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How can you improve the performance of machine tool controllers?

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Machine tool controllers are the brains of your manufacturing machines, and they can make a big difference in the quality, speed, and efficiency of your production. Whether you use CNC, PLC, or PC-based controllers, there are always ways to improve their performance and optimize your operations. In this article, we will share some tips and best practices on how to do that, based on the latest developments and trends in machine tool programming and control.

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Athul Nambolan

Management Consultant, Nomura | IIT Bombay
Shreeneet Rathi
Emrehan Isiklar

Staff Automation Engineer @ Tesla

1 Update your software

One of the easiest and most effective ways to improve the performance of your machine tool controllers is to update your software regularly. Software updates can fix bugs, enhance security, add features, and improve compatibility with other devices and systems. You should always check the manufacturer's website or contact their support team for the latest software versions and instructions on how to install them. Updating your software can also help you avoid obsolescence and keep up with the industry standards and regulations.

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Shreeneet Rathi
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Yes, always! For many machines, if not all, that uses programmed inputs/control, there is always some level of bugginess in the code.

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2 Optimize your parameters

Another way to improve the performance of your machine tool controllers is to optimize your parameters according to your specific needs and applications. Parameters are the settings that control various aspects of your machine tool's operation, such as speed, feed, acceleration, deceleration, spindle, coolant, etc. By adjusting these parameters, you can fine-tune your machine tool's performance and achieve better results. You can use trial and error, simulation, or optimization software to find the optimal parameters for your machine tool. However, you should always backup your original parameters before making any changes and test them carefully before applying them to your production.

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Athul Nambolan

Management Consultant, Nomura | IIT Bombay
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Optimising control parameters is a defacto requirement for achieving results especially for CNC machines serving their second life. But simply using software tools like Vericut can save a lot of time. Hopefully with tech like digital twin models of machine giving real time status of machine and parameters predicted datasets created from previously performed operations, at least in future, we may not even need to perform this exercise. In fact already for processes like additive manufacturing, the manual inputs of machine operations operations are already minimal.

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3 Upgrade your hardware

Sometimes, updating your software and optimizing your parameters are not enough to improve the performance of your machine tool controllers. In that case, you may need to upgrade your hardware components, such as memory, processor, drive, display, keyboard, etc. Upgrading your hardware can increase the speed, capacity, reliability, and functionality of your machine tool controllers. However, you should always consult with the manufacturer or a qualified technician before upgrading your hardware, as some components may not be compatible or may require additional modifications or adjustments.

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4 Integrate your systems

Another way to improve the performance of your machine tool controllers is to integrate them with other systems and devices in your manufacturing environment. Integration can enable data exchange, communication, coordination, and automation between your machine tool controllers and other systems, such as CAD/CAM, ERP, MES, SCADA, sensors, robots, etc. Integration can also help you monitor, control, and optimize your machine tool's performance from a central location or a remote device. You can use various methods and protocols to integrate your systems, such as Ethernet, USB, RS-232, Modbus, OPC UA, etc. However, you should always follow the manufacturer's guidelines and ensure the security and compatibility of your systems.

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5 Train your staff

Finally, one of the most important ways to improve the performance of your machine tool controllers is to train your staff on how to use them properly and efficiently. Training can help your staff understand the features, functions, and limitations of your machine tool controllers and how to program, operate, maintain, and troubleshoot them. Training can also help your staff adopt best practices, avoid errors, and improve productivity and quality. You can use various sources and methods to train your staff, such as manuals, videos, online courses, workshops, etc. However, you should always update your training materials and evaluate your staff's skills and knowledge regularly.

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Shreeneet Rathi
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I believe this is the most ignored/underrated aspect of managing automated/program-driven machine tools. Train, Train, and train all those involved at suitable levels of responsibilities. Period.

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Rodney Worley

Owner at Automated Cutting Technologies, Inc, Real Estate Investor, Potential Angel Investor
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Training operators in basic preventative maintenance (PM) is often overlooked. Generally the operator will not perform all PM tasks, but they are the person interacting with the machine for hours and hours at a time. By teaching them basic PM skills relevant to their machine they will have the skills and confidence to deal with small issues, and prevent large from becoming catastrophic.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Shreeneet Rathi
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I believe, now more than ever manufacturing engineers are required to be more interdisciplinary with the hats they wear. Be open and super-curious at your respective levels of roles, responsibilities, and involvement in any automation, data science-based, or Industry 4.0 focused projects, operations, or programmes within your reach. Learn the fundamentals of data science, go back and clear/refresh your core concepts from manufacturing systems, or get better with a set of digital tools that are soon going to become mainstream.

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Emrehan Isiklar

Staff Automation Engineer @ Tesla
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for PLC side we trust manufacturer because it is a real time system so it should not be delayed not like the PCs. So in our case’s it is firmware updates. Critical updates should apply immediately.

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How can you improve the performance of machine tool controllers?

1

2

3

4

5

6

1 Update your software

2 Optimize your parameters

3 Upgrade your hardware

4 Integrate your systems

5 Train your staff

6 Here’s what else to consider

Manufacturing Engineering

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How can you improve the performance of machine tool controllers?

1

2

3

4

5

6

1 Update your software

2 Optimize your parameters

3 Upgrade your hardware

4 Integrate your systems

5 Train your staff

6 Here’s what else to consider

Manufacturing Engineering

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