the control,
for example, the approximately
5 MB finishing program for the
runners, which contains about
100,000 lines.
The high number of points results
from a uniform distribution
of points, and thus a high accuracy
as well as a very smooth surface.
The integrated high-speed
settings Cycle832 ensures a high
and dynamic machining speed. It
activates all of the functions required
for the mold making. These
include the Look Ahead function
with resurfacing through grinding
and torque dampening, which
assumes an adjustable number
of traversing sets, thus optimizing
the machining speed.
In addition, the precontrol was employed
to prevent contouring errors during machining,
along with a COMPCAD online compressor,
which is recommended in particular
for milling freeform surfaces. In keeping
with tolerances set in Cycle832, it appropriately
combines a sequence of G1 commands
and compresses them into a splice, which
can then be executed directly by the control.
Sandra Kiriasis accepting the finished bobsled runners
from the manufacturers (from left: Wolfgang Reichart,
Siemens, Torsten Schweigert and Michael Becker, Iscar,
Manfred Buchner, Siemens and Walter Schmidt, Sescoi)
milling 2nd hole, roughing and finishing as
well as engraving cycle with company logo.
Shinny runners with Sinumerik
After the premilling of the runner contour,
it was time to process the key runner parts,
the running surfaces. The CAD/CAM program
generated from the Work NC CAM
All pictures: W. Geyer
software with a postprocessor adapted to
the Sinumerik 840D was transferred to the
control via USB. The program comprises
three parts: roughing the entire contour,
finishing the slopes on the runner and finishing
the running surfaces. The program
parts were linked via a main program and
then processed directly from the hard disk.
Smooth results
By combining Sinumerik 840D, a highspeed
control with a high information flow
rate and low record-changing times, the
ShopMill operator interface and the Work
NC CAM software, a precision machined
part was created from an unmachined one
in a very short period of time. The new bobsled
runner made of the prescribed standardized
steel has exactly the same geometry
as the previous, very successful one
made of a special material mix.
Sandra Kiriasis was not the only one enthusiastic
about the results: the surface of
the workpiece, the running surface of the
runner in this case, was extremely smooth
and almost as polished as a mirror.
The Olympic champion enthusiastically
accepted her new “old” runners. Bring on
the race for the slimmest of margins in the
ice chute.
More information:
www.siemens.com/sinumerik
E-mail: wolfgang.reichart@siemens.com
motion world 1/2007

CASE STUDY
Machining Centers
9
The horizontal machining centers
of the Mach series are equipped
with two machining spindles
Mach 1 machining center
from Honsberg equipped
with Sinumerik 840D and
Weiss spindles
Twice as
Productive
Pictures: Honsberg
To further reduce the machining
times for series workpieces, Honsberg
introduced the Mach 1-500 Synchro
at EMO 2005, which is equipped with
two spindles operating fully in synch.
The machine builder cooperated with
Siemens as the system vendor on the
project, which provided all of the
electrical equipment, including the
switchgear cabinet construction.
Transfer lines and individual machine
tools for the automotive industry
account for the primary business
of Honsberg Sonderwerkzeugmaschinen
GmbH. Its flagship product is the Mach
series horizontal machining center, which
sets itself off primarily through its two
columns and two machining spindles. Consequently,
the machines can either work
together on one large workpiece, or in parallel
on two smaller ones.
Spindles from Weiss
Honsberg has been cooperating with companies
such as Weiss in the area of machining
spindles for eight years. The motor
spindles of this Siemens subsidiary located
in Schweinfurt, Germany are ideally adapted
for the individual fields of application, and
are renowned for their robustness and reliability.
In fact, Honsberg has discovered
that the life span of these spindles is approximately
one-third longer than that of previous
models.
Equipment from Sinumerik
The electrical equipment for the Mach 1
series is based on the Sinumerik 840D, and
was equipped for the automotive industry
in accordance with the Transline 2000 standard.
The control achieves a high level of
The design principle with two columns
enables pendulum machining, as is frequently
required in the automotive industry
productivity using high-speed machining
with Look Ahead capabilities, zero lag positioning
with precontrol, NURBS, powerful
5-axis functions, technologies such as boring,
milling, turning, nibbling, stamping,
grinding, laser machining as well as the
inclusion of internal measurement systems
and several safety routines.
In the drive area, a Simodrive 611 digital
converter and 1FT6 servo motors were
utilized. The motors possess absolute value
encoders, despite the fact that the linear axes
also contain linear scales that are equipped
with absolute value encoders. The machine’s
design features a consistently distributed
periphery connected to the Profibus via
Simatic ET 200x and ET 200s.
Safety of the personnel and the machine
is ensured through the “Safety Integrated”
concept of Siemens. Apart from the components,
Siemens also supplied the complete
switchgear cabinet. As a result of the
good cooperation and well-managed distribution
of labor, it was possible to shorten
the entire development, including the construction
of the first machine, to approximately
eight months.
More information:
www.siemens.com/sinumerik
E-mail: andreas.ripper@siemens.com
motion world 1/2007

10
CASE STUDY
Test Facilities
motion world 1/2007

11
All pictures: P. Koerber
With the MPM (Model Positioning Mechanism), the model in the wind tunnel of DNW can be accelerated up to 2 g
Parallel kinematics with 1FN3 linear motors
for aircraft wind tunnel testing
Dynamic Models
Using a parallel kinematic design construction, the operators of the low-speed
wind tunnel (Niedergeschwindigkeitswindkanal, NWB) in Brunswick, Germany
are able to achieve never-before-seen dynamic load results, enabling aircraft
designs such as those for the new Airbus A380 to be optimized with very little
effort. Six Simodrive 1FN3 linear motors and a Sinumerik 840D NC control
form the heart of the “Model Positioning Mechanism” (MPM).
The Brunswick low-speed wind tunnel
(NWB) is very appropriately located
at the site of a former airport. In existence
for over 40 years, the research facility
located on the grounds of the German
society for aeronautics and aerospace (DLR)
is part of a larger wind tunnel organization
which, as a foundation under Dutch
law known as DNW (German-Dutch wind
tunnels), operates a total of 12 aeronautic
measurement wind tunnels in the Netherlands
as well as Germany.
Six of the test facilities are located in the
Netherlands, and another six in Germany,
including in Brunswick, Goettingen and
Cologne. Together, they cover a speed range
from low subsonic to seven times the speed
of sound (mach 7).
motion world 1/2007

12
CASE STUDY
Test Facilities
With its 9.1 square meters of jet surface
space, the NWB facility is the second largest
low-speed wind tunnel within the organization.
At the facility, wind speeds of up to 300
kilometers per hour are achieved, roughly
comparable to the speed at which a commercial
aircraft takes off and lands, at a
power consumption of 1.6 megawatts. On
commission of aeronautical industry and
research organizations, studies are conducted
primarily into the dynamic load behavior
of aircraft, helicopters and propulsion
units.
Apart from this, the NWB is also a test
partner for the motor sport sector, to include
commissioning contracts from the
Formula 1. The wind tunnel experts in
Brunswick have even tested such unusual
items as bicycle helmets, lights and a complete
sailboat with rigging in their tunnel.
Manipulation – the right way!
In aircraft development, it is of key importance
to – at a very early stage – be able to
evaluate the handling characteristics and
the level of dynamic loads that occur. This
is the only way to keep development risks
low and, thereby, keep close track of development
costs. Consequently, taking measurements
of model aircraft movement in
the wind tunnel is an important field of activity
at the NWB. Models of the new giant
A380 passenger jet “flew” in the wind tunnel
in order to furnish designers with data
on the aircraft’s dimensioning, as well as
load estimates of the structural design during
flight maneuvers and wind gusts.
In most wind tunnels, model planes are
moved in the measurement path using an
elaborate mechanical lever construction,
whereby the stem supporting the model
extends beyond the measurement path,
and is kept in a Cartesian arrangement
from outside of the air stream with the help
of mechanisms arranged in series.
This solution, however, has the drawback
that the required complex movements
cannot be conducted with the desired speed
and dynamics at the necessary level of
rigidity.
Special parallel kinematics
in the tunnel
Some of these drawbacks can be avoided
with the help of the so-called Stewart platform,
which is used in flight simulators
for pilot training. As of 2000, NWB has also
been using 6-axis parallel kinematics with
hydraulic bars of variable length. The results,
however, have never been entirely
convincing. First, due to the operating
principle, the hydraulic bars lack rigidity,
while the inertia of the valves limits the dynamics
and accuracy of the model’s movement.
Second, the continuously switching
valves excited vibrations in the models,
thereby corrupting the results of the measurements.
The solution based on the flight simulator
also proved unsuitable for the motor racing
measurements. The hydraulic platform
stood on the floor, therefore precluding the
customary wind tunnel measurements during
which the vehicle model is held from
above, while a conveyor belt a very short
distance beneath it was moved. However,
this arrangement can scarcely be implemented
in any other way to simulate the relative
movement of the vehicle and track.
In addition, the hydraulic system was
costly to maintain, and bore the risk of
hoses bursting or becoming loose and soiling
the measured section with oil.
The kinematics and operator interface were developed for the
DNW technicians in accordance with the special needs of flight tests
Loss of control over the valuable models, which are “packed”
with measurement technology, must be avoided at all costs
All pictures: P. Koerber
motion world 1/2007

13
New concepts from the machine
tool world
The “wind makers” of TAO Technologies
managed to find a solution in cooperation
with PKsystems (former employees of the
ZFS, the center for manufacturing technology
in Stuttgart which accompanied the
project). Together, a parallel kinematic
mechanism was developed, the so-called
Model Positioning Mechanism, or MPM
for short.
The MPM kinematic mechanism also
consists of one Stewart platform, which is
connected to the wind tunnel via six rigid
bars and six carriages positioned on two
parallel guide rails. Given the fact that it is
difficult to distinguish natural oscillations
from the aerodynamic effects when evaluating
the dynamic forces and torques, linear
motors are employed to move the carriages.
First choice: linear motors
from Siemens
Six Simodrive 1FN3 linear motors from Siemens
form the heart of the MPM
1FN3 linear motors from Siemens were
the first choice when selecting the drives,
which are also popular at the ZFS for parallel
kinematic designs. The natural oscillations
of the test facility now no longer
pose a problem: “With the MPM, the motion
is a good order of magnitude better than previously
was the case with the hydraulics,”
as Thomas Löser, project supervisor at
DNW-NWB, confirms.
Three carriages are mounted on one axle
respectively. As a result of the two-guiderail
configuration, the design requires fewer
components, thus cutting costs. All of the
carriages can be shifted independently of
one other, enabling movements with six
degrees of freedom, and providing a work
space of 1,100 millimeters in the wind direction,
300 millimeters laterally and 500
millimeters in the lift direction.
The design achieves accelerations of up
to 2.5 g, with the rigidity remaining virtually
constant throughout the entire work
area, as well as angle settings with an accuracy
of less than 0.005 degrees.
Tailoring the coordinate transformation
To allow the engineers at DNW to program
the forms of aerodynamic motion in a
Cartesian coordinate system with amplitude
data, frequencies as well as freely definable
axes of rotation, a Sinumerik 840D
was selected to serve as a control platform
to support the standard coordinate transformation.
The OEM interface of the Sinumerik
840D enables the integration of the
54 parameters needed for the kinematic description
of the transformation into the
control, which are incorporated into the NC
core of the basic control using compile cycles.
The operator interface was also configured
according to test engineer designs.
Safety first in the tunnel
As a result of the fact that the masses set in
motion, and thus the kinetic energy, are very
extensive, and the model aircraft also very
expensive, Sinumerik 840D is equipped
with the Safety Integrated components to
fulfill safety-relevant requirements, also
enabling the safety-oriented functions of
“safe speed,” “safe stop positions” and “integrated
brake test.”
The brake test is particularly essential,
because there is no counterweight for the
highly dynamic axles. At the high traversing
speed of the utilized linear motors, this
function enables the prompt signaling of
safety-relevant errors in accordance with
category 3, thereby ensuring a high degree
of protection for man, machine and last,
but not least, also models. “We must always
keep in mind that a highly sensitive strain
gauge scale is built into the model and can
be overloaded very easily. If control over the
linear motors is lost, the weight scale could
be damaged, which is valued at 100,000 euros,”
Löser explains.
Measurable success
The test facility has been up and running
since the end of 2004 without any faults.
Measurements, for example, on the new Airbus
A380, have revealed that the expectations
of DNW regarding positioning speed
and accuracy have been completely fulfilled.
With the help of the new dynamic
MPM, it is now for the first time possible to
realistically simulate flight maneuvers in a
wind tunnel.
More information:
www.siemens.com/sinumerik
E-mail: thomas.wissert@siemens.com
motion world 1/2007

14
CASE STUDY
Laser Machining
Modular laser cell for flexible 3D
material machining
Dynamic
and Flexible
Trumpf has had 3D laser machining
cells in its product line for several
years. With the new TruLaser Cell
Series 7000, the concept was once
again significantly improved,
especially regarding its usability,
productivity and modularity. The new
machine is controlled with Sinumerik
and Simodrive technology.
The applications of 3D laser machining
cells are manifold. Regardless of
whether for laser welding, laser cutting
or integration into complex production
lines, these cutting systems are equipped
for numerous production jobs, and are particularly
suitable for the automotive industry.
The experience gathered from numerous
projects was incorporated into the new
TruLaser Cell Series 7000.
Larger work area, less machining time
The compact laser machining cell features
a 2,000-millimeter x-axis (TruLaser Cell
7020) or 4,000-millimeter x-axis (TruLaser
Cell 7040), along with flexible automation
modules. The y-axis is designed as an extension
boom with a work area of 1,500 millimeters.
It includes a very slender and
compact z-axis with a 750-millimeter work
area. Two axes of rotation provide the machines
with complete 3D flexibility. The new,
compact design has led to an increased
the work area of one meter, while occupying
same amount of space.
The high dynamic performance of the
TruLaser Cell Series 7000 with an axis acceleration
of 1g saves time when needing
to position the machining head on the component.
With a PKW-B column made of highstrength
steel, for example, the machining
time is reduced by 30 percent as compared
to the predecessor machine using the new
high-speed cutting performance of the five
kilowatt laser.
“The TruLaser Cell Series 7000 economically
welds, cuts and machines surfaces
of everything from aluminum to ultrahigh-strength
steel in 2D or 3D,” as Klaus
Löffler, head of international laser systems
sales for Trumpf’s laser technology division,
explains.
Automation enhances productivity
Of key importance also for users is the option
of automating the operation to further
enhance productivity. Two-station operation,
whereby a partition divides the machine
into two work areas, enables the simultaneous
setup and machining of workpieces. This
increases the machine capacity of the job
shop operation considerably. Linear and
rotation changers simplify the handling of
workbenches and components. Thanks to the
modular construction, all automation components
are easily retrofitted.
One particular innovation is the machining
head, which features a magnetic coupling
that disengages if it collides with the workpiece.
As a result, there are fewer standstill
times. The machine is not damaged and requires
no costly readjustment.
The laser cells are available with a Trumpf
CO 2 laser with up to six kilowatts of power for
cutting applications, and up to 15 kilowatts
of power for welding applications. Trumpf
solid state lasers with up to eight kilowatts of
power are also alternately available.
Superior Siemens “laser guidance”
As with all laser machining systems of
Trumpf, Sinumerik and Simodrive are used
to handle the control and drives of the
TruLaser Cell Series 7000. Trumpf utilized
the open design of the NC core to integrate
laser-specific functions into the Sinumerik
840D, to visualize the transformation for the
3D laser head and to optimize the communication
of the laser and clearance control.
Also wireless
As a special “option” and teaching supplement,
Trumpf also offers a display panel
with a “wireless” link. The operator interface
of the main control console is mirrored
via WLAN (wireless local area network) and
VNC (virtual network computing) on a distributed,
battery-operated operator panel.
Consequently, the operator is always aware
of the current axis position. A Simatic Mobic
T8 distributed industrial webpad serves
as the access point. The “wireless design
concept” has the advantage that the user,
for example, can also take the display pan-
motion world 1/2007

15
3D laser machining systems are
suitable for many applications
The operator
is optimally protected
during
machining
The machine head
is equipped with a
magnetic coupling
that disconnects
in the event of
collisions with the
workpiece
All pictures: Trumpf
el with him (or her) to the master office, and
is always informed as to the status of the
machine.
Thanks to Sinumerik Safety Integrated,
the TruLaser Cell Series S7000 is also stateof-the-art
in terms of safety engineering.
The operator is protected against uncontrolled
axis movements and can, for example,
in two-station operation, safely set up
the second workpiece parallel to machine
operation. As a result of the fact that the
speeds are also reliably monitored, the operator
can move about safely in the work
area at any time, without any restrictions in
terms of usability.
Safety Integrated opens up new opportunities
to enhance the operating convenience.
For example, the axes remain under
control after the safety equipment is opened.
They are monitored for standstill by Safety
Integrated. Once the safety equipment is
closed, the axes are immediately ready for
operation, and the operator does not have
to switch on the power. Thanks to Safety
Integrated, it was possible to also reduce
the number of safety engineering components
as compared to the predecessor machine.
More information:
www.siemens.com/sinumerik
E-mail: thomas.wissert@siemens.com
motion world 1/2007

16
SOLUTION PARTNERS
Machining Simulation
First Sinumerik Solution Partner in Scandinavia
Test Run –
As Close As It Gets
Previously, anyone who wanted to simulate production processes on
the computer could not do without complex simulation programs
which could only be operated by specially trained employees. A new
Siemens Solution Partner is now offering a solution which even small
companies can afford, and which combines simple operation with
intelligent 3D technology.
Visual Components Oy
Business activities: 3D simulation und
visualisation in manufacturing
Headquarters: Helsinki, Finland
Employees: 15
Year of foundation: 1999
Contact:
Craig Lybeck – CEO
Mobile +358 40 770 8364
Fax +358 9 32 32 251
E-mail:
craig.lybeck@visualcomponents.com
Internet: www.visualcomponents.com
The company is based in Helsinki and
goes by the name of Visual Components
Oy. A name with a future, because
the clever Finns are on the way to becoming
one of the leading providers in the
field of simulation software. The latest product:
ILP, an inline production simulation
tool designed specially for the Sinumerik
810D and 840D controllers, which was developed
by the Swedish 3rd party developer
Optikos-Q.
The special feature is that ILP operates
directly with the axis data of the controller,
and therefore saves the time normally required
for carrying out dry test runs on the
machine until it is finally ready for series
production.
“The partnership with Siemens enables
companies to get a machining program running
quickly and reliably with the confidence
it won’t screw up production,” as Craig Lybeck,
CEO of Visual Components Oy, explains the
idea behind the software tool.
Perfectly simulated
ILP allows the simulation of CNC-controlled
processes right there on the shop floor. The
ILP software uses exactly the same data sent
to the machine drives, so it is as close as it gets
to actually machining the part. The result is
visualized in a high-resolution 3D view that
allows operators to, for example, view the setup
from different angles, examine the workpiece
and fixture setup, see all rapid tool feeds
and check for collisions, and verify that the
machining process is optimized in all respects.
With its products 3DCreate, 3DRealize,
3DVideo and now also ILP, the first Sinumerik
Solution Partner in Scandinavia now
implements 3D simulation at costs which
even smaller companies can afford. The
product portfolio ranges from simulation
through configuration to visualization. It
therefore covers all phases of the so-called
digital factory, and allows complete processes
to be simulated and different alternatives
to be tested. An astonishing performance for
a company which was not founded until 1999
by a group of experts in the field of computer
simulation, and which now boasts an annual
growth of an average 20 percent.
All pictures: Visual Components Oy
ILP (inline production simulation)
operates with the original
controller data
The latest software products from
Visual Components Oy offer new
perspectives on 3D-simulation even
for small companies
motion world 1/2007

CASE STUDY
Machining Centers
17
British machine tool
manufacturer turns to
Sinumerik
Turning and
Milling from
“X” to “Z”
Pictures: XYZ
The British machine tool
manufacturer, XYZ-Machine Tools,
has decided to enter into a
partnership with the controller
manufacturer Siemens. Both XYZ’s
vertical machining centers and
turning centers will be fitted with
Sinumerik as standard.
XYZ’s lathes
are fitted with
the ShopTurn
interface
XYZ had officially opened its German
branch in Gammertingen in
the south of Germany in 2006. In
addition to the exhibited range of machines,
a training center and model factory has also
been set up here.
The main reason for XYZ choosing Sinumerik
is the workshop-capable operator
and programming interface on its machines.
In addition, XYZ’s range of milling
machines will be covered by the ShopMill
operator interface.
With all the machine models – Mini-Mill,
VMC or high-speed processing centers –
ShopMill provides support, thanks to operator
guidance, in the determination of
workpiece zero points and tool lengths in
set-up operation as well as in the programming
of workpieces by means of a powerful
contour computer. The dynamic line graphics
with their full-scale representation of
the workpiece prevent errors and even
enable the programmed piece to be visualized
during input. Machining cycles from
pocket and island machining to free contours,
swiveling cycles with 5-axis machines
up to the high-speed setting cycle
(HSC) for mold design programs are all
available with ShopMill.
And for lathes too
The contour computer in ShopTurn calculates
challenging tangential and non-tangential
contour intersections for XYZ’s
lathes. The software has also integrated
all established cycles for the turning and
milling work, as well as manual functions
such as straight and inclined inputs for a cycle-controlled
lathe.
Spare parts availability key to purchase
decision
Another argument in favor of XYZ using
Siemens products in its machines is the
availability of service and spare parts.
Siemens is able to provide qualified service
personnel at short notice. Simply replacing
the printed circuit boards in the 810D
will ensure that it is once again ready for
use. Thanks to the option for remote diagnosis,
problems with the machine can also
be identified without having to call out a
service engineer. This also further increases
the machine’s availability.
XYZ believes that the globally accepted
user-friendly controllers and the excellent
support provided by Siemens are both crucial
factors in its commercial success to
date. With 1,000 satisfied customers and
optimally equipped training facilities, the
British machine tool manufacturer is perfectly
positioned for entry into the German
market.
More information:
www.siemens.com/sinumerik
E-mail: gustav.schabernack@siemens.com
motion world 1/2007

18 SHORT LIST
These and other interesting applications are described in detail under:
www.siemens.com/read-motionworld
CNC Design recently
equipped a Leifeld metal
spinning machine at
Murdock Metal Spinning in
Melbourne, Australia with
modern automation
technology from Siemens.
CNC Design
Volvo upgraded a transfer line for machining
break discs with state-of-the-art automation
equipment at its automotive component
factory in Floby, Sweden. The Siemens service
team completed the retrofit at the complex
plant in less than ten weeks.
Volvo
H&H Machine Tools developed a 5-axis
high-speed milling machine for a wellknown
Malaysian aerospace supplier.
CNC Design handled the automation of
the ultra-fast “Ultra 5” machine using
Sinumerik 840D, Simodrive 611D and
1FN3 linear motors.
H&H Machine Tools
motion world 1/2007

DIALOG
19
info
Do you want to find out more about automation and drive engineering
from Siemens Automation and Drives? Then visit our online information
platform on the Internet:
www.siemens.com/automation/newscenter
You will also find up-to-date newsletters on the Internet as a free subscription,
for example the Totally Integrated Automation Newsletter.
Simply register with your e-mail address at:
www.siemens.com/automation/newsletter
motion world
February 1/2007
Publisher
Siemens Aktiengesellschaft,
Automation and Drives Group (A&D),
Gleiwitzer Str. 555, D-90475 Nuremberg, Germany
www.siemens.com/automatio
Group Executive Management
Helmut Gierse, Hannes Apitzsch,
Dr. Peter Drexel, Anton S. Huber
Editorial Responsibility in Accordance
with the German Press Law
Peter Miodek
Responsible for Technical Contents
Bernd Heuchemer
Editorial committee
Wolfgang Wilcke
online
motion world online
Point your web browser to:
www.siemens.com/read-motionworld
and you can download the latest issue as a PDF file. The electronic archive
enables access to all previous issues. You can also send suggestions and
comments on the issue and the individual articles by e-mail. Your feedback
flows directly back into the compilation of motion world. Of course,
you can make changes to your subscription here, as well.
service
Everything about Sinumerik
for the shopfloor on CD-ROM
Everything you want and need to know about shopfloor-oriented Sinumerik
programming is now available on a CD-ROM. Practical programming
examples for turning and milling with ShopTurn and ShopMill let you convince
yourself directly at your PC about just how easy it is to translate a parts
drawing into a finished part. With the help of an interactive presentation,
we will demonstrate the individual work steps and the use of preconfigured
machining cycles in showing you how to more efficiently machine workpieces.
Also included on the CD-ROM: information on the brand new Sinumerik
802D sl shopfloor control, enabling even faster turning and milling cycle
times.
You can order the new CD-ROM over the Internet or through your
Siemens contact (order no. 6FC5095-0AA62-OYGO).
www.siemens.com/motioncontrol
Concept
Christian Leifels
Publishing House
Publicis KommunikationsAgentur GmbH, GWA
Corporate Publishing Zeitschriften
P.O. Box 3240, D-91050 Erlangen, Germany
Telephone +49 (0) 91 31/91 92-5 01
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publishing-magazines@publicis-erlangen.de
Editorial staff:
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Layout:
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Copy editors:
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Job number: 002100 RME63
DTP: Doess, Nuremberg
Printed by: Stürtz AG, Würzburg
Circulation: 10,000
© 2007 by Siemens Aktiengesellschaft
Munich and Berlin. All rights reserved
by the publisher.
This edition was printed on environmentallyfriendly
chlorine-free paper.
The following products are registered
trademarks of Siemens AG:
ET 200, MOBIC, ShopMill, ShopTurn, SIMATIC,
SIMODRIVE, SINAMICS, SINUMERIK, SINUMERIK
Safety Integrated, TOTALLY INTEGRATED
AUTOMATION
If trademaks, technical solutions or similar are not
included in the list, it does not imply that they are
not protected.
The information provided in this magazine
contains merely general descriptions or
characteristics of performance which in case of
actual use do not always apply as described or
which may change as a result of further
development of the products. An obligation to
provide the respective characteristics shall only
exist if expressly agreed in the terms of contract.
Order No.: E20001-MC306-B100-X-7600

No matter how high you want to take your ideas:
SINUMERIK solution line gives you the freedom
you need.
sinumerik
www.siemens.com/sinumerik-news
SOLUTION LINE
Be inspired by your imagination. And use your ideas the way you
imagine them – with SINUMERIK® solution line. Our new system
platform is essential for implementing innovative and successful
machine tools: The continuous advancements made by SINUMERIK
offer you a high degree of flexibility with minimal transition complexity.
So use the freedom that SINUMERIK solution line provides you. And lay the
foundations needed to take your company to the top. Your ideas deserve it!