Bending is even better with AMADA's 4ie control
The AMNC 4ie control is a versatile device. It can handle control and display for different AMADA machine tool types: laser cutters, laser welding units, turret punch presses, and punch/laser combinations. For a laser cutter, the operator looks at the control, and sees what is happening either on the control, or another screen, or by peeking into the work-area window.
A press brake is a different story. The operator must consult the control, then walk over to the area of operation and make the bends. However, he still needs to check the program at times. Knowing this, AMADA supplied operators with a control system that dynamically follows the operator and allows use from a position in front of the brake.
With the new control system, AMADA solves the problem of intermittent work interruption in two ways. The new AMNC 4ie is large enough and clear enough to see from a working position in front of the brake; and AMADA has a tablet-based Human Machine Interface (HMI) that acts as a subsystem of the AMNC 4ie.
We will look at more details about this setup below. First, we will look at some hardware items that separate the 4ie from its competitors and predecessors.
Sensory input and response
An important enhancement to the AMNC 4ie (see Figure 1) is the ability to “see” the operator. A tiny camera uses machine vision and facial recognition software to recognize an operator approaching. This sets into motion several actions, such as automatically setting up that person’s pre-set access rights, operation privileges, and native language.
If the operator walks away, the system goes into low-power mode. After a pre-set time with no activity, the system dials down power on the servo motor, heat exchanger, display, and the working light. All told, this low-power mode reduces the standby power by 50 percent or more by invoking this idle stop function.
Speaking of sight, the system utilizes the iCAS camera inside the press brake (mounted high under a structural crossbeam, see Figure 2) to capture an overhead view of the working area. It is another check for the operator or someone looking in remotely to ensure the setup looks correct.
To go a step further, the system can combine the real-life picture with overlaid, see-through layer that represents the part about to be bent (see Figure 3). Machine vision and augmented reality are combined to give the operator an at-a-glance understanding of the location and orientation of the next part. No goggles are required—look up at the HMI to get this view. (The iCAS camera and the iPad-based HMI applications are part of an optional Smart Operations Pack.)
For press brakes equipped with AMADA’s enhanced Bi-S II bend measurement system, the live results are displayed on the HMI (see Figure 4). AMADA’s Bi-S II live bend gauge verifies bend angles with angle-sensing probes in front of and behind the die bed.
Vision is not the only sense used with the new AMNC 4ie. The operator can wear a headset to use voice commands and get feedback from the control. Not long ago this would be considered science fiction—yet it is available today and is another practical tool to get rid of interruptions in the bending process. It also enriches the experience of the operator, who gains flexibility in keeping a job moving forward while physically moving to a previously job-interrupting position.
The main functions accessed via voice control are Start/stop; Process instrructions; Angle correction; and Alarm reset.
The input can also as a mix of voice commands and some action performed by the operator:
Operator: “AMNC start.”
System: “Start. If it’s okay, press the foot pedal.”
Operator: <steps on foot pedal>
System: “Start running.”
In this simple scenario, instead of a startup command, the user might substitute running a specific job and get a similar result (“Run job 49-B”).
Before we leave the HMI, a few technical items are in order. The HMI unit is a standard iPad that links to the AMNC 4ie via Wi-Fi. The headset with microphone is connected via Bluetooth. It is also well to note that files used on the AMNC 4ie are compatible with the databases saved to network resources—the same resources accessed by the AMNC 3i, so cross-version data compatibility is maintained. There is no need to perform an IT system upgrade. Also, the information on the HMI comes from the controller—every bit as accurate and reliable as if you used the AMNC 4ie itself.
Other enhanced features
One of the other main features of the new control is an enhanced bar code reader. Rather than just simple bar codes, the bar code reader that is built into the bottom of the AMNC 4ie can scan QR codes. What is so advantageous about that? QR codes can carry about 100 times the information of a bar code, transfer it faster while taking up smaller space, and communicate more complex information. Futurists agree that information transfer will only increase.
You may have observed the AMNC’s lack of switches and keypads. It is a very clean, efficient, and flexible approach to machine control. You let the touch screen display morph into whatever application you are using. The display might include virtual buttons, a keypad, a video, a simulation, program data—many data types. The system holds so much information that dedicated physical buttons quickly become too numerous to be useful. The same holds true for keypads with alphanumerics or other symbols. Switch aggregation shortens control task time and improves situational awareness and comprehension. And with different data types mixed in one display, actions are in context.
The new AMNC 4ie has many positive effects on fabrication business, operator accuracy and satisfaction, and quality. It brings new capabilities and advanced performance while ensuring interoperability with legacy systems, a result that makes integration simple—a characteristic any owner or manager will appreciate.