Robotics and Computer-Integrated Manufacturing 31 (2015) 1–10

Contents lists available at ScienceDirect

Robotics and Computer-Integrated Manufacturing

journal homepage: www.elsevier.com/locate/rcim

A complete CAD/CAM/CNC solution for STEP-compliant manufacturing

Wenlei Xiao n, Lianyu Zheng, Ji Huan, Pei Lei
School of Mechanical Engineering and Automation, Beihang University, 100191 Beijing, China

art ic l e i nf o a b s t r a c t

Article history: STEP-NC or ISO 14649 is the next generation of data models between CAD/CAM and CNC systems. After a
Received 30 October 2013 decade of investigation, the STEP-NC technology is still under developed. The lack of a complete CAD/
Received in revised form CAM/CNC prototype system with full bidirectional data flow hinders the improvement of STEP-NC. This
23 June 2014
paper proposes a complete CAD/CAM/CNC solution for STEP-compliant manufacturing, so as to explore
Accepted 23 June 2014
Available online 23 July 2014
the functionalities and emphases of STEP-NC technologies. Frameworks of individual CAD/CAM and CNC
systems are illustrated in detail. Architectures of STEP-compliant CAD/CAM and CNC systems are studied
Keywords: and several criteria are summarized. Finally, this paper proposes a complete prototype STEP-compliant
STEP-NC solution, which consists of a secondary developed STEP-compliant CAD/CAM system on the CATIA
CAD/CAM
platform and an open structured STEP-compliant CNC system.
CNC
& 2014 Elsevier Ltd. All rights reserved.

1. Introduction
Since the 1950s, CNC systems have become the kernel devices of
machine tools. With the advancement of information technology,
CNC hardware and software systems have been rapidly promoted
[1]. However, the programming interface between CAD/CAM and
CNC systems has remained almost unaffected for a long time until
the emergence of STEP-NC [2]. STEP-NC, namely ISO 14649 [3],
provides a new data exchange interface between CAD/CAM and
CNC systems and is considered as the next generation of CNC
programming languages. The STEP-NC standard defines not only the
tool path data model but also other related process and resource
data models for the use of object-oriented manufacturing tasks.
In order to realize the STEP-NC concept, both of the CAD/CAM
and CNC systems have to be updated. Essentially, the seamless
connection of STEP-NC needs a powerful STEP-NC post-processor in
CAD/CAM and a stable STEP-NC interpreter in CNC. A CAD/CAM
system with STEP-NC post-processor is usually called STEP-
compliant CAD/CAM system. Similarly, a STEP-compliant CNC
(STEP-CNC) means a CNC controller which takes STEP-NC as input
and controls the machine tool motion [1]. Although it is one of the
main motives to replace the conventional G/M codes, the vision of
STEP-NC is not just for providing a modern programming language.
Inspection data definitions (ISO 14649-16) enable a reverse data
flow from a STEP-CNC system back to a STEP-compliant CAD/CAM
system [4], so as to construct a close-loop machining system [5].
Since 2001, STEP-NC has been enhanced and attracted large
amounts of research interests. However, until recent years there has
been very little practical use of STEP-compliant CAD/CAM and STEP-
CNC systems. The inevitable challenge and complexity of STEP-NC
implementation make it hard to be accepted by both CAD/CAM and
CNC vendors [6]. Hence, the process of replacing G/M codes with
STEP-NC is delayed, and the feasibility of STEP-compliant systems is
doubted by many researchers and engineers. Although there have
been many researches on STEP-compliant CAD/CAM [7,8] and STEP-
CNC systems [9,10], they are essentially individual rather than collabo-
rative work. We consider that the recent bottleneck of STEP-NC is the
lack of a complete CAD/CAM/CNC solution, so that many of the
advanced functionalities of STEP-NC cannot be revealed, such as intel-
ligent control, tool path regeneration, and close-loop manufacturing.
In this paper, we summarize a variety of frameworks and
criteria for establishing STEP-compliant systems. Afterwards, we
introduce a secondary developed STEP-compliant CAD/CAM sys-
tem, and a STEP-CNC system with complete NCK (Numeric Control
Kernel) and PLC (Programmable Logical Control) functions. Com-
bining these two STEP-compliant systems together, a complete
CAD/CAM/CNC solution for STEP-compliant manufacturing can be
obtained. In this solution, the STEP-NC data flow can be fully
realized without a reluctantly developed STEP-NC to G codes
convertor [2]. Many STEP-NC functionalities have been implemen-
ted, including feature-based tool path regeneration and close-loop
machining. Though the proposed STEP-compliant CAD/CAM and
CNC systems are still on the prototype stage, they have expectable
capabilities to control a future intelligent machine tool.
2. Frameworks for implementing STEP-compliant
CAD/CAM/CNC systems

n
Corresponding author. STEP-NC requires complete improvements inside CAD, CAM
E-mail addresses: w.xiao@pku.edu.cn, xiaowenlei@me.buaa.edu.cn (W. Xiao). and CNC systems. Fig. 1 depicts a bidirectional STEP-NC data flow

http://dx.doi.org/10.1016/j.rcim.2014.06.003
0736-5845/& 2014 Elsevier Ltd. All rights reserved.
2 W. Xiao et al. / Robotics and Computer-Integrated Manufacturing 31 (2015) 1–10
Fig. 1. The bidirectional STEP-NC data flow between STEP-compliant CAD/CAM and
CNC systems.
between a CAD/CAM system and a CNC system. In the bidirectional
data flow, the exchange data should be defined using the object-
oriented modeling method, and no data leakages are allowed on
the CAD-CAM-CNC data chain. Consequently, the STEP-compliant
CAD/CAM system should have a STEP-NC post-processor and a
feature-oriented STEP-NC kernel, while the STEP-CNC system
should have a STEP-NC code parser and some intelligent functions
to support STEP-NC operations. Both of them are able to import
and export related data in STEP-NC format.
2.1. Feature-oriented CAD/CAM system
The feature-oriented STEP-NC data in the STEP-compliant CAD/
CAM system can be managed in three ways, which are subject to
three CAD/CAM frameworks respectively [11]:

A CAD/CAM system which imports and exports STEP-NC data.

A CAD/CAM system with STEP-NC data support structures.

A CAD/CAM system with kernel STEP-NC data structures.
The first framework only provides a CAD/CAM system with the
capability to map the ISO 14649 output and input to its native
geometric and manufacturing features. The second framework is
integrated with an external or internal package to manage the
STEP-NC data. The third framework supports a STEP-NC kernel for
both geometric and manufacturing data models, so that it can be
considered as the highest level of frameworks with STEP-NC
compliance. For actual implementations, it requires considerable
time and efforts to develop a brand new CAD/CAM system with
the highest level of compliance, while it has great functional
limitations to develop a STEP-NC post-processor. Besides, many
commercial software systems, like CATIA, Pro-E, SolidWorks, can
provide most of the necessary CAD/CAM functions. Therefore, the
second framework becomes popular, which means to embed a
secondary developed STEP-NC package into a mature CAD/CAM
system.
In this paper, we propose the system structure of a STEP-
compliant CAD/CAM system developed in the CATIA environment.
Unlike many other stand-alone STEP-compliant CAD/CAM systems
[7,8], the developed system provides a more flexible and inter-
active environment for STEP-NC manipulations. In addition, the
ISO 14649 data is remedied with AP203 representations, so that
the STEP-CNC system will have abundant geometric data to
represent the manufacturing project in a 3D viewer. Fig. 2 demon-
strates the structure diagram of the proposed CAD/CAM system.
The CAD/CAM system consists of five main function-blocks, each
of which deals with some certain issues in a STEP-compliant CAD/
CAM system.
(1) Feature definition block: The use of features is a magnificent
contribution of the STEP-NC technology. It can combine geometric,
process planning and manufacturing data into one unitive entity.
Therefore, it becomes more apt to represent a manufacturing
project with some manufacturing terms (hole, boss, pocket, etc.)
instead of the CSG (Constructive Solid Geometry) entities that are
widely used in contemporary CAD systems for solid modeling.
Thus, it is a major function in the feature definition block to
remedy this lack of consensus.
In previous CAD/CAM researches, two feature generation
approaches, designed by features and feature recognition, have
been mostly used [12–14]. The first approach can be only imple-
mented in a newly developed CAD/CAM system. So only the
second approach is worth considered in a secondary developed
system. Nonetheless, recognition of interactive STEP-NC features is
much more complex than prior cases, since not only geometric but
also manufacturing information has to be added into the newly
generated features. The mixture of multiple aspects in a feature
entity causes ambiguous interpretations during the feature recog-
nition process. For example, a hole can be recognized as either a
drilling hole or a boring hole contingent upon the hole size and
related cutting technologies. Sometimes, this kind of feature
determination can be only mastered by a skilled engineer.
In view of the above analysis, the STEP-NC feature definition
block uses an elementary yet reliable method for feature genera-
tions. That is to manually define the feature with its geometric and
manufacturing parameters. By this way, the required STEP-NC
features are clearly instantiated and further manipulated in the
process planning block.
(2) Process planning block: The process planning block gener-
ates process related STEP-NC entities. As the core function block of
a STEP-compliant CAD/CAM system, it provides a STEP-NC
mechanism to plan the manufacturing process. The process plan-
ning tasks are categorized into high-level and low-level.
The high-level process planning handles with the major man-
ufacturing entities, such as project and workingstep and workplan.
In addition, it provides some functions to regulate the interrela-
tionships among those defined entities, for example optimizing
the execution order of massive workingsteps.
The low-level process planning defines the rest necessary data
models involved in a machining operation, including manufactur-
ing operation and resource definitions. Operation definitions
(strategy, technology, tool path, etc.) indicate how a workpiece is
made, while resource definitions (cutting tool, probing tool, etc.)
provide necessary information to generate a machining operation.
All the process planning functions have to be developed from
scratch, as no similar definitions have been implemented in the
CATIA environment.
(3) Data exchange block: A STEP-compliant CAD/CAM system
should have the capabilities to export and import STEP-NC codes.
It is important to exchange the NC data in an ISO 14649 manner, so
that the lack of consensus can be avoided. The exported STEP-NC
codes contain feature, process and resource data that are inter-
related in a manufacturing project, while the imported STEP-NC
 W. Xiao et al. / Robotics and Computer-Integrated Manufacturing 31 (2015) 1–10 3

Manufacturing feature
3D model design New project creation
definition

ISO 14649-10

hole plane slot Workpiece

definition
Attributes
pocket definition
surface ...
AP 203 / AP 224

2
High-level process Low-level process
planning planning
Workplan
creation Operation Resources
definition definition
Workingstep
creation
its_secplane
strategy
technology

...

probing_tool
its_feature
cutting_tool

...
toolpath

Sequence STEP-NC data exchange

optimization

STEP-CNC
P21 File P28 File

Reverse optimization ARM AIM EB LB

Procedure
optimization

Operation Resource
Inner connection
optimization optimization ARM : Application Reference Model
AIM : Application Integrated Model
EB : Early Binding
4 3 LB : Late Binding

1 Feature definition block 2 Process planning block

3 Data exchange block 4 Off-line closed-loop manufacturing block

Fig. 2. Framework of the proposed STEP-compliant CAD/CAM system.

codes contain measured and probed data which are also con- (4) Off-line closed-loop manufacturing block: One of the advan-
structed in STEP-NC format. tages in using STEP-NC is the support of closed-loop manufactur-
Generally, nearly all the proposed STEP-compliant CAD/CAM ing. Reverse processing block deals with the off-line closed-loop
systems have proposed ISO 6983 exporters in parallel, so as to optimization using feedback process data that are imported from a
connect conventional CNC controllers that accept G/M codes. STEP-CNC system. The optimization process consists of three
However, G/M codes exportation disobeys the intent of STEP-NC, phases, which are procedure optimization, operation optimization
which causes information loss during the post-processing process and resource optimization. Those three levels of optimization
and hinders the realization of intelligent manufacturing. This conform to the object-oriented and top-down design concepts of
reluctant solution is mainly due to a lack of real STEP-CNC systems STEP-NC [18].
that are able to accept ISO 14649 codes as their machining Procedure optimization calculates global optimizing results for
instructions. With the development of STEP-CNC technologies, workingstep executing sequences. Operation optimization adjusts
this transitional solution will become unnecessary. corresponding manufacturing strategies and technologies, which
Using a reverse post-processor, the STEP-compliant CAD/CAM will afterward affect the tool path regeneration in the CAD/CAM
system is able to translate the imported data into its intrinsic system. Resource optimization adjusts the resource parameters
geometric and manufacturing data. The imported data contain that are used in former manufacturing operations and not well
essential information for closed-loop manufacturing. Recently, the suited.
most attended reverse manufacturing data are the probing based
inspection [15], as described in the current draft of ISO 14649-16 2.2. Intelligent STEP-CNC system
(Data for touch probing based inspection) [16]. However, there are
not merely inspected data that should be fed back to the CAD/CAM Since the emergence of STEP-NC in 2001, there has existed a
system. The closed-loop manufacturing needs to consider its long-standing negative view of the STEP-NC technology. The
feedback as more generalized process data, such as inspection, conventional CNC system is considered as powerful enough to
chatter, cutting force, servo drive signal, and machine tool cap- handle with most of the machining tasks, so that STEP-NC is
abilities [15,17]. unnecessary. In fact, this viewpoint has misread the vision of
4 W. Xiao et al. / Robotics and Computer-Integrated Manufacturing 31 (2015) 1–10
STEP-NC on the next generation of intelligent control. In spite of
that, without the support of STEP-CNC instances, this debate
would still persist for a longer time. In this regard, the lack of
STEP-CNC controllers has been considered as a major hindrance to
the popularization of STEP-NC. Currently, very few STEP-CNC
prototypes have been developed and commercial CNC controller
vendors seem to have limited interests in promoting STEP-CNC
technologies, though many researchers have pointed out that it
will be a future drawback to CNC vendors who do not follow the
new standard. Fortunately, the development of open-CNC tech-
nologies provides another option to develop STEP-CNC prototypes
[19,20]. It becomes technically feasible to develop an intelligent
STEP-CNC system based on the open-CNC architectures.
According to the way how STEP-NC is implemented, future
STEP-CNC systems are categorized into three classes [1]:

STEP-CNC with conventional control, which simply incorporates
ISO 14649 in a conventional controller via post processing.

STEP-CNC with new control, which has a STEP-NC interpreter
and can execute motions based on the machining strategies
and sequences defined in a ISO 14649 program.

STEP-CNC with new intelligent control, which is able to per-
form NC tasks intelligently and autonomously based on com-
prehensive information of ISO 14649.
The first type of STEP-CNC system is a transitional scheme before
conventional CNC systems get eliminated. It only uses the STEP-NC
format to define tool path data, thus most advantages of STEP-NC
have not been revealed. Basically, it can only be considered as a
CNC controller that can parse “G-code” in STEP-NC format.
Therefore, a real STEP-CNC system has to be established, which
can fully parse feature-based STEP-NC codes and execute some
tool path generating and intelligent manufacturing functions
[10,21]. However, due to the great developing workload and some
technical difficulties, very few STEP-CNC prototypes fall into the
second category, and until recently no third type of STEP-CNC has
been developed. The lag of STEP-CNC implies a fact that, without
the support of commercial CNC vendors, it is difficult to develop a
practically useful intelligent STEP-CNC system.
In order to facilitate the development of STEP-CNC, criteria
have to be addressed concretely, considering both requirements
from CAD/CAM systems and CNC controllers. Therefore, we sum-
marize some criteria for developing an intelligent STEP-CNC
system, where criteria (1)–(5) are for the need of CAD/CAM and
(6)–(10) are for the need of CNC.
(1) STEP-NC interpreter: The STEP-NC interpreter is a standard
component in an intelligent STEP-CNC system to accept ISO 14649
programs. Correspondingly, feature-oriented objects are imple-
mented inside. It is important that the interpreter is strictly
compliant with the ISO 14649 standard, so that the “Made once
and run anywhere” (MORA) concept of STEP-NC can be realized.
(2) STEP-NC executor: STEP-NC requires the motions of a
machine tool to be faithfully executed according to machining
strategies and workingstep sequences that are specified in a ISO
14649 program. The STEP-NC executor tries to accomplish this task
and avoid misunderstanding the manufacturing intent designed
previously in a STEP-compliant CAD/CAM system.
(3) Tool path generation: According to the definition of ISO 14649,
toolpath is an optional attribute of a workingstep. Thus, a STEP-CNC
system should be able to generate the tool path data in an ISO 14649
manner. With an integrated tool path generator, machine tool users
can locally and instantly regenerate the tool path when they want to
change some related machining parameters. In this way, the STEP-
CNC system possesses a flexible manufacturing capability.
(4) 3D STEP-NC viewer: Normally, a feature-based and object-
oriented STEP-NC program contains much more information than
conventional G-code. Except for tool path data, it contains feature
data for workpiece, process data for manufacturing strategies and
technologies, resource data for related auxiliary devices (cutting
tool for example), etc. Because of the extremely abundant infor-
mation it carries, a STEP-NC program is friendly for computerized
processing instead of human reading. Therefore, some auxiliary
tools are needed to help people understand the STEP-NC program.
Since many entities have their geometric aspects, it becomes
necessary to develop a 3D viewer to present the STEP-NC
information.
(5) E-manufacturing ability: The conventional manufacturing
process is limited in a sole CAD/CAM/CNC system, while the STEP-
NC technology enables a distributed and networked manufactur-
ing process. The support of XML (STEP-XML) gives a STEP-CNC
system the capabilities to access STEP-NC data through network.
(6) Interaction of STEP-NC info: The object-oriented structure of
STEP-NC data makes it possible to edit the machining parameters
on a STEP-CNC controller. Practically, an intelligent STEP-CNC
controller must provide users the possibility to interact with the
controller. STEP-NC data are then read, edited and updated directly
on the Man–Machine Interface (MMI) of a STEP-CNC system.
Flexible manufacturing is thus realized.
(7) On-line closed-loop manufacture: On-line closed-loop man-
ufacture means that the feedback information is collected and
processed on a CNC controller rather than uploaded to a CAD/CAM
system. In contrast to off-line closed-loop manufacture, on-line
closed-loop manufacture reduces the periods number of the
closed-loop optimization, so as to obtain a faster response. For
example, a CNC controller can determine the machining errors by
machining features and inspection data, and immediately con-
struct a fine machining workingstep for the following machine
tool motion.
(8) Sensor-based manufacture: An intelligent STEP-CNC system
must support sensor feedbacks. In order to make efficient use of
sensors in machine tools, future CNC controllers need to change
their machining parameters or trajectories in real time according
to the sensor signals and events [22,23]. In this case, tool paths
become volatile and need to be on-line computed. This advanced
technology requires a reconfigurable sensor network in advance.
Hence, both the software and hardware architectures of an
intelligent STEP-CNC system have to be improved.
(9) Open-CNC architecture: The open-CNC architecture is note-
worthy during the implementation of an intelligent STEP-CNC
system. Many intelligent machining functions are so complicated
that they need to be developed on a universal PC platform, which
means the conventional CNC system with a hardware-based
customized structure is unfitted for establishing an intelligent
STEP-CNC system. A CNC system mainly consists of three key
components: man–machine interface (MMI), programmable logi-
cal controller (PLC) and numerical control kernel (NCK). Until
recently, the technology of a fully PC-based industrial controller
with a soft MMIþPLC þNCK structure has been tending to mature,
and commercial products have also emerged. In this regard, it is
encouraged to develop an intelligent STEP-CNC based the open-
CNC architecture.
(10) Reconfigurable control network: As indicated in criterion (8), a
reconfigurable control network is important for constructing the
hardware architecture of an intelligent STEP-CNC system. The current
best solution is an industrial Ethernet fieldbus. Using the industrial
Ethernet, it is convenient to reorganize the network structure.
3. Developing a STEP-compliant CAD/CAM system
As a part of the integrated STEP-compliant systems proposed in
the previous section, a STEP-compliant CAD/CAM system which
 W. Xiao et al. / Robotics and Computer-Integrated Manufacturing 31 (2015) 1–10 5

ENTITY manufacturing_feature (* m1 *)
ABSTRACT SUPERTYPE OF (ONE OF(region, Workplan
project
two5D_manufacturing_feature, transition_feature)); Top milling -top milling
its_id: identifier; |-security plane
its_workpiece: workpiece; Security plane
its_operations: SET [0:?] OF machining_operation; Plane milling |-plane milling
END_ENTITY; technology |-technology
ENTITY two5D_manufacturing_feature (* m1 *)
ABSTRACT SUPERTYPE OF (ONE OF(machining_feature, function |-function
replicate_feature, compound_feature)) strategy |-strategy
SUBTYPE OF (manufacturing_feature); -top inspecting
Top inspecting
feature_placement: axis2_placement_3d;
END_ENTITY; Drilling -drilling
ENTITY machining_feature (* m1 *) Boring -boring
ABSTRACT SUPERTYPE OF (ONE OF(planar_face, pocket, slot,
Step,Round_hole, toolpath_feature, Profile_feature, Hole inspecting -hole inspecting
boss, spherical_cap, rounded_end, thread)) Pocket rough milling -pocket rough milling
SUBTYPE OF (two5D_manufacturing_feature); Pocket pre-inspecting -pocket pre-inspecting
depth: OPTIONAL elementary_surface;
Pocket fine milling -pocket fine milling
END_ENTITY;
ENTITY pocket (* m1 *) Pocket post-inspecting -pocket post-inspecting
ABSTRACT SUPERTYPE OF (ONEOF(closed_pocket, open_pocket))
SUBTYPE OF (machining_feature);
its_boss: SET [0:?] OF boss;
slope: OPTIONAL plane_angle_measure;
bottom_condition: pocket_bottom_condition;
planar_radius: OPTIONAL toleranced_length_measure;
orthogonal_radius: OPTIONAL toleranced_length_measure;
END_ENTITY;
ENTITY closed_pocket (* m1 *)
SUBTYPE OF (pocket);
feature_boundary: closed_profile;
END_ENTITY;

Fig. 3. Definition of the entity pocket using EXPRESS language.

Defining working_step Defining cutting_tool

Fig. 5. Process planning block. (a) High-level process planning. (b) Low-level
process planning.

Fig. 4. Create a pocket feature in the STEP-compliant CAD/CAM system.

blocks. According to the framework described in Section 2, all the

could process STEP-NC manufacturing information and export
STEP-NC programs is presented in this section. The system was
developed as a plug-in component into the CATIA environment.
Until recently, CATIA has been widely used as an excellent
secondary development platform for CAD/CAM applications. It
provides a number of powerful functions and four approaches
to access secondary developments, including Automation API
(Application Programming Interface), Knowledge Ware, Interactive
User Defined Feature and CAA (Component Application Architec-
ture). This paper adopts CAA (V5, C þ þ) as the main programming
method for it has the best performance of integration, function-
ality and efficiency. CAA functions in an object-oriented program-
ming manner, especially relies on COM (Component Object Model)
and OLE (Object Linking and Embedding) technologies [24].
3.1. Feature definition
In the current STEP-compliant CAD/CAM system, the STEP-NC
feature definition block is the foundation of all other function
manufacturing features are defined manually. Here we propose an
example for defining a pocket feature.
As referenced from ISO 14649-10, the pocket entity is defined
as Fig. 3. At first, the feature is defined as a closed pocket with its
attributes (its_id, its_workpiece and its_operations) automatically
assigned by default. Then, the feature_placement attribute is
determined by a user-given coordinate system. Afterwards, by
selecting a set of related geometric elements, the attributes depth
and feature_boundary are determined. The boss attribute needs to
be manually given by the user if any boss feature exists. Since the
boss feature is an optional attribute, it is set to null as default.
Detail parameters (slope, planar_radius and orthogonal_radius),
which are correlative to a pocket, are specified by selecting the
corresponding dimension labels on a CAD model (as shown in
Fig. 4). At last, the attribute bottom_condition is manually given as
planar_pocket_bottom_condition. Fig. 4 shows the result after
defining the pocket feature.
Here, we would like to point out that the manual mechanism of
feature definition is not the most efficient way on all conditions.
6 W. Xiao et al. / Robotics and Computer-Integrated Manufacturing 31 (2015) 1–10

Sometimes, it is more suitable to combine both feature definition

and recognition for some complex features. For example, it is
Paths
believed as possible to automatically recognize attributes after
Inspecting path.1 the feature is preliminarily defined as a closed pocket and all
correlative geometric elements or facets have been selected. This
View.1
mechanism will be studied in future researches.
Inspecting path.2

View.2
3.2. Process planning
Inspecting path.3

View.3
The process planning block is a core component in the proposed
system, containing both the high-level and low-level process
Inspecting path.4 planning functions. The high-level process planning is to create
a workplan and its sequenced workingsteps. A workingstep can
View.4
be either a milling, drilling, boring or inspecting task. All the
workingsteps will be executed one by one in sequence. Fig. 5
(a) demonstrates the tree structure of a workplan and its working-
steps. The low-level process planning is to define the detail
parameters of each workingstep. The major parameters of a work-
ingstep entity are its_secplane, its_feature and its_operation. The
attribute its_secplane is determined by selecting an existing plane,
and the attribute its_feature is set by choosing an existing feature
defined by the feature definition block. The attribute its_operation
is defined in a dialog as shown in Fig. 5(b) (defining working_step).
Involved operation attributes include approach&retract planes,
cutting tool, strategy, technology, function, toolpath, etc., wherein
some of them can be automatically generated (for example the
toolpath). Therefore, most efforts of the low-level process planning
are made to define the attribute its_operation. In this paper, we
further divide the defining tasks into operation definition and
resource definition. The operation definition provides the process
information to a machining operation, while the resource definition
provides the resource entities used in the operation. As shown in
Fig. 6. Off-line close-loop manufacturing. (a) Theoretical inspecting point gener- Fig. 5(b), the user can create a workingstep and a cutting tool by
ated by CAD/CAM. (b) Measured inspecting point probed by CNC. using corresponding dialogs.

ISO-10303-21;
HEADER;
FILE_DESCRIPTION((''),'1');
FILE_NAME('D:\casestudy','2013/9/10','Administrator','MICROSOF-1DE82C of BUAA720-513',$,'ISO
14649',$);
FILE_SCHEMA(('INSPECTION_SCHEMA'));
ENDSEC;
DATA;
#1=PROJECT('EXECUTE EXAMPLE1',#4,(#2),$,$,$);
#2=WORKPIECE('SIMPLE WORKPIECE',$,$,$,$,#3,($));
#3=BLOCK('Rectangular Block',$,100.2,120.2,50.2);
#4=WORKPLAN('Main Workplan',(#5,#15,#32,#42,#52,#73,#83,#105,#115),$,$,$);
#5=MACHINING_WORKINGSTEP('Top milling',#6,#,#7,$);
#6=PLANE('secplane.1', $);
#7=PLANE_FINISH_MILLING($,$,'FINISH PLANAR FACE1,10,$,#8,#12,#13,0,$,$,#14,2.5,0);
#8=MILLING_CUTTING_TOOL('',#9,(#11),,$,$);

ENDSEC;
END-ISO-10303-21; P21 Code
<?xml version="1.0" encoding="GB2312" ?>
<STEP-XML>
<PROJECT name="PROJECT" id="id1">
<its_id name="identifier">'EXECUTE EXAMPLE1'</its_id>
<WORKPIECE name="WORKPIECE" id="id2">
<its_id name="identifier">'SIMPLE WORKPIECE'</its_id>
<BLOCK name="BLOCK" id="id3">
<its_id name="identifier">'Rectangular Block'</its_id>
<its_length name="length">'100.2'</its_length>
<its_width name="width">'120.2'</its_width>
<its_height name="height">'50.2'</its_height>
</BLOCK>
<Main_Workplan name="WORKPLAN" id="id4">
<Machining_Workingstep name="Plane milling" id="id5">
<its_id name="identifier">'Plane milling'</its_id>
<its_secplane name="SECPLANE" id="id6">
<its_secplane_id name="identifier">'Security plane 1'</its_secplane_id>
</its_secplane>
<its_operation name="PLANE_FINISH_MILLING" id="id7">

</STEP-XML> P28 Code

Fig. 7. Data exchange.

 W. Xiao et al. / Robotics and Computer-Integrated Manufacturing 31 (2015) 1–10 7

+24V
In Out +5V

Spindle 0 0
Coolant 1 1 Digital
+5V
Air pressure 2 2
STEP-NC program Door 3 3
Sync manager
Light 4 4
Emergency 5 5 D/A
Real time Analog
STEP-NC interpreter arrangement Axis limits 6 6
Lubrication 7 7 A/D

STEP-NC memory structure PLC mapping PLC

STEP-NC execuator PLC-IO

Process planning Machine functions

Look ahead
X axis X axis PID D/A
Manufacturing feature
Tool path generator acc/dec
FI
Position feedback
Y axis Y axis
acc/dec Ring PID D/A
FI
Ring buffer
Z axis Z axis Position feedback
buffer Ring
acc/dec FI
buffer PID D/A
Acceleration & Fine interpolation
Fine interpolation
Deceleration buffer
Tool path buffer Position feedback

Look ahead buffer

MMI NCK Servo Motor

PC-based CNC

MMI+PLC+NCK PLC-IO, Sensors and Servo motors

Software based Hardware based

Fig. 8. System architecture of the STEP-CNC prototype.

3.3. Off-line closed-loop manufacturing
The off-line closed-loop manufacturing function is established
based on the bidirectional data flow. The probing inspection task is
a typical application [25]. Fig. 6 presents a touch probing inspec-
tion example. Fig. 6(a) shows the probing points generated by the
STEP-compliant CAD/CAM system, and (b) shows the comparison
between theoretical and measured points. This kind of informa-
tion can be further used as a reference for the optimization
process.
3.4. Data exchange
STEP-NC programs could be generated and exported after
process planning. The exported STEP-NC files can be formatted
either in P21 (clear text) or P28 (XML), as shown in Fig. 7. The P28
format is specified in ISO 10303-28. It uses the Extensible Markup
Language (XML) to represent EXPRESS schema and STEP data.
Using the XML format, it is convenient to represent and exchange
STEP-NC data. Since many mature XML parsers have been devel-
oped, people have no need to spend too much time and effort on
the SDAI (Standard Data Access Interface) technology for a P21
parser. Moreover, the use of XML also helps to exchange data
via the Internet, so that an e-Manufacturing network can be
constructed.
4. Developing a STEP-compliant CNC system
This section proposes a prototype STEP-CNC system with the
above mentioned framework. A fully PC-based CNC system is
realized by means of soft-PLC and soft-NCK technologies. There
are a number of resources available on a PC platform for imple-
menting the PC based CNC system. However, the poor real-time
performance of the PC platform is a major impediment to this
purpose. This problem has hindered the development of open-CNC
for a long time until industrial control was greatly promoted by
the fast-growing IT technologies in recent years. Many innovative
techniques, such as industrial PC (IPC), industrial Ethernet, com-
pilers, have been gradually introduced into the industrial control
field. Some commercial products have also come out, among
which the TwinCAT platform is considered as one of the most
prominent. A soft-PLC that conforms to the IEC 61131-3 standard
8 W. Xiao et al. / Robotics and Computer-Integrated Manufacturing 31 (2015) 1–10
Coordinates panels
STEP-NC program structure STEP-NC 3D Viewer
- project
- workingstep
- security_plane security_plane
- feature
- operation
approach_plane
reference_plane
profile_length
STEP-NC Data Viewer
Control Panel
STEP-CNC Interface
Machine functions
Operation
Fig. 9. STEP-CNC MMI.
(CoDeSys) is integrated in the TwinCAT system. In the CoDeSys
environment, a soft-NCK kernel can be then developed [26].
4.1. Architecture
Fig. 8 shows the architecture of the prototype STEP-CNC
system, consisting of both software and hardware aspects. In order
to establish an open-structured and reconfigurable hardware
platform, the EtherCAT bus is adopted for connecting servo motors
and PLC-IOs. EtherCAT is a fast industrial Ethernet technology,
which can support a synchronized cycle time up to 100 μs. More-
over, sensor and actuator devices from different vendors can be
seamlessly integrated together, as long as they have the EtherCAT
interfaces. The fast, open and reconfigurable characteristics of
EtherCAT can perfectly fulfil the demands of STEP-CNC, as afore-
mentioned in Section 2. Using the IPC technology, it is possible to
develop a fully software based CNC system (soft-CNC), including
MMI, PLC and NCK. The soft-CNC architecture provides open and
portable CNC packages for machine tool integrators, so that a
minimal effort need to be undertaken when adjusting the CNC to
different machine tools. Besides, there is no need to replace any
devices on the master side. Usually, MMI processes the interaction
between humans and machines, PLC deals with multiple inputs
and output arrangements (including both digital and analog IOs),
and NCK provides the necessary functions for motion controls. For
a STEP-CNC system, most of the STEP-NC related functions are
implemented in MMI. Hence, comparing to conventional CNC
systems, the MMI of STEP-CNC is much more powerful and
complex. Besides, MMI has become not only an interaction inter-
face, but also an STEP-NC data processing center.
MMI is a major difference between conventional and STEP-
compliant CNC systems. In view of this, we will discuss the MMI of
STEP-CNC in detail, whereas PLC and NCK of STEP-CNC are not in
the scope of this article.
cutting_ tool 4.2. MMI of STEP-CNC
The MMI of the proposed STEP-CNC system is presented in
distance
Fig. 9. It contains a STEP-NC data viewer and a STEP-NC 3D viewer
toolpath for processing and displaying the imported STEP-NC data.
workpiece The STEP-NC data viewer provides a concise way for the STEP-
NC interaction between users and machines. It interprets a STEP-
NC program and manages information in an object-oriented
manner (as shown in Fig. 9). A STEP-NC program has at least one
workplan, which contains many workingsteps, and each working-
step consists of three primary attributes: security_plane, feature
and operation. The detail parameters can be accessed by clicking
on each item, and corresponding dialogs are pulled up, where
parameters can be inquired and edited.
The STEP-NC 3D viewer renders the STEP-NC information in a
3D environment. By this way, various geometric entities can be
visually represented. The displayable data include workpiece,
toolpath, cutting_tool, etc. A tool path generator is implemented
in the prototype STEP-CNC system. Although the generator is still
on the prototype stage, the flexibility of intelligent STEP-CNC has
already revealed by adjusting machining parameters locally on the
CNC system. Fig. 10 presents such an example, in which the tool
path generating function is tested on different conditions. Machin-
ing parameters involved in milling a planar face (security plane,
cutting depth, size of raw piece, approach and retract strategies)
are individually changed. Tool paths are accordingly generated on
line, and simultaneously displayed in the 3D viewer.
4.3. Virtual manufacturing
In order to verify the STEP-NC technologies, a real machine tool
equipped with STEP-CNC is needed. However, it is expensive to
construct a real machine tool. Besides, the difficulty and cost are
usually beyond the abilities of most CAD/CAM and CNC researchers.
In order to solve this problem, the STEP-CNC can be firstly verified in
a virtual manufacturing environment before connected to a real
machine tool. For this purpose, we established a simulated machine
tool and make it virtually controlled by the STEP-CNC controller
through an Ethernet interface. Since the STEP-CNC system was
developed on a IPC platform, it is very easy to share the same LAN
(Local Area Network) port in real and simulated controls. The system
structure is shown in Fig. 11. By switching the Ethernet cable to real
and simulated controls, the STEP-CNC system can be verified.
5. Discussion and conclusion
In order to further popularize the STEP-NC technology, a
complete CAD/CAM/CNC solution is proposed. For a long time,
STEP-compliant CAD/CAM and STEP-CNC systems have been
separately studied. The major contributions in this paper are to
comprehensively study the STEP-compliant systems and summar-
ize their frameworks and criteria. A real STEP-NC data flow
between a STEP-compliant CAD/CAM system and a STEP-CNC
system is developed. Although the systems proposed in this paper
are still on the prototype stage, they are very useful attempts, as
many hardware technologies and software architectures have
been tested. The authors also find that the present most feasible
approach for implementing STEP-NC is to develop a secondary
developed CAD/CAM system and an open structured CNC system.
In our future researches, more detailed STEP-NC technologies will
 W. Xiao et al. / Robotics and Computer-Integrated Manufacturing 31 (2015) 1–10
Fig. 10. STEP-CNC prototype. (a) Change the security plane. (b) Change the cutting depth. (c) Change the size of raw piece. (d) Change approach & retract strategies.
EtherCAT
Real control
LAN Port
Simulated control
STEP-CNC
TCP/IP
Virtual Machine Tool
Fig. 11. Virtual manufacturing.
be studied, such as feature recognition, complex tool path genera-
tion, intelligent sensor-based control, and closed-loop optimization.
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