July 2017 - The Renishaw Equator and trade, flexible gauge is now offered with IPC (intelligent process control) software, providing the functionality to fully automate tool offset updates in CNC manufacturing processes. Improved capability in precision part machining, reduced setting and process adjustment time, and integration with automation systems are some of the benefits that users can now expect.

IPC is used with the existing software running on the Equator controller, using recent historical gauging data to determine process corrections. Connection to a compatible machine tool can be as simple as connecting an Ethernet cable from the Equator to a CNC machine. This capability has already been used by Renishaw customers worldwide to achieve considerable performance gains across a wide variety of industries, applications and CNC machine types, including lathes, machining centres and highly automated machining cells.

The new IPC software allows constant monitoring and adjustment of a machining operation, keeping part dimensions close to nominal and well within process control limits. The IPC software can average results across several parts to determine the true process mean for adjustment of each cutting tool.

The ability to correct a process automatically with IPC software eliminates the potential for manual data entry errors and removes the requirement for an expert to decipher traditional measurement reports into a process correction value at the CNC machine.

An Equator gauging system can be connected to one or multiple CNC machine tools, so that parts from different machines can be gauged on one Equator, with the offset updates being sent to the corresponding machine (part/machine identification is required). Connection to multiple machines requires an Ethernet hub or is via an existing factory network. Closed loop unmanned process control of a cell of machines is possible and a key requirement when used in conjunction with factory automation systems.

Options within the IPC software can constantly monitor the process and detect excessive tool offset update values, indicating tool failure or high rates of wear, and automatically signal to the machine that the tool needs changing. IPC software has proven to be particularly useful for conventional CNC lathes or Swiss-style sliding head machines where integration of a conventional machine tool probing system may be difficult due to machine configuration or tool station availability.

The first release of the new IPC software allows connection to one or multiple machine tools, with direct Ethernet links from the Equator Controller to Fanuc, Mazak and Okuma CNC controls. Fanuc controls that have been tested and proven include the 0i, 30i, 31i and 32i, with the Focas2 option installed. Mazak controls currently supported are the Smooth X, Smooth G, Matrix2 and Matrix controls with the Mazak API installed. The Okuma OSP300L and OSP300M controls are supported, on machines with the Thinc API installed.

Future software releases will further increase CNC control compatibility.