Rolls-Royce choose Series i as 'preferred CNC system'

Citation

(1998), "Rolls-Royce choose Series i as 'preferred CNC system'", Aircraft Engineering and Aerospace Technology, Vol. 70 No. 6. https://doi.org/10.1108/aeat.1998.12770faf.005

Rolls-Royce choose Series i as 'preferred CNC system'

Rolls-Royce choose Series i as "preferred CNC system"

Keywords Aeroengines, Fanuc, Machine tools, Rolls-Royce

Included in the comprehensive duties of the Plant Maintenance Department at Rolls-Royce plc's Hucknall site is responsibility for all of the many and highly varied types of machine tools used for the production of aero engine components. This diverse spread of machinery has brought with it equally widespread use of computer numerical control (CNC) systems ­ some 20 or more ­ which the Plant Maintenance Management Team has found to be totally unwieldy from the maintenance aspect because it means carrying a substantial stock of high-value spares to minimise down time.

A programme of assessing the comparative merits of available CNC systems was instigated about 18 months ago, with senior electrical maintenance engineer Rick Davies as project engineer, with the aim of reducing the number of systems for future use and thus securing the many benefits which a high level of standardisation might bring.

In the course of this programme the GE Fanuc i System was identified as having sufficient advantages to be recommended as the preferred system. Two versions of the system have been acquired and are already in use, both as retrofits and as OEM systems on new machines, and are being found to fulfil the department's earlier expectations. Two Series 160i, complete with Fanuc drive packages, are now running on large three-axes vertical turning lathes (a Webster & Bennett and a Churchill Froriep), and two Series 16i have been supplied with newly-installed Binns & Berry CNC lathes (Plate 2).

At Rolls-Royce, the company's probable future needs are anticipated and it is encouraging that GE Fanuc appear to have gone wholeheartedly for new technology with the i Series. Accordingly, full advantage is being taken of the networking capabilities of the system to provide, for example, condition monitoring and highlighting trends which will help reduce downtime etc. All CNC machines at the plant are downloaded with programs from the central "proven/approved" directory and so new ones written at the machine are first transmitted up the network for such approval.

The neat colour LDC screen is appreciated, as is the ability to view the animated machining features during an operation, as well as being able to prepare programs while the machine is running another job. A useful memo pad built-in with the control system is finding favour with operators as a ready means of leaving instructions or data at shift changes.

The system's Open Architecture, which can execute application software under Windows 95 formats, is expected to be a great help in the future as useful programs become commercially available and, already, this capability is used in conjunction with the extensive tool database held by Rolls-Royce.

Plate 2 Rolls-Royce engineer operating GE Fanuc controls on newly installed Binns & Berry CNC lathe

A single tool magazine might contain upwards of 360 tools. Currently this kind of benefit is of more immediate benefit at Hucknall than the undoubted future application of using the systems for operating multi-axes machinery over and beyond the three controlled on the VTLs as will be the potential for producing finely sculptured surfaces opened up by operating the NURBS capability with state of the art digital servo/digital spindle technologies. It is features like these which helped convince our engineers that the system is indeed largely "futureproof".

Another advantage of the GE Fanuc i Series in relation to the complex needs at Hucknall is the availability of a lower performance level system which is, nevertheless, ideally configured for use with the less complicated lathes and similar machine tools along with top-level models. It is therefore possible to standardise on one generic Series, with all that this means in terms of training and spares holdings, without either extending to massive "overkill" capabilities on the one hand or running up against operational limitations on the other.

As a plant maintenance department, the miniaturised CNC control unit is particularly attractive and the way in which the unit incorporates a compact CNC printed circuit board behind the LCD, with only a single optical fibre cable connection to the servo amplifiers, are all promising pointers to easier maintenance. The ability to make a major system component change with only 15 minutes downtime is highly satisfactory.

For further details contact GE Fanuc UK. Tel: (+44) 1908 84 4000; Fax: (+44) 1908 84 4000. GE Fanuc, European HQ. Tel: (+352) 72 79 79 222 Fax: (+352) 72 79 79 315. Web Site Address: http://www.GEFanuceur.