Closed-Loop Process Control for CAM-Based Machining
Ellistat and TopSolid integrate automated process control into CAM workflows to reduce setup time and stabilize machining quality in industrial production environments.
www.ellistat.com
Ellistat and TopSolid have implemented a native integration between automated process control software and CAM systems, enabling closed-loop machining automation directly from CAM data. The cooperation targets CNC machining workshops seeking reduced setup effort, improved dimensional accuracy, and higher process stability.
Context of the Cooperation
Ellistat develops automated process control (APC) systems for CNC machining, focusing on dimensional control and variability reduction through data-driven compensation. TopSolid provides integrated CAD/CAM software widely used in turning and multi-axis milling environments.
The cooperation addresses a persistent challenge in machining operations: manual setup and adjustment of new parts, which increases lead time, introduces variability, and depends heavily on operator experience. Integrating APC directly with CAM software reduces configuration complexity and enables scalable automation across different machines and part families.
Technical Solution and Responsibilities
The integration is realized through Ellistat’s ELLICAM module, which connects Ellistat APC with TopSolid CAM from version 7.20 onward. TopSolid provides access to native CAM data, including 3D part geometry, machining operations, tool definitions, coordinate systems, and offsets.
ELLICAM extracts this information via standard STEP-based interfaces and transmits it to APC using application programming interfaces (APIs). APC analyzes the data to configure a closed-loop control model without manual parameterization. Based on dimensional measurements of a single machined part, APC calculates compensation values and sends corrections directly to the CNC controller via DNC protocols or CNC APIs. Machine learning algorithms update correction models continuously to account for systematic deviations.
Deployment and Integration
The solution is deployed as a TopSolid add-in combined with Ellistat APC software connected over a standard industrial network. No prior APC expertise is required from CAM programmers. Configuration time for new parts is reduced because toolpaths do not need to be redefined specifically for process control. The system integrates with existing CNC machines used in turning, three- to five-axis milling, and combined machining operations.
Applications and Use Cases
Target applications include high-mix, low- to medium-volume machining, precision components, and production environments with frequent part changes. Typical use cases involve automated first-part conformity, reduction of scrap during startup, and stabilization of dimensional accuracy across batches. These mechanisms support industrial automation strategies and digital infrastructure initiatives in machining workshops.
Results and Expected Impact
According to implementation data, automated extraction of CAM data reduces APC configuration time by approximately 80%, with initial setup times decreasing from several hours to minutes. By basing corrections on measured deviations and closed-loop feedback, the system improves repeatability and reduces reliance on manual adjustments, contributing to predictable quality and improved machine utilization.
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