Application of a cyber-physical system and machine-to-machine communication for metal processes

Adoption of an NC and/or CNC machine tools for metal machining has been a norm in contemporary manufacturing industry. Most of the machining information comes from the digital data generated from the adopted CAD/CAM software system. This can be served as the basis in forming a traditional flexible machining system (FMS) and/or computer integrated manufacturing system (CIM) for the integration among highly digitalized hardware. However, traditional FMS might become isolated digital islands if the used hardware and software are not digitally linked appropriately. This might result in, for example, reworking, errors, and risks in manufacturing industry practices. This research focused on developing an IMS (intelligent manufacturing system) through the synergy of communication of machine tools, process management, and production knowhow to enable a cyber-physical system. The system architecture and the networking technique of the system are illustrated in this paper through a case study on a precision mold making system. The case study showed that about 40% of mold production time could be shortened. Furthermore, the learning curve of machinery operation could be eased, and the workload of an operator could also be reduced. This has then successfully demonstrated that networked production system with the integration of manufacturing information could be used to facilitate an IMS.