At every step during the program creation process, Prospector feeds
real-time data such as stock condition, machining stage (rough vs.
finish), minimum radii, size and depth of area(s) to be machined, to
the PowerSource engine. Armed with this information,
PowerSource executes rules in the database that to come up with the
optimal program and parameters according to your rules.
PowerSource Insight is the easy to learn, easy to use application
program provided with Prospector that allows you to establish your
own rules and settings for every scenario you might imagine.
Rule sets are segmented into separate configurations for each
material type to address specific applications or situations.
For example, you can establish different configurations to address:
- Different machine tools. A high speed machine tool for
finishing would likely require different programming techniques
than an older machine.
- Different machining stages. Roughing of mold cores and
cavities is typically done on a different machine using different
techniques and tooling than semi-finish and finish operations.
- Different part types. Methods for smaller jobs such as
lifters and slides may be quite different than larger jobs.
- Night shift vs. day shift. Perhaps during days, you may
choose more aggressive machining techniques than the night shift.
- Different users. Every machinist has their own ideas
about the best way to tackle a given job. Each can setup
their own unique configuration to reflect their preferences.
The architecture of PowerSource provides a high degree of security
that lets you set standards for the entire shop. Critical
parameters such as tolerances for finishing can be established on a
shop-wide basis and locked. By locking key parameters, you
ensure that they can never be accidentally changed for any program
created on any system in the shop.
Because tooling is a critical factor to determine proper machining
methods, the tooling database for Prospector is integrated into the
PowerSource database. The easy to use PowerSource Tooling
application program lets you design a custom library of only those
tools that are appropriate for every possible machining scenario.
All tool types from end mills to boring bars are supported.
Speeds and feeds are associated with the tools for every material
type defined in the database. The versatility of the database
allows you to assign different speeds and feeds for the same tool
depending on the machining stage (e.g. rough vs. finish) or
machining strategy (e.g. lace vs. Z-Planar). Tool station
numbers may be associated with specific tools to facilitate the use
of automatic tool changers.
In addition to tooling, tool assembly components
can be modeled and stored in the database. When tool
assemblies are used, the entire assembly is automatically
checked for possible collisions with stock.
- Reduce the opportunity for
human error. Skill-based systems are largely
dependent on the individual's skill, knowledge and experience with
the software. You can not be certain that every operator will have
this knowledge and skill to avoid improper use of the software or
inadvertently entering a bad value for a key parameter. The
PowerSource system virtually eliminates human error associated
with skill-based programming systems. This means your staff spends
less time editing cutter paths (and welding).
- Enhance the capability of
less experienced or skilled operators.
Because you pre-program rules and settings into the knowledge
base, shop users with less experience automatically benefit
because the system will suggest the right machining tactics.
- Enforce shop rules and conventions.
With Prospector you can be sure that machinists and operators are
following your shop rules and conventions. With PowerSource, you
have the master controls for all Prospector shop floor programming
systems. By establishing plant-wide system database defaults that
represent your standards, you can lock these setting and rules
such that they can not be countermanded by the operators on the
- Tailor each system to adapt
to machine tool characteristics. Local PowerSource databases can be programmed for specific machine tools
to get the most productivity out of your equipment. For example,
rules and settings for your roughing machine can be setup separate
from the rules for your high-speed finishing machine. This ensures
that machines are being programmed according to their capabilities
and and in a manner that maximizes their efficiency.
Address machining of all components of a job. The
flexible PowerSource database lets you group rules according to
their intended application. This means that when programming an
electrode, the system automatically calls up the proper rules for
electrode machining. Similarly different rules, feeds and speeds
may be established when cutting steel vs. aluminum. You decide
what makes the most sense for your shop.
Reduced variability and consistent high quality of workmanship.
PowerSource makes sure everyone is programming the same types of
jobs in a consistent manner. This ensures that from user to user,
job to job, you are producing consistent results that translate
into on-time delivery of high quality tools. No more surprises.
- Reduce or
eliminate reliance on "experts". Relying on
skill-based programming systems means you must recruit specialists
who understand that system in-depth to produce results. Why be
held hostage to the "computer gurus" to do your NC programming?
With Prospector, anyone can program and achieve the same results.
The system is so easy to learn, in just a couple of days new
operators are up and running.
With Prospector on the job it's like having your best machinist
constantly coaching every operator. Knowledge-based programming
helps eliminates possibilities of human error and reduces
variability. From user to user, job to job, your shop is producing
consistent results with high quality workmanship and on-time
delivery. No more surprises. PowerSource Technology makes sure
things are done right the first time and every time.