WO2007134442A2

WO2007134442A2 - Computerized digital controller for controlling a computer numerical control (cnc) machine

Info

Publication number: WO2007134442A2
Application number: PCT/CA2007/000888
Authority: WO
Inventors: Thomas Gaasenbeek
Original assignee: Thomas Gaasenbeek
Priority date: 2006-05-22
Filing date: 2007-05-22
Publication date: 2007-11-29
Also published as: WO2007134442A3

Abstract

A computerized digital controller for controlling a CNC machine comprises a microprocessor, computer memory, a first input/output port for receiving program instructions and data from a CNC part program generator computer, and a second input/output port for transmitting program instructions and data to and receiving data from a CNC machine. Software is executable by the microprocessor for receiving program instructions and data from a CNC part program generator computer through the first input/output means and receiving data from a CNC machine through the second input/output means, for loading the program instructions and data into an input stack in the computer memory, for manipulating the program instructions received from the CNC part program generator computer to thereby produce augmented program instructions for the CNC machine, for loading the augmented program instructions into an output stack, and for transmitting the new CNC part program instruction through the second input/output means to a CNC machine.

Description

COMPUTERIZED DIGITAL CONTROLLER FOR CONTROLLING A COMPUTER NUMERICAL CONTROL (CNC) MACHINE

FIELD OF THE INVENTION

[0001] The present invention relates to digital numerical control machines, and more particularly to digital numerical control machines for controlling a computer numerical control (CNC) machine.

BACKGROUND OF THE INVENTION

10002] There are in excess of two million Computerized Numerical Control (CNC) machines in the world. They are a mainstay of discrete manufacturing. What makes CNC machines powerful is that computerized numerical control enables script languages to be run so that almost any type of part can be automatically made.

10003} There are several significant problems with present CNC machines. First, CNC machines are not readily re-programmable since CNC machines are typically hard coded. Also, a very significant problem is closed hardware and software architectures. Tt is necessary to know the particular programming language used by the specific CNC machine, as these languages are not universal, In many cases, they have different data formats and different communication protocols. The problems that stem from this include insufficient memory, poor download capabilities, unusual protocols, inflexible ladders, expensive parts, service difficulties, and so on. Also, there are only so many people who know how each machine works. This non-universality has cost billions of dollars to the world's manufacturing economy, Moreover, due to these above stated problems, communication with CNC machines is not wide spread, although such communication would be highly desirable.

[0004] Further, the above discussed limitations of CNC machines has lead to another significant problem in that companies buy machines to handle specific functions, produce specific parts, or perform specific processes. They purchase the machine that is best suited to their particular needs. In order to meet other needs, it is typically difficult, at best, to reprogram a particular CNC machine, although it would be extremely desirable to do so.

[0005J One of the reasons that these problems developed is that the ongoing development of computerized numerical control machines has been very focused on what is happening inside the CNC machine, and what is happening when the tool of the CNC machine is working on a part. The overall process of automation of CNC machines has not been focussed on, as it has been in other areas of manufacturing, such as process control.

fOO06J Over the past several years, various attempts have been made to improve the programming of CNC machines, both in terms of ease of programming and the amount of functionality that can be achieved, and also the communication with CNC machines and between CNC machines.

[0007] Direct numeric control (DNC), which is also referred to as distributed numerical control, is a file transfer mechanism for machine tools that permits remote communication with a CNC machine, so that the CNC machine can be queried or instructed. Serial ports, PCI cards, or other forms of media transfer, are used for transferring files. However, only a very small segment of the market uses any form of DNC remote protocol.

(0008J The highest form of DNC is commonly referred to as FMS (Flexible Manufacturing Systems), and has been known several years. Unfortunately, FMS is very expensive and notoriously inflexible. In order to overcome this problem, patches can be incorporated into the existing code. This solution is very clumsy, time consuming and expensive.

[0009] Recently, Global HMl (Human Machine Interface) a sub-committee of OMAC, an organization dedicated to the development and use of open interoperable control and automation systems technologies, has provided a schema for how various machines, such as CNC machines, ought to communicate. It is desirable to have a web based TCPlP, preferable using a language such as XML, to permit machines to communicate with the outside world.

JOOOl 01 One system that attempts toovercome some of the shortcomings of present CNC machines and the like, is found in United States Patent 7,110,918 issued September 19, 2006 to Celestini, and entitled Self-contained System and Method for Remotely Monitoring Machines. This system uses a machine monitoring device (MMD) connected to the monitored machine. The MMD receives inputs from the machine via input connectors and performs desired transformations. Results of the transformations are stored in an on-board database system within the MMD. Reports on machine status, quality, maintenance, production, and performance are generated by consulting the database system. Reports can be generated at fixed intervals or on demand and may be transmitted over a network. A server, such as a web server or the like, resident within the MMD makes reports remotely viewable from client computing devices on the network via web page interfaces or the like and also allows for remote configuration of the MMD via such interfaces. The monitoring device also has output connectors for transmitting MMD output signals, such as digital output signals or the like, that may be used for activating buzzers, lights or email notifications that can be escalated. MMD output signals may also be used for pausing or stopping machines.

[00011] It is an object of the present invention to provide a dynamic computer aided machining system that allows for the control of CNC machines, which system is highly flexible in its implementation and operation.

[00012] It is an object of the present invention to provide a dynamic computer aided machining system that allows for the control of CNC machines, which system is inexpensive to implement and to operate.

[00013) Other advantages, features and characteristics of the present invention, as well as methods of operation and functions of the related elements of the structure, and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following detailed description and the appended claims with reference to the accompanying drawings, the latter of which is briefly described herein below.

SUMMARY OF THE INVENTION

[00014] In accordance with one aspect of the present invention there is disclosed a novel computerized digital controller for controlling a computer numerical control (CNC) machine. The digital controller comprises a microprocessor for processing software required to operate the digital controller and processing program instructions for the CNC machine. There is computer memory operatively connected to the microprocessor. A first input/output means is operatively connected to the microprocessor for receiving program instructions and data from a CNC part program generator computer. A second input/output means is operatively connected to the microprocessor for transmitting program instructions and data to and receiving data from a CNC machine. There is software executable by the microprocessor for receiving program instructions and data from a CNC part program generator computer through the first input/output means and receiving data from a CNC machine through the second input/output means; software executable by the microprocessor for loading the program instructions and data into an input stack in the computer memory; software executable by the microprocessor for manipulating the program instructions received from the CNC part program generator computer to thereby produce augmented program instructions for the CNC machine; software executable by the microprocessor for loading the augmented program instructions into an output stack; and software executable by the microprocessor for transmitting the new CNC part program instruction through the second I/O means to a CNC machine.

f00015] In accordance with another aspect of the present invention there is disclosed a novel method of controlling a computer numerical control (CNC) machine comprising the steps of: receiving program instructions and data from a CNC part program generator computer; loading the program instructions and data in a stack in the computer memory; manipulating the program instructions received from the CNC part program generator computer to thereby produce augmented program instructions for the CNC machine; loading the augmented program instructions into an output stack in the computer memory; transmitting the augmented CNC part program instructions through the second input/output means to a CNC machine.

[00016] Other advantages, features and characteristics of the present invention, as well as methods of operation and functions of the related elements of the structure, and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following detailed description and the appended claims with reference to the accompanying drawings, the latter of which is briefly described herein below.

BRIEF DESCRIPTION OF THE DRAWINGS

100017] The novel features which are believed to be characteristic of the computerized digital controller according to the present invention, as to its structure, organization, use and method of operation, together with further objectives and advantages thereof, will be better understood from the following drawings in which a presently preferred embodiment of the invention will now be illustrated by way of example, ϊt is expressly understood, however, that the drawings are for the purpose of illustration and description only, and are not intended as a definition of the limits of the invention. In the accompanying drawings:

(00018] Figure 1 is a simplified block diagrammatic view of the preferred embodiment of the computerized digital controller according to the present invention;

[00019] Figure 2 is a perspective view of the printed circuit board embodying the computerized digital controller of Figure 1 ;

[00020] Figure 3 is a simplified block diagrammatic view of the computerized digital controller of Figure 1;

[00021] Figure 4 is a chart showing the computerized digital controller according to the present invention code pre-process method utilizing application program extensions; and,

[00022] Figure 5 is a simplified block diagrammatic view of (he computerized digital controller according to the present invention, showing the operational software modules.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

[00023] Reference will now be made to Figures 1 through 5, which show the preferred embodiment of the computerized digital controller according to the present invention of the present invention. The computerized digital controller 20 is for controlling a computer numerical control (CNC) machine 22. Preferably, the digital controller is mounted in removable and replaceable relation on a CNC machine 22, and, as best seen in Figure 1, the computerized digital controller 20 is disposed in data communicating relation between a CNC parts program generator computer 29 and the CNC machine 22. The CNC parts program generator computer 29 might be a CAD/CAM system, a DNC Server, a File Messaging System, and so on.

[00024] The preferred embodiment computerized digital controller 20 of the present invention comprises a microprocessor 30 for processing software required to operate the computerized digital controller 20 and processing program instructions for the CNC machine 22. The microprocessor 30 preferably comprises an embedded microcontroller chipset, but could comprise any suitable microprocessor, microcontroller, or the like, and could even be a single board computer run by an operating system such as WUIdOWS_7M.

[00025] There is an inherent advantage in having the computerized digital controller 20 of the present invention being mounted on, or at least in close proximity to, the CNC machine 22 it is controlling. There is an assurance that it can communicate immediately with the CNC machine 22 it is controlling, and without data corruption. In contrast, in cases where when data has to travel long distances, the data may become corrupted, in which case the process at the machine would go awry. In some cases a hundred thousand dollar part, such as a main piece of an aircraft landing gear, might not be made correctly. Therefore, data integrity is very important; however, it is very difficult to guarantee data integrity when data has to travel over long distances through many buffers and many complex systems. The computerized digital controller 20 can report back that the file has been unaltered and that it is running as it should for security purposes.

[00026] There is also computer memory 32 operatively connected to the microprocessor 30.

The computer memory 32 comprises any suitable type of random access memory. Further, the computer memory 32 additionally comprises removable and replaceable non-volatile memory, $uch as flash memory, so that files (program instructions, data, and so on) may be made readily available, as desired.

[00027] A first input/output means 41 is operatively connected to the microprocessor 30 for receiving program instructions, including part program instructions, and data from a CNC part program generator computer 29 and for transmitting data to the CNC parts program generator computer 29. In the preferred embodiment, as illustrated, the first input/output means 41 comprises a serial port, but alternatively may comprise any suitable type of data port, such as a USB port, or may be a wireless data port.

[00028] A second input/output means 42 is operatively connected to the microprocessor 30 for transmitting program instructions and data to and receiving program instructions and data from the CNC machine 22. In the preferred embodiment, as illustrated, the second input/output means 42 comprises a serial port, but alternatively may comprise any suitable type of data port, such as a USB port, or may be a wireless data port. [00029] A third input/output means 43 is operatively connected to the microprocessor 30 for transmitting information to and receiving instructions from an interface means for presenting information to an operator and for receiving input from operator. In the preferred embodiment, as illustrated, the third input/output means 43 comprises a serial port, but alternatively may comprise any suitable type of data port, such as a USB port, or may be a wireless data port. Also, the third input/output means 43 may comprise a suitable keyboard and a computer monitor.

[00030] In general, the present invention provides new ways for a CNC operator to interact with the CNC machine 22. An operator can use a handheld terminal, a bar code reader, or file messaging system, and so on.

[00031] As can be best seen in Figures 3 and 4, there is software 50 executable by the microprocessor 30 for receiving program instructions and data from a CNC part program generator computer 29 through the first input/output means 41 , as indicated by arrow "Al" in Figures 3 and 4, and receiving data from the CNC machine 22 through the second input/output means 42, as indicated by arrow "E2" in Figure 4. The program instructions are typically part program instructions, and maybe in any suitable format, such as G-code or M-<xκle, or the like.

[00032] As can also be seen in Figures 3 and 4, there is software 52 executable by the microprocessor 30 for loading the program instructions and data into an input stack 54 in the computer memory 32, as indicated by arrows "B" in Figure 4. In essence, the input stack 54 shows a "snapshot" of the status of the CNC machine 22 at that point in time, and represent the function(s) the CNC machine 22 will be performing. The instructions and data in the input stack 54 can then be "looked at" by the software, and decisions can be made by the software in order to amend and augment the instructions and data in the input stack 54, thereby permitting known changes in the operation of the CNC machine 22, as will be discussed in greater detail subsequently.

(00033] In the preferred embodiment, as illustrated, the computerized digital controller 20 according to the present invention also comprises software 56 executable by the microprocessor 30 for manipulating the program instructions and data received from the CNC part program generator computer 29, as indicated by arrows "C" in Figure 3. The manipulation of the program instructions and data thereby produce augmented program instructions and augmented data for the CNC machine 22. The computerized digital controller 20 according to the present invention further comprises software 58 executable by the microprocessor 30 for generating additional part program instructions. The additional part program instructions arc generated by means of mathematical calculations, and are generated by means of logical operators, and are a sub-set of the overall augmented program instructions and augmented data.

[00034] These augmented program instructions and augmented data, and especially the additional part program instructions, might include tool offset instructions, instructions as to the location of a tool or tools, comments to an operator, instructions to track the cutting time of a tool for tracking tool life, "suspend execution" instructions while waiting for an operator or waiting for a robot to move, instructions to record the motion of the tool, and instructions to change the tool as per calculations related to tool wear, and so on.

[00035] More specifically, as one example, the instructions as to the location of a tool or tools might include the location of a particular tool and each tool that is functionally identical to it. In this manner, if a tool unexpectedly breaks, one of the other functionally identical tools can readily be physically selected since its exact location is known, and can be used to complete the ongoing job with a minimum of delay and disruption. This is not possible with known prior art systems in CNC machines or used in conjunction with CNC machines.

[00036] Also, as another example, the instructions to change the tool as per calculations related to tool wear might include tracking tool time usage, the cutting rate of the material and also the type of material being used. The tool wear of any tool, even a newly developed tool from a new material, can be calculated using these and other variables, by means of an equation or a lookup table, for instance, particular to that tool. In this manner, any tool can be run until it is near the end of its useful life, and can be changed before it provides unacceptably poor cutting performance. Similarly, tool wear could also be tracked by monitoring tool speed and power consumption of the CNC machine 22. If the power consumption of the CNC machine 22 slowly increases at approximately a predetermined known rate, as a tool is used, it can be concluded that the tool is becoming dull, and the appropriate time for the tool to be changed can be determined. Further, the feed rate of the material could be altered as the tool becomes dull, as calculated by the software of the present invention. Again, these amended and augmented operations are not possible with known prior art systems in CNC machines or used in conjunction with CNC machines.

100037] There is software 60 executable by the microprocessor 30 for loading the augmented program instructions into an output stack 66, and loading the additional part program instructions into the output stack 66, as indicated by arrow "D" in Figure 4.

[00038] The present invention further comprises software 62 executable by the microprocessor

30 for generating operator messages and loading the operator messages into the output stack 66, also as indicated by arrow "D" in Figure 4. The messages in the output stack 66 are transferred to the third input/output means 43, and then to the output device such as a computer monitor. This is very useful for machine shops and the like, that manufacture different types of components all of the time. The system can also explain to the operator what is going to happen.

J00039] The present invention further comprising software 64 executable by the microprocessor 30 for generating operational instructions executable by peripheral devices and loading the operational instructions into the output stack 66, also as indicated by arrow "D" in Figure 4. The peripheral devices are connected to the computerized digital controller 20 through a fourth input/output means 44, which is a serial port in preferred embodiment of the present invention, but may also be a USB port, and so on. Such operational instructions might include construction to the electrical power system of the machine shop to shut down the overall power to the CNC machine

22, for the purpose of saving energy. It should be noted that this is different than a specific instruction to the CNC machine 22 itself.

[00040] The computerized digital controller 20 of the present invention can change the functionality of the CNC parts program, or can add a new feature to the CNC parts program, or to tweak H in some way. New code as determined by the software operating on the computerized digital controller 20 of the present invention, is just added in. This is in direct contrast to the prior art where it is necessary to add extra I/O, or to redo an entire operating system. Instead of having to provide all the combinations and permutations that might be required, the present invention provides them a structure where operators can add desired functionality.

[00041 ) For instance, if the computerized digital controller 20 senses that too much power is being drawn on the spindle of the CNC machine 22, the feed of material into the CNC machine 22 can be changed dynamically to preserve tools from being broken, or prevent surfaces from being miss-cut.

[00042] Also, tool offsets can now be correctly calculated and applied automatically, in a dynamic (ongoing) manner. Further, machines can be benchmarked and their operation can be tracked and flagged if it is outside normal operational specifications. All these functions are now possible and easy on even the oldest CNC machines.

[00043] There is also software 68 executable by the microprocessor 30 for transmitting the augmented CNC part program instructions through the second input/output means 42 to the CNC machine 22, as indicated by arrow "El" in Figures 3 and 4.

[00044] In order to run the CNC machine 22, the computerized digital controller 20 of the present invention decompiles the part program instructions, and optimization algorithms such as stripping characters, feed rate, optimization for acceleration, deceleration, and so on, are applied. Also, custom machine codes that will have a peripheral work with it, are inserted. All of that is done offline and then is recompiled, and sent through the second input output means to the CNC machine 22, or to peripheral devices, or to other computers, handheld devices, and so on. The re-compiled code can be parsing, for management, for production schedules, for tooling, for offsets, for control like single block or cycle start or block skip, or many other functions.

[00045] In the preferred embodiment, as illustrated, the present invention further comprises software 70 executable by the microprocessor 30 for applying over-riding rules and generating additional part program instructions, data, operator messages and operational instructions executable by peripheral devices. The over-riding rules comprise over-riding maintenance and production rules.

[00046] Examples of over-riding rules might include: (1) determining the delivery dates of presently available jobs and possibly performing first the job with the earliest delivery date; (2) keep each machine working on parts as much as possible so as to minimize foreseeable delays; and (3) if a specific job is behind schedule, the "safe code checking routine" can be temporarily omitted

[00047] The present invention also relates to holonoic manufacturing, which involves the individual devices challenging, competing, communicating, and arbitrating production schedules. Holonic manufacturing is an independent process wherein each machine is a node on a larger network and can make its own decisions. The basic rule is to not do something until it should be done. This implies that it is now on how long will take to do the task. For instance, if machine A produces parts that feed to machine B, and machine B has broken down, there is no point in feeding more parts to machine B until it is operational.

[0004S] Holonic manufacturing is very difficult to implement. Essentially, it is just not practical as there is no good way to implement it, until now, with the computerized digital controller 20 of the present invention. The computerized digital controller 20 of the present invention allows holonic manufacturing to be enabled, either directly or through a rules based system. Some overall long-term advantages might include economy, performance, safety, benchmarking, dealing with labor shortages, and improved forward scheduling. For instance, a communication, such as e-mail or other type of text message, could be sent to the operator of a pallet truck, or the like, to start picking up pallets in three hours, since that job will be finished at that time.

100049] There is also software 72 executable by the microprocessor 30 for transmitting the augmented CNC part program instructions through (he first input/output means 42 to the CNC part program generator computer 29, as indicated by arrow "A2" in Figures 3 and 4.

[00050] The present invention also provides a file messaging system wherein the computerized digital controller 20 can communicate with the outside world by means of direct communication with a microcomputer, communication with a microcomputer over the Internet, sending and receiving e-mail, sending a facsimile, communication with a PDA, and even posting information on a web site.

[00051] In the preferred embodiment, as illustrated, the present invention also comprises a method of controlling a computer numerical control (CNC) machine comprising the steps of:

receiving program instructions and data from the CNC part program generator computer 29, as indicated by arrow "A" in Figure 4;

loading the program instructions and data in a stack in the computer memory 32, as indicated by arrows "B" in Figure 4;

manipulating the program instructions received from the CNC part program generator computer 29 to thereby produce augmented program instructions for the CNC machine 22, as indicated by arrows "C" in Figure 3;

loading the augmented program instructions into an output stack 66 in the computer memory 32, as indicated by arrow "D" in Figure 4; and,

transmitting the augmented CNC part, program instructions through the second input/output means 42 to the CNC machine 22, as indicated by arrow "El" in Figure 4.

[00052] As can be readily seen from the above description, the computerized digital controller

20 of the present invention is in essence a coprocessor for CNC machines, and provides adaptive control for CNC machines.

[00053] The present invention also permits the thorough implementation and maximization of OEE (Overall Equipment Effectiveness), which is a subfunction of lean manufacturing (minimizing waste). OEE can be defined as the percent performance times the percent availability times the percent quality. The basic premise is if it cannot be monitored, it can't be controlled in order to minimize the waste. The present invention enables enterprise level coordination and ultimization and in large plants that might have several thousand machines. There is no other technology they can do this.

[00054] Also, as can readily be seen, the present invention permits internetworking the factory floor. With the present invention, companies can send drawings, have safety code checks, perform code marking, monitor tool life, perform robot interfacing, conform to OMAC (Open Modular Architecture Controls), all of which is otherwise unknown.

[00055] Other variations of the above principles will be apparent to those who are knowledgeable in the field of the invention, and such variations are considered to be within the scopή of the present invention. Further, other modifications and alterations may be used in the design and manufacture of the computerized digital controller of the present invention without departing from the spirit and scope of the invention.

Claims

I CLAIM:

1. A computerized digital controller for controlling a computer numerical control (CNC) machine, said digital controller comprising:

a microprocessor for processing software required to operate said digital controller and processing program instructions for said CNC machine;

:> computer memory operatively connected to said microprocessor;

first input/output means operatively connected to said microprocessor for receiving program instructions and data from a CNC part program generator computer;

second input/output means operatively connected to said microprocessor for transmitting program instructions and data to and receiving data from a CNC machine;

1 software executable by said microprocessor for receiving program instructions and data from a CNC part program generator computer through said first input/output means and receiving data from a CNC machine through said second input/oulput means;

software executable by said microprocessor for loading said program instructions and data into an input stack in said computer memory;

> software executable by said microprocessor for manipulating said program instructions received from said CNC part program generator computer to thereby produce augmented program instructions for said CNC machine;

software executable by said microprocessor for loading said augmented program instructions into an output stack; and, software executable by said microprocessor for transmitting said augmented CNC part program instructions through the second input/output means to a CNC machine.

2. The computerized digital controller of claim 1 , wherein said digital controller is mounted on a CNC machine.

3. The computerized digital controller of claim 2, wherein said digital controller is disposed in data communicating relation between a CNC parts program generator computer and said CNC machine.

4. The computerized digital controller of claim 1, wherein said digital controller is mounted in removable and replaceable relation on a CNC machine.

5. The computerized digital controller of claim 1, wherein said first input/output means is also for transmitting data to said CNC parts program generator computer.

6. The computerized digital controller of claim 1 , wherein said program instructions received from said CNC part program generator computer include part program instructions.

7. The computerized digital controller of claim 1 , further comprising software executable by said microprocessor for generating additional part program instructions and loading said additional part program instructions into said output stack.

8. The computerized digital controller of claim 7, wherein said additional part program instructions are generated by means of mathematical calculations.

9. The computerized digital controller of claim 7, wherein said additional part program instructions are generated by means of logical operators.

10. The computerized digital controller of claim 1 , further comprising software executable by said microprocessor tor generating operator messages and loading said operator messages into said output stack.

11. The computerized digital controller of claim 1 , further comprising software executable by said microprocessor for generating operational instructions executable by peripheral devices and loading said operational instructions into said output stack.

12. The computerized digital controller of claim 1 , further comprising software executable by said microprocessor for applying over-riding rules and generating additional part program instructions, data, operator messages and operational instructions executable by peripheral devices.

13. The computerized digital controller of claim 1, wherein said over-riding rules comprise over-riding maintenance and production rules.

14. The computerized digital controller of claim 1, wherein said microprocessor comprises an embedded microcontroller chipset.

15. The computerized digital controller of claim 1, wherein said computer memory comprises random access memory.

16. The computerized digital controller of claim 15, wherein said computer memory additionally comprises flash memory.

17. The computerized digital controller of claim 15, further comprising third input/output means operatively connected to said microprocessor for transmitting information to and receiving instructions from an interface means for presenting information to an operator and for receiving input from operator.

18. The computerized digital controller of claim 1, wherein said first input/output means comprises a serial port.

19. The computerized digital controller of claim 1, wherein said first input/output means comprises a USB port.

20. The computerized digital controller of claim 1, wherein said second input/output means comprises a serial port.

21. The computerized digital controller of claim 1, wherein said second input/output means comprises a USB port.

22. A method of controlling a computer numerical control (CNC) machine comprising the steps of:

receiving program instructions and data from a CNC part program generator computer;

loading said program instructions and data in a stack in said computer memory;

manipulating said program instructions received from said CNC part program generator computer to thereby produce augmented program instructions for said CNC machine;

loading said augmented program instructions into an output stack in said computer memory;

transmitting said augmented CNC part program instructions through the second input/output means to a CNC machine.

23. The computerized digital controller of claim 22, further comprising the step of receiving data from said CNC machine.

24. The computerized digital controller of claim 22, further comprising the step of transmitting data to said CNC part program generator computer.

25. The method of claim 22, further comprising the steps of generating additional part program instructions and loading said additional part program instructions into said output stack.

26. The method of claim 25, wherein said additional part program instructions are generated by means of mathematical calculations.

27. The method of claim 25, wherein said additional part program instructions are generated by means of logical operators.

28. The method of claim 22, further comprising the steps of generating operator messages and loading said operator messages into said output stack.

29. The method of claim 22, further comprising the steps of generating operational instructions executable by peripheral devices and loading said operational instructions into said output stack.

30. The method of claim 22, further comprising the step of applying over-riding rules and generating additional part program instructions, data, operator messages and operational instructions executable by peripheral devices.

31. The method of claim 22, wherein said over-riding rules comprise over-riding maintenance and production rules.

32. The method of claim 22, further comprising the steps of transmitting information to and receiving instructions from an interface means for presenting information to an operator and for receiving input from operator.