Direct numerical control

Direct numerical control (DNC), also known as distributed numerical control (also DNC), is a common manufacturing term for networking CNC machine tools. On some CNC machine controllers, the available memory is too small to contain the machining program (for example machining complex surfaces), so in this case the program is stored in a separate computer and sent directly to the machine, one block at a time. If the computer is connected to a number of machines it can distribute programs to different machines as required. Usually, the manufacturer of the control provides suitable DNC software. However, if this provision is not possible, some software companies provide DNC applications that fulfill the purpose. DNC networking or DNC communication is always required when CAM programs are to run on some CNC machine control.

Wireless DNC is also used in place of hard-wired versions. Controls of this type are very widely used in industries with significant sheet metal fabrication, such as the automotive, appliance, and aerospace industries.

History

1990s to present

The PC explosion in the late 1980s and early 1990s signalled the end of the road for proprietary DNC terminals. With some exceptions, CNC manufacturers began migrating to PC-based controls running DOS, Windows or OS/2 which could be linked in to existing networks using standard protocols. Customers began migrating away from expensive minicomputer and workstation based CAD/CAM toward more cost-effective PC-based solutions. Users began to demand more from their DNC systems than secure upload/download and editing. PC-based systems which could accomplish these tasks based on standard networks began to be available at minimal or no cost. In some cases, users no longer needed a DNC "expert" to implement shop floor networking, and could do it themselves. However, the task can still be a challenge based on the CNC Control wiring requirements, parameters and NC program format.

To remain competitive, therefore, DNC companies moved their offerings upmarket into DNC Networking, Shop Floor Control or SFC, Manufacturing Execution Systems or MES. These terms encompass concepts such as real-time Machine Monitoring, Graphics, Tool Management, Traveler Management and Scheduling. Instead of merely acting as a repository for programs, DNC systems aim to give operators at the machine an integrated view of all the information (both textual and graphical) they require in order to carry out a manufacturing operation, and give management timely information as to the progress of each step. DNC systems are frequently directly integrated with corporate CAD/CAM, ERP and Computer-aided Process Planning CAPP systems.

Special protocols

A challenge when interfacing into machine tools is that in some cases special protocols are used. Two well-known examples are Mazatrol and Heidenhain. Many DNC systems offer support for these protocols. Another protocol is DNC2 or LSV2 which is found on Fanuc controls. DNC2 allows advanced interchange of data with the control, such as tooling offsets, tool life information and machine status as well as automated transfer without operator intervention.

Machine monitoring

One of the issues involved in machine monitoring is whether or not it can be accomplished automatically in a practical way. In the 1980s monitoring was typically done by having a menu on the DNC terminal where the operator had to manually indicate what was being done by selecting from a menu, which has obvious drawbacks. There have been advances in passive monitoring systems where the machine condition can be determined by hardware attached in such a way as not to interfere with machine operations (and potentially void warranties). Many modern controls allow external applications to query their status using a special protocol. MTConnect is one prominent attempt to augment the existing world of proprietary systems with some open-source, industry-standard protocols and XML schemas and an ecosystem of massively multiplayer app development and mashups (analogous to that with smartphones) so that these long-sought higher levels of manufacturing business intelligence and workflow automation can be realized.

Alternatives

Smaller facilities will typically use a portable PC or laptop to avoid the expense of a fully networked DNC system. In the past Facit Walk Disk and a similar device from Mazak were very popular.