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310-S USER`S MANUAL

1. e C TL Units Millimeters Inches Eset Software Limits Enabled Disabled Program Timer On OOff Pallet Clamp Required On O Off Lid Fault On O Off Update Parameter Create Parameter Figure 7 1 Location of the Phasing Setup controls Spindle Operation When running the spindle in automatic mode refer to Spindle Control Unit sub section the maximum speed the software will allow is 40 000 RPM however this is not necessarily a safe speed for every spindle and tool Warning Each spindle has different requirements and limits The user should be familiar with the specifications of the spindle and tools before use Before Enabling the Spindle 1 Verify that the air supply is connected to the spindle If the spindle is an air turbine spindle then there should be one air hose connected to the spindle An electric spindle with an air bearing will have two air hoses One of the air hoses will be for the air bearing and the other is for cooling An electric spindle with ceramic bearings will have one air hose connected to it for cooling air Check with the spindle user s guide to ensure all connections are properly setup 2 Verify that the electrical connection between the spindle and the 363 S is secure Starting the Spindle 1 From the CNC Control Panel the spindle is controlled from the Program Tab Click the Enable Spindle button to enable the air supply to the air beari
2. Figure 7 8 Jog Tab 5 Open the protective lid 6 Place the tool into the collet with the working end towards the workpiece pallet mounting area 66 Operation September 2011 VIII Operation a Ifthe tool has a taper place only the widest part of the tool into the collet b Only place the round part of the tool into the collet never the flutes c The automatic collet will pull the tool slightly into the spindle when clamped 7 Clamp the tool using the Clamp Tool button located in the Program Run Tab of the Control Panel The Clamp Too button is in the same location as the Release Tool button 8 Verify that the tool is clamped by pulling lightly on the tool Warning Tools are sharp Do not touch the cutting surfaces of the tool Only handle tools by the taper or the shank 9 Close the protective lid Tool Removal Jog the Z stage away from the pallet Turn off the spindle Verify that the tool is clear of the workpiece and pallet Also verify that the spindle is off Release the collet using the Release Tool button on the Program Run Tab of the Control Panel Figure 7 8 Open the protective lid Remove the tool from the collet DM 2 0 NS Warning Tools are sharp Do not touch the cutting surfaces of the tool Only handle the tool by the taper or the main body 7 Close the protective lid 67 Operation September 2011 Microlution AN VIII Operation Tool Changing
3. September 2011 Microlution IV Software Introduction AA SOFTWARE INTRODUCTION Upon opening the Microlution 363 S CNC Control Software the main interface window is visible as indicated in Figure 4 1 This window is divided into four main panels and a menu bar across the top Each button on the menu bar will open a separate window containing additional functionality The panels in the main interface window are used for direct control of and feedback from the Microlution 363 S CNC machine tool Located within each panel are several tabs as shown in Figure 4 1 A tab can be toggled by pressing the corresponding button at the top of its panel The functionality of each tab as well as each panel is described in this section Also described in this section is the functionality of each control button located within the various tabs of the Microlution 363 S CNC Control Software A step by step set of instructions on how to operate the 363 S machine tool through the CNC Control Software is detailed in the Operation section of this manual The remainder of this section is organized as follows First instructions for how to use the on screen keyboard are given Next the menu buttons and their corresponding windows are detailed Next the four panels are presented and the tabs within each of these panels are described in detail Also included in this discussion is a description of the functionality of each of the buttons within the tabs
4. Subprogram Example 00000 Main program start G90 Set coordinate system to absolute mode G54 Apply workpiece offset 1 G1 F1000 Set linear mode and feedrate X15 Y15 Z10 Move to 15 15 10 M98P0002L2 Call subroutine 0002 twice X15 Y 15 Z10 Move to 15 15 10 M65P0003X2Y3Z5 Call macro 0003 pass parameters X Y Z X 15 Y 15 Z10 Move to 15 15 10 M98P0002L4 Call subroutine 0002 four times X 15 Y15 Z10 Move to 15 15 10 M65P0003X5Y1Z3 Call macro 0003 pass parameters X Y Z XO YO ZO Move to 0 0 0 M30 End program rewind 00002 Subprogram 0002 start G91 Set coordinate system to incremental mode G1 F500 Set linear mode and feedrate X5 Move 5 in x axis X 5 Move 5 in x axis Y5 Move 5 in y axis Y 5 Move 5 in y axis Z 5 Move 5 in z axis Z5 Move 5 in z axis G90 Set coordination system to absolute mode M99 End subprogram call 00003 Subprogram 0003 start G91 Set coordinate system to incremental mode G1 F500 Set linear mode and feedrate Z q126 Move in z axis by negative Z parameter value X q124 Move in x axis by positive X parameter value Y q125 Move in y axis by positive Y parameter value X q124 Move in x axis by negative X parameter value Y q125 Move in y axis by negative Y parameter value Z q126 Move in z axis by positive Z parameter value G90 Set coordinate system to absolute mode M99 End subprogram call 89 Operation Sept
5. 13 Software Introduction September 2011 IV Software Introduction Touchscreen Alignment Procedure Microlution 363 S e Microlution 363 S g A 2 Y rolution Setup New Open Login Admin Update ARA ep Offset Distance To Go Position Panel AXIS CAMERA ERROR STATUS Position mm Velocity mm min Offset mm WEP OFFSETS WARNING status View Panel x 00128 0 0 0000 Tooi t2 _tomer 2 _Too s 25 26 Ina Tool sa Measured Length Diameter A A Y PA MAS 265992 0 0000 0 0000 Normal 3 28 9298 0 0000 0 0000 Normal PROGRAM BART TOOL 4 28 9883 0 0000 0 0000 Normal PATTERN CHANGER Control Panel 5 29 2889 0 0000 0 0000 Normal 6 292962 0 0000 0 0000 Normal On off cedros 7 29 0184 0 0000 0 0000 Normal 1 Clic k to uch the Elo Feedrate 1000 00 mm min Flood Coolant O O 8 29 5364 0 0000 9 0000 Normal 5 a 9 288919 0 0000 0 0000 Normal icon in the system Override 100 Arcont O iho 28 7911 ooo Tomo Normal 11 29 1232 E j Normal z 52 Elo Touchscreen Properties tray on the bottom EJ le singeBlock O Q a 28 0034 Normal right side of the Optionalstop O D o r Spindle Control screen In the pop up Spindle 1 JOG COMBINE OFFS amp CenterDesico Tool MDI TERMINAL SENS ut Panel menu select Align Ea Sat sep Al FoAighMowebitontod Eare
6. M110 3 Robot Door is Open Check Format M110 3 Required Inputs Optional Inputs M110 4 Robot Door is Closed Check Format M110 4 Required Inputs Optional Inputs M112 1 Mandrel Clamp Format M112 1 Required Inputs Optional Inputs M112 2 Mandrel Unclamp Format M112 2 125 Supported G and M Codes September 2011 Supported G and M Codes Microlution LAN Required Inputs Optional Inputs M112 3 Mandrel is Clamped Check Format M112 3 Required Inputs Optional Inputs M112 4 Mandrel is Unclamped Check Format M112 4 Required Inputs Optional Inputs M201 Robot Pulse Sync Format M201 Required Inputs Optional Inputs M202 Robot Pulse Clock Format M202 Required Inputs Optional Inputs M203 1 Robot Data On Format M203 1 Required Inputs Optional Inputs M203 2 Robot Data Off Format M203 2 Required Inputs Optional Inputs M204 1 Robot Load On Format M204 1 Required Inputs Optional Inputs M204 2 Robot Load Off Format M204 2 Required Inputs Optional Inputs M205 1 Robot Enable Load On Format M205 1 Required Inputs Optional Inputs M205 2 Robot Enable Load Off Format M205 2 Required Inputs Optional Inputs 126 Supported G and M Codes September 2011 Microlution IX Supported G and M Codes AN M206 1 Robot Pre Load On Format M206 1 Required Inputs Optional Inputs M206 2 Robot Pre Load Off Format M206 2 Required I
7. VIII Operation G90 G10 L12 P23 R 9 G91 G10 L11 P1 R 0 01 G90 G10 L13 P14 RO 15 G10 L50 P1 RO P35 R24 P952 R 5 P804 R0 09 G11 Set tool 23 diameter offset to 9 Increment tool 1 length compensation by 0 01 Set tool 14 diameter compensation to 0 15 Start user variable setting Set user variable 1 system variable P7000 to O Set user variable 35 system variable P7034 to 24 Set user variable 952 system variable P7951 to 5 Set user variable 804 system variable P7803 to 0 09 End user variable setting 91 Operation September 2011 Microlution VIII Operation AN Conditional Statements The following logic statements are supported the Microlution 363 S The logic statements are valid in sub routines and macro calls only and cannot be used in a main program 1 If condition action If condition Action 1 Action 2 Endif 3 While condition action While condition action Action 1 Action 2 Endwhile 5 GOTO line number If condition action condition consists of one or more sets of expression comparator expression joined by logical operators AND or OR action is a program command With an action statement or statements following on that line it will execute those statements provided the condition is true If the condition is false it will not execute those statements With no statement following on that line if the cond
8. Current Tool Figure 4 8 Dashboard 21 Software Introduction September 2011 Microlution IV Software Introduction LO Control Panel The panel in the bottom right corner of the Main Interface Window is the Control Panel as seen in Figure 4 9 The Control Panel is the primary interface through which the user runs CNC programs and operates the laser and tool changer if available The four tabs in this panel are for program running part patterning laser operation and manual tool changer setup and operation Control Panel On Off Feedrate Feedrate mm min Flood Coolant O O Override Air Coolant O BE 00 Optional Stop O Spindle Control an ES RPM MM Spinde 4 Figure 4 9 Control Panel Program Tab The Program Tab Figure 4 10 is used to run a single pre existing G code program on the 363 S It is also used to control the spindle operation feedrate coolant and program run modes Table 4 2 lists the different buttons located in the Program Tab and the functionality of each button Refer to the Operation section of this manual for a step by step set of instructions for using the Program Tab 22 Software Introduction September 2011 Microlution IV Software Introduction HAN Program Control Panel Feedrate On Feedrate v Flood Coolant O Override Air Coolant O En ea Single Block O Optional Stop gt Spindie Control mo al Spindle 2 1000
9. Example The example does the following operations a Measure a feature at 2 points along X direction to determine the center of the feature along X temporary values during the cycle b Update the value of the G55 Parameter 1 Arbitrarily selected X offset accordingly to center the co ordinate system on the feature c Apply G55 Parameter 1 offset d TakeaZmeasurement at the center e Set the G55 Z offset such that Z 0 is 6mm Parameter 2 Arbitrarily selected above the surface The example starts with the approximate work offsets stored in G54 Parameter 3 Arbitrarily selected and the tool length and diameter stored in tool offset number 2 Parameter 4 Arbitrarily selected At the end of the program the correct work piece offsets are stored in G55 Parameter 1 Arbitrarily selected G56 Parameter 5 Arbitrarily selected and G57 Parameter 6 Arbitrarily selected are used to stored Code G10 L2 P2 X Q2000 G4 P0 01 G10 L2 P2 Y Q2001 G4 P0 01 G10 L2 P2 Z Q2002 G4 P0 01 G54 GO X0 YO G90 G43 H2 G1 Z10 F1000 X 30 measurement 2 8 G65 P9811 X 26 H2 S3 Z10 X30 Z 8 G65 P9811 X26 H2 S4 Z10 X0 YO G4 P0 1 Copy the X offset from G54 Parameter 3 to G55 Parameter 1 L2 P2 corresponds to G55 Parameter 1 Q2000 is the X offset for G54 Parameter 3 Dwell Copy the Y offset from G54 Parameter 3 to G55 Parameter 1 L2 P2 corresponds to G55 Parameter 1 Q2001 is
10. Apply Saved Applies a previously saved program origin as the current program origin First select the desired offset G54 through G59 from the drop down box Next the Save Save Active Origin es as 8 Active Origin button will save the active origin as the selected offset The Save to File button will save all of the offsets G54 through G59 to a user selected file Save To File a a This allows multiple origin offsets to be saved for later use Retrieve From File Retrieves a set of saved program offsets G54 through G59 from the saved file Set New Program Updates the active program origin with the values next to the selected X Y or Z buttons If enabled Orange the active origin will be updated with the number next to this button when the Set New Program button is pressed 41 Software Introduction September 2011 Microlution IV Software Introduction HAN If enabled Orange the active origin will be updated with the number next to this button when the Set New Program button is pressed If enabled Orange the active origin will be updated with the number next to this button when the Set New Program button is pressed Sensor Tab Tool Sensor option required The Sensor Tab shown in Figure 4 27 is used to perform an automated tool sense routine There are buttons for both a tool length sense and a tool diameter sense When the operations are finished the re
11. Note To set the zero plane using this method the tool will touch the surface and remove some material If surface finish is critical it may be best to use the fixture as the zero reference and then move the tool out the thickness of the part and reset the zero After many iterations the fixture will need to be resurfaced because many small holes lt 10um will have been machined by the multiple zero setting operations Note Be sure to move the tool back far enough to clear the part before zeroing the other axes or starting a program run to prevent tool breakage or part damage Hint By adjusting the lighting so that a shadow is cast by the tool onto the work piece Figure 7 22 the distance between the tool and its shadow is a good indication of how far the tool is from the work piece Similarly with the proper camera location in reflective material the tools reflection can be seen in addition to the tool As the tool gets closer to the surface the tool and its reflection will get closer The two will appear to be touching when the tool is touching the surface Figure 7 22 The tool and its shadow 103 Operation September 2011 Microlution Vill Operation LM Using the Handheld Pendant Select the MDI Tab within the Input Panel of the Main Interface Window 2 Click the Enable Handwheel Button This will allow the user to manually adjust each stage along a coordinate axis by using the handheld pendan
12. Part Pattern Figure 7 29 Part Pattern Tab 3 Use the Browse button to find the NC program for the Y Click the Add button to add it to the sequence Use the Browse button to find the NC program for the Click the Add button to add it to the sequence Click the Combine button to create the combined NC program which will be displayed in the G code Tab of the View Panel 4 Set the start and end index Start Index 1 1 End Index 2 5 5 Change to the Program Run Tab to enable the spindle set its speed and start the spindle Change back to the Part Pattern Tab and click the Start button to start the machining process 140 Appendix A September 2011 Microlution Xl Appendix A AN Legacy Cleaning Maintenance Filter Bag Inspection The coolant filter is located at the rear of the machine The coolant filter bag should be inspected once a month under typical use Under heavy use or in processes that create a large quantity of chips the filter should be inspected more frequently To inspect the filter bag remove the filter housing lid by unfastening the C clamp Remove the lid and inspect the filter bag If the filter bag is full it needs to be replaced Filter Bag Replacement 13 Remove the lid of the filter housing 14 Drain the coolant by placing a pan or bucket under the coolant housing and unscrewing the drain stopper at the bottom of the housing 15 After all the coolant has been drained remove the filter bag by
13. Target RPM amp Absolute Relative 10000 _set rx 29 mm E Edge Acceleration Tool El Increment FY 29 mm A Disable Touch ul sm Pz 0 0 mm A a ENS as o a po Jog Speed M592 mm min 4 hitp www elatouch com Action Y axis closed loop mode disabled a El J H lAction Z axis closed loop mode disabled Wea laction tool offsets refreshed start 4 3 M Microlution 3 SEH 7 57 AM 2 Touch the center of B the targets that pop up on the screen Touch targets from position of normal use r 3 Repeat steps 1 and 2 until you are satisfied with the alignment 14 Software Introduction September 2011 Microlution IV Software Introduction AN On Screen Keyboard A third party software package is used as an on screen keyboard to input characters and commands into the machine tool s computer The keyboard is initiated upon startup of the machine Figure 4 2 shows the layout of the on screen keyboard Table 4 1 gives a description of the menu buttons on the keyboard For more information about the touch screen keyboard you can visit the software s official website at http www chessware ch Table 4 1 On screen keyboard menu button descriptions Button Image Function Pulls up the main menu for the keyboard It is usually a good idea to change the mode to Floating after startup so that the key
14. function green no communication red OK green module error red ON 8 x green sensor inputs shorted 1 x red ON 8 x green I O Mapping The following table shows the variable mapping and recommended usage for the 1 0 lines ROBOT I O MAP 1 O NUMBER USAGE M VARIABLE DESCRIPTION M CODES OUT1 RESERVED M7101 RESERVED RESERVED OUT2 RESERVED M7102 RESERVED RESERVED OUT3 RESERVED M7103 RESERVED RESERVED OUT4 LOAD M7104 LOAD SIGNAL M204 1 HIGH M204 2 LOW OUTS ENABLE M7105 ENABLE ROBOT MACHINE OK M205 1 HIGH M205 2 LOW OUT6 PRELOAD M7106 PRELOAD REQUEST M206 1 HIGH M206 2 LOW OUT7 PART RELEASED M7107 PART RELEASED CONFIRMATION M207 1 HIGH M207 2 LOW OUTS SPARE M7108 SPARE M208 1 HIGH M208 2 LOW OUT9 SPARE M7109 SPARE M209 1 HIGH M209 2 LOW OUT10 SPARE M7110 SPARE M210 1 HIGH M210 2 LOW OUT11 SPARE M7111 SPARE M211 1 HIGH M211 2 LOW OUT12 SPARE M7112 SPARE M212 1 HIGH M212 2 LOW IN1 RESERVED M7121 RESERVED N2 ROBOT ERROR M7122 HIGH OK LOW ERROR IN3 RESERVED M7123 RESERVED N4 LOAD COMPLETE M7124 HIGH COMPLETE LOW IN PROGRESS IN5 RELEASE PART REQUEST M7125 HIGH RELEASE LOW CLAMP N6 SPARE M7126 SPARE IN7 SPARE M7127 SPARE N8 SPARE M7128 SPARE IN9 SPARE M7129 SPARE IN10 SPARE M7130 SPARE IN11 SPARE M7131 SPARE IN12 SPARE M7132 SPARE 100 Operation September 2011 VIII Operation Automatic Part Loading Sequence G201 A sequence for automatically loading parts is inc
15. All axes should now be open loop Move the y axis until it rests at the bottom Shut down the computer Once the computer has powered down flip the switches on the back panel to turn off power to both the machine and computer Slowly reduce the supply air to the machine ensuring the y axis is still resting at the bottom of the machine until the supply air pressure is zero DEBAN ZO A Software Startup and Homing the Motors ES Open the 363 S CNC Software by clicking the icon on the desktop Open the Setup Panel by pressing the Setup menu button in the upper left hand Refer to Software Introduction section for a definition of panels Homing for each motor is part of the Phasing Setup on the left side Figure 7 1 Press the Begin Phasing button illustrated in Figure 7 1 to home the X Y and Z stage motors The X stage homes first The Y stage homes after the X stage and finally the Z stage homes After the Z stage has homed verify that the phasing status is complete in the phasing status window The machine is now ready to operate 5 If initialization fails press the Reset button and then Begin Phasing to reinitialize Mm aos 59 Operation September 2011 Microlution VIII Operation AN MACHINE Machine Setup Phasing Setup Tool Changer Alignment Reset E E Pressure On Off Motor 1 Phase Set O O Motor Phase complete Me Motor 2 Phase Set Motor 3 Phase Set mena Me
16. Esa ais m oo MN Spinde 4 Figure 4 10 Program Tab Table 4 2 Program Tab buttons and their functions Button Function Executes the program from the first line If the program has been paused it will resume Cycle Start from the paused line Pauses the program following the execution of the line during which the Pause button was Pause A pressed Pressing Cycle Start will resume the program from the paused location Halts execution of the G code and motion of the machine even if it is in the middle of a Stop move Pressing Cycle Start after pressing the Stop button will resume the current move and then execute the next line Flood Coolant Starts or stops flood coolant flow Air coolant must be turned off to turn on flood coolant Air Coolant Starts or stops air coolant flow Flood coolant must be turned off to turn on air coolant This changes the function of Cycle Start If Single Block is on each time Cycle Start is Single Block pressed the machine will only execute the next program line If Single Block is off the program will continue executing until stopped or completed Software Introduction September 2011 Microlution IV Software Introduction AA When optional stop is on program execution will pause when an M01 command is given Optional Stop in the CNC program If optional stop is turned off all MO1 commands will be ignored during program execution The text
17. Jaeger Z33 D11100 02S2Y Specifications 11 Machine Information September 2011 Machine Information Microlution AN Maximum Speed Air for Collet Opening Standard Size Collet Chuck Weight Continuous Power Maximum Power 100 000 RPM 0 55 MPa 0 7 MPa 80 PSI 101 PSI 3 175 mm 1 8 diameter 1 1 kg 2 4 lbs 360 W 410 W Table 3 8 80 000 RPM Electric Motor Driven Air Bearing Spindle NRA 5080 Specifications Maximum Speed Air Consumption for Air Bearing Spindle Accuracy Standard Size Collet Chuck Weight Maximum Power 80 000 RPM 100 liters min 0 49 MPa 3 53 CFM 71 PSI lt 1 micron 0 00004 3 175 mm 1 8 diameter 0 96 kg 2 1 lbs 300 W Table 3 9 160 000 RPM Air Turbine Air Bearing Spindle ABS 1600 Specifications Maximum Speed Proper Air Pressure for Air Turbine Air Consumption for Air Turbine Proper Air Pressure for Air Bearing Air Consumption for Air Bearing Spindle Accuracy Radial Bearing Load Capacity Thrust Bearing Load Capacity Standard Size Collet Chuck Weight Maximum Power 160 000 RPM 0 29 MPa 0 49 MPa 42 psi 71 psi 100 liters min 0 49 MPa 3 53 CFM 71 PSI 0 49MPa 71 PSI 40 liters min 0 49MPa 1 41 CFM 71 PSI lt 1 micron 0 00004 lt 6 N O 0 49 MPa 1 35 Ibf 71 PSI lt 6 N O 0 49 MPa 1 35 lbf O 71 PSI 3 175 mm 1 8 diameter 0 91 kg 2 lbs 14W 12 Machine Information
18. Microlution 363 S 00 0000 00 too oras wrorrscts LASER View Para 00 0000 E i Workpiece Probing Error X axis Fatal Following Error Limit Exceeded 00 0000 Active G codes M codes G1 1 G18 G20 G40 G43 G54 1 G90 G94 G99 M00 M05 M07 Current Tool Tool Length Measurement Error O Y axis Fatal Following Error Limit Exceeded Tool Diameter Measurement Error Z axis Fatal Following Error Limit Exceeded Tool Breakage Error X axis Amplifier Fault Tool Dirty Error Y axis Amplifier Fault Control Panel E Stop Tripped Z axis Amplifier Fault Off Feedrate On X axis Software Limit Exceeded X axis Warning Following Error Exceeded Flood Coolant C Feedrate mm min Y axis Software Limit Exceeded Y axis Warning Following Error Exceeded Override Air Coolant O Z axis Software Limit Exceeded Z axis Warning Following Error Exceeded E EN Single Block _ Optional Stop C Tool Changer Fault Lid Open Fault System Pressure Fault Spindle Control E JOG COMBINE OFFSET Spindle 1 A E A MDI TERMINAL SENSOR USER Target RPM 10000 Increment Pallet ID eS On Screen Keyboard Tool Number 1 Figure 4 1 Program Start up Screen with CNC Control Panel Dashboard View Panel Input Panel and Menu Buttons in the top row Also the on screen keyboard button is shown in the lower right of the screen
19. Press SELECT TOOLS again to finish selection 4 Inthe Sensor Tab Press SENSE SELECTED TOOLS A program will automatically be written to the MDI and executed 75 Operation September 2011 Microlution VIII Operation DAN Manual Operation Mode Below are the steps to use the workpiece sensor manually using the touch screen interface Make sure a tool is loaded in the spindle Press tool length or the tool diameter sensing button in the Sensor Tab The measurements are saved to data registers for tool number 1 The measurement data also appears in the text box next to the button NTS Implementation in an NC Program Standard implementation within an NC program might look like this below is a description of each step T1 M6 G120 B1 H1 G54 G43 H1 1 T1 M6 Load tool number 1 2 G120 B1 JO H1 Tool measurement cycle This command will measure length and diameter for tool number 1 using the length experience J parameter 3 G54 apply workpiece offset This command is required every time prior to applying a tool length offset 4 G43 H1 apply tool length offset This command applies the tool length offset for tool 1 76 Operation September 2011 Microlution VIII Operation DAN Z Axis Fixture Probing G123 Cycle The G123 cycle performs a z axis probing cycle using force feedback from the machine s linear motors to determine the trigger location This is feature is only available for select s
20. and safety instructions BEFORE operating or servicing the machine e This machine is automatically controlled and may start at any time e This machine can cause bodily injury Do not operate with the protective lid open a Safety September 2011 Microlution II Safety AN Observe and Obey All Warnings Listed Below e Do not operate without proper training e Personal Protective Equipment o Always wear safety goggles o Abrasion resistant gloves are recommended when handling sharp tools workpieces and workpiece pallets Caution must be taken as gloves may become entangled in rotating or moving parts within the machine e The electrical power must meet the specifications in this manual Attempting to run the machine from any other source can cause severe damage and will void the warranty e DONOT power up machine until after the installation is complete e NEVER service the machine with the power connected e Improperly fastened parts machined at high speeds feeds may be ejected and puncture the protective lid Machining oversized or marginally fastened parts is not safe e The window in the protective lid must be replaced if damaged or severely scratched Replace damaged windows immediately e Do not process toxic or flammable material Deadly fumes can be present Consult material manufacturer for safe handling of material by products before processing e The machining process may generate fine dust l
21. 0000 0 0000 4 G57 0 0000 0 0000 0 0000 5 G58 0 0000 0 0000 0 0000 6 7 8 G59 0 0000 0 0000 0 0000 G54 1 P1 0 0000 0 0000 0 0000 G54 1 P2 0 0000 0 0000 0 0000 9 G54 1 P3 0 0000 0 0000 0 0000 10 G54 1 P4 0 0000 0 0000 0 0000 11 654 1 P5 0 0000 0 0000 0 0000 12 G54 1 P6 0 0000 0 0000 0 0000 13 G54 1 P7 0 0000 0 0000 0 0000 Figure 4 20 Workpiece Offsets Tab Tool Offsets Tab The Tool Offsets Tab displays the values of all the tool offsets and compensation factors on the 363 S shown if Figure 4 21 All offsets can be accessed through paging back and forth or through searching for an offset number Offsets can be saved and recalled for later use Table 4 10 gives a description of each of the items on the panel Table 4 10 Tool Offsets on the 363 S fe eee Previous Page Button ne previous page button allows Users to flip back through the previous pages of offsets stopping at the first page The index to offset button enables the user to type in a tool Index to Offset Button offset number press the button and be automatically taken to the correct offset page with the desired offset selected Next Page Button The next page button allows users to flip through the next pages of offsets stopping at the last page The tool offset table holds the important information about each tool including tool position description length mea
22. 1 394 referring to reference parameter Z Z axis offset value G54 1 P1 G54 1 P394 Tool length offset data setting group Enable Bene frat tne 10 updating tool length offsets Parameter P denotes Eta R Parameter value the tool with range 1 36 referring to H1 H36 p Tool diameter offset data setting group Enable i P Tool reference 12 updating tool diameter offsets Parameter P denotes Sidmeter R Parameter value the tool with range 1 36 referring to H1 H36 p Tool length compensation data setting group 11 Enable updating tool length compensation P Tool reference aa AE Parameter P denotes the tool with range 1 36 parameter referring to H1 H36 Tool diameter compensation data setting group Enable updating tool diameter compensation P Tool reference 13 R Parameter value Parameter P denotes the tool with range 1 36 parameter referring to H1 H36 User variable data setting group Enables updating user variables Parameter P denotes the variable P Variable reference 50 i F R Parameter value with range 1 1000 referring to system variables parameter P7000 P7999 Data Setting Examples G90 G10 L2 P1 XO Y10 Z7 G91 G10 L20 P11 X 5 Y1 Z2 G90 G10 L10 P3 R15 add 2 to Z axis Set workpiece offset G54 to 0 10 7 Set tool 3 length offset to 15 Update workpiece offset G54 1 P11 Add 5 to X axis add 1 to Y axis 90 Operation September 2011
23. 1 067 N175 Y 1 746 N180 Z 06 N185 X 2 465 Y 1 758 N190 X 31 Y 1 401 N195 X 2 066 Y 1 111 Figure 4 4 PMAC Editor Pi The Open button will open a dialog box allowing the user to browse for a preexisting file After selecting the desired file clicking the Open button in the dialog box will load the file into the editor Open Program 17 Software Introduction September 2011 Microlution AN IV Software Introduction A Login a The Login menu button will open a window where a user login name and password can be entered shown in Figure 4 5 The default user is loaded upon startup and this button must then be used in order to change users Microlution ZA User Name Password Figure 4 5 User login window Administration gt The Admin menu button will open a new window for user account setup shown in Figure 4 6 By double clicking on a user account in the user account list box the controls that user has access to can be modified On the right side of the window is a list of all available controls These controls can be toggled on off for each user The controls that are deactivated can be either shown as disabled or hidden depending on the radiobutton that is toggled Also the user login name and password can be changed in their corresponding text boxes After any modifications have been made to a user account the Save button must be pressed to implement and save those changes The controls for add
24. A E L aE A Ada AAA 90 Conditional Statements oense do Eeee ta o SEEE E eE ATE T E EEE ea re SEE in 92 If c ondition actio Mpe erin i E E E EEA A TE A ne EE Re 92 While condition faction essaten aanne reran ticas 93 GOTO data rn e er a e ds 93 Palletehanging rsh a a oo 95 REMOVINGtHe o E E E EE ETE E 96 MAEA Il E E E E E EAA A E E EA AE 97 TOOlSETE aeea E E E E E E EE E 98 Using the Handheld Pendant iia AS E ASIA Acida d 104 Executing a Progra peresno Eene e Ai 105 Manually Running a Program by Using the Terminal Panel ccconcococonccncconononaannnncconanonannnanonncnnnns 105 Automatically Running a Program by Using the Combine Tab and the Program Tab cccccono 107 Part Offsets 2s coccesnsceb O NN 108 Save Current Location to a File eee eeeeeescecsseceeeeeceseeeeececaeeeeaeecaeeseaeecsaeeeeeeecsaeeeeeecsaeeeeeeesaeeneeeees 108 Recall Saved Location from a File oo eee eeeseesseceeccecseeceeceeceaeeeeeeecaecseaeecaeeseaeecaeeseaeecsaeeseaeesaeeeeaeeenas 109 Set KNOWN Location as Program Origin ccccccecscscecececseececeescecececececececeeecececececececececececeeeeececeeeeeeeeees 109 Cleaning Mainteman Ei A dd dades dveoke hives 110 GIG ANN Bie ers ioc scord Abeer A des nes 111 Maintenance naene ON 113 S pported AIM a e oa 116 Appendix a Legacy Custom Order ccccccssecsssseessecesseecseecssseccssecssseecaeecssseecasecesseceasecesseceasecesseceauecesteeesaeeseas 129 Spindle Changing Kinemat
25. AN Warning Magnetic force decreases rapidly as distance increases Spindle can accidentally be pulled into the work piece pallet rubber boot or other parts of the operator or machine when removing the spindle be careful Warning Tool bits are sharp Handle tool bits with care Figure 7 3 Removing the spindle Installing the Spindle 1 Within the MDI Tab of the CNC control panel move the Z stage away from the pallet mounting area 2 Verify that the spindle is disabled within the Program Run Tab of the CNC control panel Refer to Spindle Operation section for information on the location of the Disable Spindle button 3 Open the protective lid 4 Hold the spindle above the mounting area with the balls roughly lined up with the Vee blocks 5 Lower the front balls onto their Vee blocks while holding the spindle at approximately a 30 degree angle working end pointed down 6 Once the front balls locate in their Vee blocks as shown in Figure 7 3 lower the back of the spindle into the other blocks 7 Check that the spindle is seated firmly on the Vee blocks 8 Attach the spindle s air and electrical connections if necessary Refer to the supplied spindle user s manual for detailed information on the spindle s air and electrical connections Warning Magnets will pull the spindle toward the attachment point Keep fingers clear Warning Tool bits are sharp Never touch the tool bit Workpie
26. CFM 100 PSI supplied to the air regulator at the rear of the machine Air supply should be clean and dry Air Requirements NOTE Check that the air regulator at the rear of the machine is set to 90 psi NOTE Air consumption will vary based on spindle selection and accessories The machine plugs into a standard 110 VAC outlet Electrical Requirements NOTE The machine requires 20 Amps Ensure the circuit is rated for 20 Amps Operating Conditions The Microlution 363 S is a high performance precision micro manufacturing machine tool and as such must be operated under specific environmental conditions Only operate machine indoors in a safe location free from explosive vapors and or flammable liquids Table 3 3 Operating Conditions Preferred Operating Temperature Range 20 0 C to 22 2 C 68 F to 72 F 15 6 C to 26 7 C 60 F to 80 F Operating Temperature Range NOTE Operating machine at a temperature not in the preferred operating temperature range may affect the accuracy of the machine Storage Temperature Range 0 Cto 45 32 F to 113 F The relative humidity should be maintained within a Ambient Humidity range of 50 to 65 non condensing Altitude 0 m to 1829 m 0 ft 6000 ft 10 Machine Information September 2011 Microlution Il Machine Information AN Spindle Specifications Microlution Inc offers different spindle options for
27. EUNA Warning Tool bits are sharp Never touch the tool bit Figure 7 19 Pallet and machinable fixture plate during removal replacement of pallet 97 Operation September 2011 Microlution VIII Operation AN Automatic Part Loading An actuated lid and I O interface options are available to facilitate automated part loading This section describes these options and their usage Manual Operation of Robot Lid and Door The robot lid has both manual and automatic entry To manually access the machining area ensure the interlock is unlocked and lift the lid upward and to the right using the handle If the power to the machine is off the interlock can be unlocked by turning the toggle on the interlock however the machine will not run with the interlock unlocked Automatic entry is achieved through the clear robot door Buttons in the User Tab in the Microlution software interface can be used to actuate the clear door open to the right or closed to the left Do not attempt to force the automatic door by hand A pinch sensor detects an error condition when the door closing action is blocked LID HINGES HANDLE DAMPER INTERLOCK GAS SPRING PINCH Ley CYLINDER LIMIT SWITCHE DOOR GUIDE RAILS 98 Operation September 2011 Microlution VIII Operation LO Robot I O Interface Communication between the machine and the robot is handled using a Turck Modbus TCP I O module located on the back of
28. G201 Pallet Change option required Moo Programmed Stop M01 Optional Stop M02 End of Program M03 Spindle Clockwise S M05 Spindle Off M06 Tool Change option required T M07 Air Coolant On M08 Cutting Fluid On option required M09 Cutting Fluid Air Coolant Off 116 Supported G and M Codes September 2011 Supported G and M Codes Microlution AN M30 End of Program with Rewind M98 Subroutine Call LP M99 End Macro Subroutine Call M101 Pallet Clamp M102 Pallet Unclamp M103 Machine Light On option required M104 Machine Light Off option required M106 Tool Guard Retract option required M107 Tool Guard Extend option required M110 1 Robot Door Open option required M110 2 Robot Door Close option required M110 3 Robot Door is Open Check option required M110 4 Robot Door is Closed Check option required M112 1 Mandrel Clamp option required M112 2 Mandrel Unclamp option required M112 3 Mandrel is Clamped Check option required M112 4 Mandrel is Unclamped Check option required M201 Robot Pulse Sync 3R robot option required M202 Robot Pulse Clock 3R robot option required M203 1 Robot Data On robot option required M203 2 Robot Data Off robot option required M204 1 Robot Load On robot option required M204 2 Robot Load Off robot option required M205 1 R
29. Hardware Introduction September 2011 Hardware Introduction Microlution amp 406 ON Sey A 17 NE ri Figure 5 8 Pneumatic regulators 54 Hardware Introduction September 2011 Microlution V Hardware Introduction AN Back of the Machine The back of the machine consists of all the air power computer and accessory cable connections Figure 5 9 shows the back of the machine as well as all of the cables connection locations Figure 5 9 Back of the machine 55 Hardware Introduction September 2011 Microlution V Hardware Introduction AN The following items reference Figure 5 9 1 Handheld Pendant Connection 2 Ethernet Connection 3 USB Connection 2 ports 4 Compressed Air Input and Regulator air input is similar to McMaster p n 6534K46 5 Air Filter and Mist Separator 6 Power Entry Box 7 Chip Chute 8 Electrical Cabinet Cooling Fans 56 Hardware Introduction September 2011 Microlution Vi Installation Transportation INSTALLATION TRANSPORTATION Installation Intstallation must be performed by Microlution technician The steps below are provided for customer reference The 363 S should be stored and operated according to specifications listed in Table 3 3 Air and power should meet specifications listed in Table 3 2 The following installation instructions reference Figure 6 1 Place the supplied isolation pads under the feet of the 363 S
30. Releases and clamps the automatic tool chuck automatic tool changing spindles only Pressing this button when it displays Release Tool will release the tool Pressing the button when it says Clamp Too will clamp the tool Move to Zero Moves to program origin Set to Zero Sets current axis position to program zero Set selected axes to closed loop enable The motors will keep the axis in the Close Loop a commanded position when in closed loop mode Set selected axes to open loop disable When an axis is in open loop mode it Open Loop p p p p can be moved manually Pressing the button when it displays Enable Handwheel will enable the handwheel on the handheld pendant Pressing the button when it displays Disable Handwheel will disable the handwheel Enable Handwheel MDI Tab The MDI Manual Data Input Tab is used for manually executing G and M code commands outside of a CNC program shown in figure 4 23 Commands can be executed by typing them into the text box Multiple lines can be executed at the same time by typing them all in the text box and pressing the Execute button There are buttons for most G and M code commands that are available on the 363 S Pressing one of these buttons will automatically insert the command into the text box 38 Software Introduction September 2011 Software Introduction Combine Tab COMBINE OFFSET TERMINAL SENSOR USER _ i
31. Use a wrench to adjust the feet height until the machine is level Make sure all equipment is switched off Attach air supply to inlet on back of machine as shown in Figure 6 1 Attach power cable to rear of 363 S but DO NOT plug into 120 VAC outlet see Figure 6 1 Connect the monitor to the machine see Figure 6 1 Attach handheld pendant to rear of 363 S see Figure 6 1 Attach manual laser pendant to rear of 363 S if equipped Verify filters for coolant and air are in place 10 Add coolant to filter case reservoir until the coolant level is one to two inches below the top of the filter CPI es re Handheld Pendant USB Monitor AC Air Supply Figure 6 1 Machine air electric and peripheral connection schematic 57 Installation Transportation March 2010 Microlution Vi Installation Transportation AN Transportation The 363 S should be moved with a pallet jack or fork lift Warning The 363 S weighs more than 317 kg 700lbs and can cause serious injury or death if handled improperly Warning The machine is top heavy Do not tip Pallet Jack or Fork Lift 1 Place forks under the machine 2 Make sure forks touch both sides or front and back of the machine frame so that they do not damage internal equipment 3 Centrally locate load on the lift forks Keep in mind that the center of gravity of the machine is shifted towards the side of the machine with the moti
32. Value of the posts Format G65 P9809 Xx and Yy and Zz Aa Bb Cc Dd Ee Where denotes optional inputs Compulsory inputs Xx X X position of the first identification post in mm in absolute co ordinates and Yy y Y position of the first identification post in mm in absolute co ordinates and Zz z Z height of the surface corresponding to a 0 input value no post present in mm in absolute co ordinates The height of the post above this surface is specified by parameter Dd Optional inputs Aa a Number of posts Specifies the number of posts used by the pallet identification code Default value 3 Only positive input acceptable Bb b Spacing of the posts along X Specifies the spacing of the posts along positive X direction Default value 5mm Only positive input acceptable Cc c Measurement mode Sets the measurement mode for the machine Value can be either O regular mode or 1 fine mode Default value 0 regular mode e g C1 will set the machine to fine measuring mode Dd d Height of the posts Specifies the height of the post above the Zz input parameter when a post is present Default value 2mm Only positive input acceptable Ee e Clearance above the posts 82 Operation September 2011 Microlution VIII Operation DAN Specifies the clearance value for the probe to retract above the posts Default value 2mm Only positive input acceptable Example T1 M6 Load appropriate measuring p
33. block mode and optional stop mode can be toggled on and off using toggle buttons as well The spindle can be enabled and its speed adjusted before or during program execution The feedrate can also be scaled during program execution using the or override buttons Start the program by clicking the Cycle Start button the program will stop when it reaches the end of the file and or the Pause or Stop buttons are pressed 107 Operation September 2011 Microlution VIII Operation AN Part Offsets Part offsets are recordable program home locations There are 6 program home locations that can be saved to G code commands This feature may be useful if there are multiple common parts that are run on the 363 S and each has a different program home location Each part s home location could be set as one of the stored G code home commands Before running any programs for a particular part the saved home location could be recalled by selecting it and clicking the Apply Saved button This decreases the setup time for common NC programs Save Current Location to a File 1 Open the Jog Tab Figure 7 30 and click on Set to Zero This will make the current location the program home origin This will also update the active offset shown in the Dashboard Open the Offset Tab Figure 7 31 From the drop down box select the desired save location G54 G59 Click Save This will take the active program origin and save it to the selected G code o
34. button to power on the spindle control unit The Nakanishi spindle control unit is located inside the machine above the pneumatic regulators 1 2 10 3 11 4 5 6 7 8 9 Figure 5 7 60 000 RPM spindle control unit 133 Appendix A September 2011 Microlution Xl Appendix A AN The following items reference Figure 5 7 1 Load Meter This meter monitors the load on the spindle If the yellow or red LEDs are lit an overload situation exists and the controller will automatically shut down if the situation persists CAUTION Continued operation under overload conditions will result in overheating and may lead to spindle or controller damage 2 Run LED This light will flash when the spindle is operating 3 Warning LED The Warning LED will flash when a hazardous condition has been detected 4 Error LED The error LED will blink when a serious error is detected The spindle will automatically shutdown 5 Error Reset Button This button will reset and allow restarting of the spindle after an error has been corrected Some errors cannot be reset until after the power to the spindle control unit has been turned off To cycle power to the spindle control unit open the Program Run Tab within the CNC Control Panel Click the Disable Spindle button to turn off power to the spindle control unit Press the Enable Spindle button to power on the spindle unit 6 Gear Mode Select Button Set Gear Mode to display the ro
35. coolant and the moving parts The protective lid also keeps chips and coolant from exiting the working area The computer monitor functions as the display for all machining software The machine body and control systems housing protects the control systems and shields users from the internal electronics The vibration isolation pads shelter the machine from any floor vibrations The spindle control unit manages the spindle speed and monitors any spindle errors Refer to the Spindle Control Unit section for detailed information about the spindle control unit The handheld pendant allows the user to manually control the movement of the X Y and Z stages The emergency stop button is located on the handheld pendant More information about the handheld pendant is available in the Handheld Pendant section and in the Using the Handwheel section Protective Lids Touchscreen Monitor Handheld Pendant Machine Body and Control Systems Housing Spindle Control Regulators PC Figure 5 5 Front of the machine 51 Hardware Introduction September 2011 Microlution V Hardware Introduction AN Handheld Pendant 1 Handwheel Each rotation increment of the handwheel moves the selected axis by the selected increment amount l 2 Axis Selection Dial TS Adjusts which axis the handwheel controls Positions 4 5 and 6 are currently inactive 3 Increment Selection Dial Adjusts the handwheel scaling factor X1 moves each stage on
36. features The upper left corner of this pattern should be at X 5 Y 10 in machine coordinates For this program the origin is the center of the X at the surface of the material to be removed Note Feedrates are ignored for simplicity in this example The first NC program looks like this N1 GO X 1 Y1 5 Move tool to starting location N2 G1 Z 0 25 Plunge tool into work piece N3 G1 X1 Y 1 5 Cut N4 GO Z1 Pull tool from work piece The second NC program looks like this N1 GO X1 Y1 5 Move tool to starting location N2 G1Z 0 25 Plunge tool into work piece N3 G1X 1 Y 1 5 Cut N4 GOZ1 Pull tool from work piece The following is a step by step set of instructions that lead the user through the setup process of creating an array within the Part Pattern Tab of the CNC Control Panel 1 Set up the pattern parameters using the Part Pattern Tab of the CNC Control Panel Number of row 2 Number of columns 5 X spacing center to center mm 3 2mm width 1mm between each column Y spacing center to center mm 6 3mm height 3mm between each row Origin X mm 4 Smm 1mm from center to left edge Origin Y mm 8 5 10mm 1 5mm from center to top edge 139 Appendix A September 2011 Microlution Appendix A AN Xl Example Continued 2 Click the Set button and the chart in the Axis Tab of the View Panel will show ovals depicting the location and spacing of the array Figure 7 29
37. manual for instructions on this procedure MACHINE CAMERA Machine Setup Phasing Setup Tool Changer Alignment Reset Pressure On or O Motor 1 Phase Set Motor 1 Phase Complete Motor 2 Phase Set Motor 2 Phase Complete 2 Motor 3 Phase Set M E reso MS O Units Millimeters Inches Set Software Limits Enabled Disabled Program Timer On Off Pallet Clamp Required On Off Eid Paul en CI N Update Parameter Create Parameter Figure 4 3 Setup Window New Program a 16 Software Introduction September 2011 Microlution AN IV Software Introduction Clicking the New menu button will open a simple text editor shown in Figure 4 4 to write short programs The editor also has the ability to download the program directly to the 363 S memory by pressing the Download button The editor is shown in Figure 4 4 PMACEditor N75 X 2 466 Y 1 066 N80 Y 1 067 N85 X 2 465 Y 1 051 N90 X 2 103 Y 1 11 N95 G3 X 1 998 Y 1 083 1 022 J 132 N100 G1 X 263 Y 1 37 N105 X 245 Y 1 373 N110 Y 1 375 N115 X 239 Y 1 388 N120 X 24 Y 1 39 N125 X 2 465 Y 1 758 N130 X 2 466 Y 1 746 N135 Z 04 N140 X 2 465 Y 1 758 N145 X 264 Y 1 394 N150 X 267 Y 1 393 N155 X 2 03 Y 1 102 N160 G2 X 2 103 Y 1 11 I 051 J 124 N165 G1 X 2 465 Y 1 051 N170 X 2 466 Y
38. offset Existing offset value error Uu u Upper tolerance limit If this value is exceeded no tool offset or work offset is updated and the cycle stops with an alarm Where applicable this tolerance applies to both the size and position Default value 5mm e g U1 sets the upper tolerance limit to 1mm Vv v Null band This is the tolerance zone in which no tool offset adjustment occurs Default value 1micron Example Measuring a single surface in X T1 M6 Load appropriate measuring probe G54 XO YO Apply correct work offset and go to start position G43 H1 Activate tool length offset for particular tool G1 X 20 YO Goto appropriate X Y location for measurement G1Z5 Goto appropriate Z location for measurement G65 P9811 X 10 Q5 S2 U1 VO 01 Call single surface measurement continue with program The X offset for G55 S2 will be updated by the error of the surface position 80 Operation September 2011 Microlution VIII Operation DAN Pallet ID function G65 P9809 Posts A No of posts B Spacing of posts along X D Height of the posts E Clearance above the posts Current work offset origin Description The cycle measures a specified zone on the pallet to identify the pallet number Pallet identification geometry description The pallet identification function identifies the posts as features of different Z heights The shape of the post is not as important can be a circle square or any
39. offsets on the 363 S shown if Figure 4 20 All offsets can be accessed through paging back and forth or through searching for an offset number Offsets can be saved and recalled for later use Table 4 9 gives a description of each of the items on the panel Table 4 9 Workpiece Offsets on the 363 S AA PA previous Pece Button The previous page button allows users to flip back through the previous pages of offsets stopping at the first page The index to offset button enables the user to type in an offset Index to Offset Button number press the button and be automatically taken to the correct offset page with the desired offset selected 35 Software Introduction September 2011 Microlution IV Software Introduction HAN The workpiece offset table holds the offsets for G Codes G54 Workpiece Offset Table G59 and G54 1 P1 394 These offsets can be updated by the user through this table The save to file button writes all the current workpiece offsets Save to File Button a gt A NE to a file and saves it to a user specified destination The receive from file button takes a user specified offset file Retrieve from File Button and replaces all the current workpiece offset with the offsets from that file G CODE AXIS CAMERA l ERROR STATUS TOOL OFFSETS WARNING STATUS View Panel Workpiece Offset X axis mm Y axis mm Z axis mm 1 G54 0 0000 0 0000 65 0000 2 G55 3 9400 20 5500 5 8800 3 G56 0 0000 0
40. probing routines on the 363 S using a probe attached to the spindle collet Probe guidelines A probe is a precision tool with which a measurement is performed The probe is clamped in the spindle collet and just like a machining tool The probe needs to have an accurate and end zone which is concentric to the tool shank in the form of a small sphere or cylinder which would be used for the actual measurement Recommended diameter for the end zone is 2mm which would enable measurements of smaller features An example of a probe would be a tool blank no flutes of 2mm diameter at the end which is ground well on a 1 8 shank size Triggering The trigger is set up to detect any difference between the commanded position and the actual position during measurements When the difference exceeds a preset value a reading is taken and stored as the measured value To create this difference the motors apply a limited amount of force in order to feel when the probe makes contact with the measurement surface However care should taken not to measure any thin wall or delicate features as the force may be enough to cause permanent damage to the part Follow the same procedures as during a cutting process to keep hands out of the machine to prevent possibility for operator injury Precautions Before performing the measurements ensure that the correct work offset and tool offsets are applied The g codes are designed to operate in the currently ac
41. replace the back cover 113 Cleaning Maintenance September 2011 Microlution VIII Cleaning Maintenance DAAN Coolant Change The coolant should be replaced at least as often as the filter bag If the coolant begins to get foamy and or begins to smell bad the coolant should be changed independently To change the coolant follow these instructions 1 Remove the filter vessel from the stand follow steps 1 3 in the Filter Replacement section above so that both drain ports can be accessed Place a pan or bucket inside the stand under one of the two drain ports Turn the valve on the drain port that the bucket is under to allow coolant to flow out of the tank When all the coolant has drained close the valve and repeat steps 2 and 3 for the other port New coolant can be poured into the top of the tank Replace filter vessel and back cover of the coolant system stand 0029 Coolant Pump Maintenance If the coolant pump begins to leak or you notice a drop in performance contact Microlution for assistance and or replacement Electrical Panel Fuses If a fuse burns out on the electrical panel it will need to be replaced This can be done by removing the left side panel and accessing the power distribution box The power distribution box is on the middle left of the electronics panel and has a clear cover There are 4 fuses F1 is 10A fast acting F2A and F2B are 5A slow blow type fuses F3 is 3A slow blow fuse CAU
42. spindle is clear of the workpiece and the pallet Also verify the spindle is off Open the protective lid Place the tool into the collet with the working end towards the workpiece pallet mounting area a Ifthe tool has a taper place only the widest part of the tool into the collet b Only place the shank of the tool into collet never the flutes Place the other M10 wrench on the collet nut and turn counterclockwise until tight Remove both wrenches Close protective lid Place one M10 wrench on the lock nut close to the spindle 10 Standing in front of the machine turn the collet nut counterclockwise with fingers until finger tight Collet Nut o E O OND Lock Nut Figure 7 5 80 000 RPM spindle tool changing 62 Operation September 2011 VIII Operation Tool Removal Jog Z stage away from pallet Turn off spindle Verify tool is clear of part and pallet and spindle is off Open protective lid Place one M10 wrench on the lock nut close to the spindle Remove wrench from collet nut Loosen collet nut further with fingers Remove wrench from lock nut 10 Remove tool from collet 11 Close protective lid WO ONANARWNE Place the other M10 wrench on the collet nut and turn clockwise until loose 63 Operation September 2011 Microlution Vill Operation AN Tool Changing Manual Collet 160 000 RPM Air Turbine Air Bearing This section describes how to install and remove tools from the 16
43. the 363 S The specifications for the most common spindles offered are listed in Tables 3 4 through 3 8 Please see the Hardware Introduction section for more information on the different applications of each spindle Table 3 4 50 000 RPM Electric Motor Driven High Precision Bearing Spindle NR40 5100 ATC Specifications Maximum Speed 50 000 RPM Air for Collet Opening 0 55 MPa 0 61 MPa 80 PSI 87 PSI Spindle Accuracy lt 2 microns 0 00008 Weight 0 74kg 1 63 Ibs Power Consumption Rating 18 A 30 Maximum Output Power 350 W Table 3 5 40 000 RPM Electric Motor Driven High Precision Bearing Spindle NR 5041E ATC Specifications Maximum Speed 40 000 RPM Air for Collet Opening 0 50 MPa 0 56 MPa 73 PSI 87 PSI Spindle Accuracy lt 2 microns 0 00008 Standard Size Collet Chuck 3 175 mm 1 8 diameter Weight 1 34 kg 2 95 lbs Power Consumption Rating 18 A 30 Maximum Power 350 W Table 3 6 50 000 RPM Electric Motor Driven High Precision Bearing Spindle IBAG HF45A60CP Specifications Maximum Speed oan RPM 60 000 RPM with liquid chilled spindle Air for Collet Opening 0 55 MPa 0 7 MPa 80 PSI 101 PSI Pressure Air Seal 0 2 MPa Spindle Accuracy lt 2 microns 0 00008 Standard Size Collet Chuck 3 175 mm 1 8 diameter Weight 2 3 kg 5 1 Ibs Continuous Power 500 W Maximum Power 975 W Table 3 7 100 000 RPM Ceramic Hybrid Ball Bearing Spindle
44. the Y offset for G54 Parameter 3 Dwell Copy the Z offset from G54 Parameter 3 to G55 Parameter 1 L2 P2 corresponds to G55 Parameter 1 Q2002 is the Z offset for G54 Parameter 3 Dwell Apply G54 Parameter 1 work offset Change to absolute mode and move to X 0 and Y 0 Apply appropriate tool offset tool 2 here Parameter 4 Move to Z 10mm Moves to an appropriate negative X location for Location will depend on size of feature Move to appropriate Z location for measurement Location will depend on size of feature Measurement move with appropriate tool offset H2 Parameter 4 and G56 Parameter 5 S3 Location will depend on size of feature Retract in Z Moves to an appropriate positive X location for measurement Location will depend on size of feature Move to appropriate Z location for measurement Location will depend on size of feature Measurement move with appropriate tool offset H2 Parameter 4 and G57 Parameter 6 S4 Retract in Z Move to zero position Dwell G10 L2 P2 X Q2000 Q2010 Q2015 2 Set X offset for G55 as previous value plus error L2 P2 corresponds to G55 Parameter 1 85 Operation September 2011 VIII Microlution Operation AN G4 P0 1 G10 L2 P3 XO G4 P0 1 G10 L2 P4 XO G4 P0 1 G55 G43 H2 XO YO Z10 G65 P9811 ZO H2 S2 G10 L2 P2 Z Q2007 6 G55 G43 H2 M30 Q2000 is X offset for G54 Parameter 3 Q2010 is X offset stored in G56 Parameter 5 by measurement 1 Q
45. the desired tool in the spindle 2 Make sure the tool is clear of the part 3 Move the X and Y axes to place the surface that will be the zero reference for the Z axis directly in front of the tool 4 Turn the spindle on 5 Set the spindle speed to the low end of the tool s recommended speed 6 Use the handwheel to step in towards the part on the I Z axis Figure 7 20 Tool near the workpiece 7 Monitor the location of the tool using the camera surface illustrated in Figure 7 20 8 As the tool gets closer the X and Y axes can be fine adjusted to make sure the tool is in line with the desired zero reference 9 Decrease the step size to the smallest setting on the handwheel when the tool is close lt 500um to the part 10 Move the tool closer to the material in steps and check using the camera for the presence of chips around the tool 11 Watch the camera screen for any chips to indicate that the tool has touched the part Figure 7 21 Note Small tools break easily Approach increment should be less than 5 of the tool diameter to avoid breaking the tool 12 As soon as the tool touches the part stop incrementing the Z axis closer 13 Select only the Z axis on the MDI Tab of the CNC Control Panel Figure 7 21 Chips created during tool setting 102 Operation September 2011 Microlution VIII Operation AN 14 Click the Set to Zero button within the MDI Tab to set the current Z location as the program zero
46. the machine This module contains the capability for 12 digital inputs and 12 digital outputs and is described in the figure below IN1 THRU IN4 WIRING MODBUS TCP CONNECTION FIBER OPTIC CONNECTIONS IN5 THRU IN12 WIRING IN1 IN5 OUT5 IN2 IN6 OUT6 IN3 IN7 OUT7 IN4 IN8 OUT8 OUT1 IN9 OUT9 OUT2 IN10 OUT10 OUT3 IN11 OUT11 OUT4 IN12 0UT12 POWER SUPPLY WIRING O O ARE 1 0 0 3 P O T 0 L 4 male female POWER SUPPLY 99 Operation September 2011 VIII Operation Microlution The following table shows the specifications for the I O module TURCK I O MODULE SPECIFICATIONS Power supply Supply voltage Load supply Current consumption Operating current Digital inputs Input voltage Supply current Switch point 0 1 Input filter Max input current Digital outputs Output voltage Output current per channel Load type Short circuit protection Switching frequency Load factor Galvanic isolation LED indications Bus Module status Inputs Short circuit Outputs 24 VDC 21 6 28 8 VDC 24 VDC 21 6 28 8 VDC 75 mA 8 inputs acc to EN 61131 2 24 VDC 19 29 VDC 500 mA short circuit protected 3 5 VDC 11 30 VDC 3 0 ms lt 7mA 8 outputs acc to EN 61131 2 24 VDC 20 29 VDC 500 mA ohmic inductive lamp load cyclic 500 Hz 100 channels operating voltage no between channels no operating voltage fieldbus depending on bus system
47. the user to highlight tools that are Select Tools currently in the system Pressing the Select Tools button a second time will disable all tool buttons and save the current setting 27 Software Introduction September 2011 Microlution AN Software Introduction Index Carousel Indexes the tool carousel to the tool number listed in the textbox to the right of the button Index Carousel to Spindle Tool Indexes the tool carousel to the tool number that is currently in the spindle if the spindle tool is known The spindle tool is established after the first tool change after power up Open Gripper Opens the tool changer gripper to allow user to remove tool if necessary Close Gripper Closes the tool changer gripper to allow user to replace tool if necessary Open Door Opens tool changer door Close Door Closes tool changer door Pressure On Off Switch Turns the air pressure for the pneumatic tool changer on or off The air pressure should be on for all tool changes Select All Highlights all tool buttons indicating that all tools are in the system Unselect All Removes the highlight from all tool buttons indicating that no tools are in the system Load Tool Performs a tool change After pressing the Load Tool button choose a highlighted tool button to change to that tool X Button Cancels a tool change started with the Load Tool button but before t
48. 0 000 RPM air turbine and air bearing spindle with a manual collet Figure 7 6 Equipment 1 2 5mm hex wrench 1 Collet pin 1 M5 1 Wrench Figure 7 6 160 000 RPM spindle tool changing Tool Installation Figure 7 6 1 Jogthe Z stage at least 40mm away from pallet Turn off the spindle 3 Verify that the spindle is clear of the workpiece and the pallet Also verify that the spindle is disabled within the CNC control Panel 4 Open the protective lid 5 Place the tool into the collet with the working end towards the workpiece pallet mounting area a If the tool has a taper place only the widest part of the tool into the collet b Only place the round part of tool into the collet never the flutes 6 Remove the hex screw from the spindle with 3 32 hex wrench 7 Place the collet pin in the hole where the hex screw was removed 8 Standing in front of the machine turn the collet nut counterclockwise with fingers until finger tight 9 Place the M5 1 wrench on the collet and turn counterclockwise until tight 10 Remove the wrench and collet pin 11 Replace the hex screw in the spindle with a 3 32 hex wrench 12 Close the protective lid D 64 Operation September 2011 VIII Operation Tool Removal Figure 7 6 Jog the Z stage at least 40mm away from the pallet Turn off the spindle Verify that the tool is clear of the workpiece and pallet Also verify that the spindle is off Open the protect
49. 0 5mm Note The tool sense type B can either be 1 tool length sense only 2 tool length sense with one sided diameter sense or 3 tool length sense with two sided diameter sense G121 Tool Sense Breakage Detection Format G121 H L S Required Inputs H Tool number Optional Inputs Default L Tolerance for breakage detection 0 1 mm S Spindle speed 5000 rpm G123 Automatic Workpiece Detection Format G123 H J W X Y Z Required Inputs Optional Inputs Default H Tool number tool 1 J Offset off of the detected location 0 mm WwW Workpiece offset number 0 X Detection location along the X axis current location Y Detection location along the Y axis current location Z Initial Z axis move destination current location Note The workpiece offset number can be 0 6 The numbers 1 6 represent the workpiece offsets G54 G59 The number O enables the user to immediately apply without saving it to a particular workpiece offset G201 Pallet Change Format G201 Required Inputs Optional Inputs Moo Program Stop Flag Format Moo Required Inputs Optional Inputs M01 Optional Stop Flag Format MO1 Required Inputs Optional Inputs Note The optional stop flag will only stop the program if the optional stop indicator located in the Program Panel is ON 123 Supported G and M Codes September 2011 Microlution IX Supported G and M Codes AN M02 End of Program Flag Format M02 Required Inputs Opti
50. 15 Cleaning Maintenance September 2011 Microlution LAN SUPPORTED G AND M CODES IX Supported G and M Codes Table 9 1 Supported G and M Codes Code Description Parameters G00 Rapid positioning XYZ G01 Linear interpolation XYZF G02 CW circular interpolation XYZIJKForXYZRF G03 CCW circular interpolation XYZIJKForXYZRF G04 Dwell P G10 Data Setting L P R X Y Z G11 Data Setting End G17 X Y plane selection G18 X Z plane selection G19 Y Z plane selection G20 Set units to inches G21 Set units to millimeters G28 Return to machine reference position metric only XYZ G28 1 Machine at reference position check G40 Tool radius compensation off G41 Tool radius compensation left D G42 Tool radius compensation right D G43 Apply Tool Offset FHZ G49 Remove Tool Offset FHZ G54 G59 Work Offsets One Through Six Additional G65 Macro Call A M P Z G80 Canned cycle cancel G81 Drilling spot drill XYZRF G82 Drilling cycle counter bore XYZRPF G83 Drilling cycle peck XYZRQF G90 Absolute Positioning G91 Incremental Positioning G98 Canned cycle Initial Level return default G99 Canned cycle R return level G120 Tool length diameter measurement option required BHFIJ G121 Tool breakage detection option required HLS G123 Machine Workpiece Measurement option required HJWXYZ
51. 2015 is X offset stored in G57 Parameter 6 by measurement 2 Dwell Reset X offset for G56 Parameter 5 to zero Dwell Reset X offset for G57 Parameter 6 to zero Dwell Apply G55 Parameter 1 work offset This offset has the new X offset centered on the feature Apply appropriate tool offset tool 2 here Parameter 4 Move to zero position Move to appropriate location for measurement Measurement move with appropriate tool offset H2 Parameter 4 and G56 Parameter 5 S3 Location will depend on size of feature This will update the Z offset for G56 Parameter 5 Offset Z offset by 6mm to have the Z axis zero 6mm above the work piece surface Apply G55 Parameter 1 work offset Has the X offset such that tool is centered along X Has Z offset such that Z axis zero position is 6mm above the surface Apply appropriate tool offset End program 86 Operation September 2011 Microlution VIII Operation LM Subroutines and Macro Program Calls Subroutine and macro program calls hereafter jointly referred to as subprograms can be performed by the Microlution 363 S Subprograms can be very useful in order to reduce the amount of redundant code contained in the main program Subprograms are also unique because they enable the use of conditional statements Conditional statements are further explained in the next section Setup and Organization Subprograms can be accessed by main programs in 3 ways First the subprograms
52. 41E ATC amp 50 000 NR40 5100 ATC RPM Electric Motor Driven Spindles with Automatic Tool Changing Capability pictured in Figure 5 4 ocoonccnnnoccncconoccnononanonoonnnnconnnccnnnnnnnccnnnss 48 50 000 IBAG HF45A60CP RPM Electric Motor Driven Spindles with Automatic Tool Changing Capabilit A noni A E E E E E E E 48 80 000 RPM Electric Motor Driven Spindles NRA 5080 cccscccccsssscecsssceceessececsessececsesseceeseseceaas 48 160 000 RPM Air Turbine Air Bearing Spindle ABS 1600 ccccccccssscccsssseceesssseceesseeeceesseeeeneseeees 48 Front Of tHE MACHiNG oidos dni cas a A de e T A Ee EES T EEE 51 Handheld Pena ci e eea A E A E A EA Deas 52 Machinfe Regulatorss r a eco 53 Backof the Mac Me A ia Stoacawies 55 Installation transportation P aE E PA AA EEE AAEE E EEEE AAEE E IAEA SE AE E E 57 ON A A TRE E AAA E T 57 ME E EE E EEE EE EEO 58 1 Table of Contents September 2011 Microlution i Table of Contents Pallet Jack or FOrK Lifts cds da de A EE R E ES ES 58 Operation ser eacrs ees A AA AAA di 59 Power On PLO COCUFE cid dis da ade Add dada das 59 PoWer DOWN POCA ii A a E a aa eno 59 Software Startup and Homing the MOTOFS ccccconccoonnnnnnccnnononnnnnnncnnnnnonnnnnnncnnnnnenonnnnnnnnnnnnnnnnnnnnnnannnnnnnnnnnnnos 59 Sl O a ae 60 Before Enabling the Spindle t ari aea ea e E a E A EE EEO EENE 60 selana aaeoa ERE E A EA 60 Changing the SpindleSpeed e er a sche a oa cd 61 Disablinge the Sp
53. Automatic Tool Changer The automatic tool changer automatically loads and unloads tools from the machine Figure 7 9 shows a layout of the hardware components Table 7 1 Tool requirements for the automatic tool changer Description Specification Tool Length L 38 1 mm 1 5 Tool Shank Diameter D 3 18 mm 0 125 Tool Collar Outer Diameter D 9mm Diameter standard size Tool Collar Thickness t 7mm standard size Tool Collar Location A 19mm 0 75 from tool tip oa b hd t Figure 7 9 Tool dimensions Manual Operation Mode The touchscreen interface enables manual operation of key tool changer functions These operations can be found in the Tool Changer Tab shown in Fig 7 10 Also Table 7 2 gives a description of the manual interface functions 68 Operation September 2011 VIII Microlution Operation AN Part Tool Program Laser Pattern Changer Control Panel Figure 7 10 Manual interface for tool changer operation Table 7 2 Tool changer manual interface buttons and their functions Button Function Home Resets communication between the PC and the tool changer controller In addition it performs a homing move with the tool carousel to re establish the proper carousel orientation Carousel Up Down Raises and lowers the carousel arm Ensure that the carousel is raised before executing a tool change Lowe
54. Changing Kinematic Mount Type The spindle mounting system is designed to be very repeatable Additionally the mounting system allows for quick removal and attachment so that spindles can be cleaned inspected changed etc The spindle is held in place by two ball and Vee block connections and two ball and split Vee connections The balls are located at the four corners of the spindle mount The two Vees are located closest to the pallet on the Z axis of the machine as shown in Figure 7 2 The two split Vees are also located on the Z axis but are farther from the pallet See Figure 7 2 The holding force is provided by four permanent magnets The arrangement of the Vee and split Vee blocks and the implementation of the rare earth magnets provide an exact kinematic support mounting system that has sub micron repeatability Vee Blocks Split Vee Blocks Magnets Figure 7 2 Spindle attachment points Removing the Spindle Jog the Z stage away from the pallet at least 40mm Turn off the spindle Verify that the tool is clear of the workpiece and the pallet Also verify that the spindle is off Open the protective lid Disconnect the air and electrical connections on the spindle if possible Lift the back of the spindle off the split Vee blocks as illustrated in Figure 7 3 withdraw the spindle from the working volume and pull away from the front Vee blocks au PWN bP 129 Appendix A September 2011 Microlution Xl Appendix A
55. During first programmed stop Remove spindle install laser and close lid Press start to resume program operation start workpiece measurement cycle During second programmed stop Remove laser install spindle and close lid Press start to resume program operation Pou Ni 132 Appendix A September 2011 Microlution xI Appendix A Spindle Control Unit 60 000 RPM Spindle Control Unit for use with electric motor driven spindles Use the Nakanishi spindle control unit operation manual in conjunction with these guidelines If the spindle control unit is displaying an error code refer to the Nakanishi manual or to tables 5 1 and 5 2 to determine the cause for the error Use the guidelines below to help troubleshoot the problem e E stop error The E stop circuit may be tripped Make sure that the E stop button on the handheld pendant is not pushed e Air supply error The cooling air is not adequate for the spindle Check the spindle cooling air pressure gauge on the side of the machine as shown in Figure 5 8 to make sure pressure is at least 71 psi e Difficulty clearing errors If you think that all the potential causes for errors have been checked try restarting the spindle control unit by cycling power to the spindle control unit To cycle power to the spindle open the Program Run Tab within the CNC Control Panel Click the Disable Spindle button to power off the spindle control unit Press the Enable Spindle
56. G1 X10 YO F500 G122 W1 MO G54 G43 H1 S10000 M3 1 M5 Spindle Stop This step stops the spindle so that it can be removed 2 MO Programmed Stop This step suspends program execution to allow the operator to remove the spindle install the laser and close the lid 3 G1 X10 YO F500 Move to measurement position This step moves the spindle to the desired measurement position In this case the desired position is X10 YO 4 G122 W1 Workpiece measurement cycle This step executes the workpiece measurement and saves the measurements to the desired offset register In this case the measurements are saved to G54 5 MO Programmed Stop This step suspends program execution to allow the operator to remove the laser install the spindle and close the lid 6 G54 Apply workpiece offset This step applies the appropriate workpiece offset 131 Appendix A September 2011 Microlution Xl Appendix A AN 7 G43 H1 Apply tool length offset This step applies the appropriate tool length offset In this case the offset for Tool 1 is applied A current tool measurement is required prior to this step to ensure that the proper tool length offset is applied 8 S10000 M3 Start spindle rotation This step restarts the spindle rotation at the specified speed In this case the spindle speed is set to 10 000 rpm Below are the steps that the operator must follow when performing a workpiece sensing operation within the NC code
57. L BROS CHANGER LASER Control Panel Feedrate On Off Feedrate mm min Flood Coolant O O Override Air Coolant O BEE oo Optionaistop O ma JOG COMBINE OFFSET Spindle 1 pp MDI TERMINAL SENSOR USER Input Panel Increment nm Figure 7 26 Combine Tab and Program Run Tab within the Main Interface Window ele ral E Aee Spindle Control The Combine Tab allows larger NC programs to be loaded into memory on the PC and transferred to the controller using a rotary buffer There is no program size limit when running a program this way The Combine Tab is accessible in the Input Panel of the Main Interface Window The Combine Tab is shown in Fig 7 26 With the tab open an NC program can be loaded into the program queue by clicking the Browse button and selecting the appropriate file from the dialog box After the NC program has been loaded into the queue clicking the Load button will load the program into the rotary buffer and it will consequently appear in the program box in the G Code Tab of the View Panel shown in Fig 7 26 Note Large programs may take a few moments to display Once the program is loaded program execution can be controlled through the Program Tab of the Control Panel If necessary air and flood coolant can be turned on and off by clicking their corresponding toggle buttons Single
58. Microlution Microlution i i Table of Contents TABLE OF CONTENTS Introduction using this manual cccceesccessecesscecssecesseecssecesseecsseceseeeessecesseeessecesseeesaeceseecsaecesseecsaeceseecsaeeeeeess 5 O NE NN 6 READ BEFORE OPERATING THIS MACHINE ccceceseeseceececececeeseeuececececeeseaueeeceeecesseaueaeceseceseesaeaeeeeeeeseesaaees 6 Observe and Obey All Warnings Listed BelOW occcocococooncnncnnconononnnononcconononnnnnnncnnnnnonnonnnncnnnnnonnnnnnncnnnnnnns 7 Machine Information tacon io nara ie Rada RA nana Se NEA 9 General Machine Specifications cocoococonccncconononaonnnnonnnonononnnnncnnonnnnonnnnnnnnnnnononnnnnnncnnnnnennnnnnnnnnnnnennnnnnncnninnnns 9 Machine Request E 10 Operating CON AS A a 10 Spindle SPECITICATIONS a A A E E A ASIA 11 SoftWare IATFODUCTION vna tica ID bd A de AE dd i 13 Touchscreen Alignment Procedure ccccecsessscccececsesseaesecececeeeeaseecececeesesassesecsceesesesaeseescessesesaeseesesseeseaaees 14 ON CEN KE DO ii a cra 15 MENU BUS aa 16 Panels air EEEE cossaenshityabaasesleceunspuothadaenasatesussunaseveadech ont AEE EE e AAEE EEE 21 Dashboard NO 21 Control PAM A ANNO 22 View lira a E A E AA AA AA A E TEE AA T Ea 29 RN 37 Hardware io AAA O E EEE E ENE a ia 44 Coordinate AXES viii a AAA ERE A AA ET Aa 44 Pall tand Spindle MOUNTING ter oia 45 Work Piece Mounting System seteia a e a e a Ea eA EE SE 46 Spindle Introduction 48 40 000 NR 50
59. Recovery Cause s System Response Procedure Machining cycle will stop See Probing Workpiece Probing Error ee Probing Manual la Me BE E Spindle rotation will stop Manual Check for beam Tool measurements not within al blockage es Machining cycle will stop specified repeatability band Spindle rotation will sto Re run tool Tool sensor beam blocked p p length measurement Tool Length Measurement Error Check for beam Tool measurements not within o blockage Tool Diameter Program will stop Re run tool specified repeatability band Measurement Error Spindle will sto Tool sensor beam blocked P p diameter measurement Tool Breakage Alarm Tool breakage detected System pause Replace tool 32 Software Introduction September 2011 IV Software Introduction Microlution AN Tool Dirty Alarm Dirty tool detected E stop button pressed Controller watchdog fault Regen resistor temperature fault E Stop Circuit Tripped X Axis Travel Limit ae Software travel limit exceeded Exceeded Y Axis Travel Limit Software travel limit exceeded Exceeded Z Axis Travel Limit Exceeded Following error limit exceeded Following error limit exceeded Following error limit exceeded X Axis Following Error Y Axis Following Error Z Axis Following Error Amplifier fault Amplifier fault Amplifier fault X Axis Amplifier Fault Y Axis Amplifier Fault Z Axis Amplifier Fault Warning error limit exceeded Warning erro
60. TION Ensure machine is off and that there is no power flowing to the power distribution box before replacing fuses Regular Dust Ingress Check Overview This section describes an update to the machine preventative maintenance for the Optomill to check for dust ingress into the X Y stage This check should be performed monthly to ensure error free operation Procedure 1 Power down machine 2 Thoroughly clean machining area to remove plastic dust using a brush and vacuum 3 Remove the fixed top cover on the X Y stage see figure below using a Phillips screwdriver 4 Removethe moving mirror plate on the X Y stage see figure below using a Phillips screwdriver 5 Inspect internal components of X Y stage for dust ingress Record observations and take pictures for future reference If significant dust is observed contact Microlution 6 Replace mirror plate and fixed top cover 7 Remove machine side panels see figure below and inspect machine cabinet for dust Record observations and take pictures for future reference Vacuum any dust observed in machine cabinet 8 Replace machine side panels 114 Cleaning Maintenance September 2011 Microlution Vil Cleaning Maintenance HAN 5 X Y Stage Mirror Plate 4 Fasteners Total X Y Stage Fixed Top Cover 9 Fasteners Total Figure 8 3 X Y stage chip guard removal IDE PANELS 4 FASTENERS PER PANEL Figure 8 4 Machine side panel removal 1
61. a ripped or cracked protective rubber boot can allow chips and coolant to enter the machine and cause severe damage to the motion control and electronic systems 141 Appendix A September 2011 Microlution xl Appendix A HA Laser Inspection LT 9010 Confocal Laser Option Required Use the Laser Inspection Tab to measure machined parts without removing the pallet from the machine After completing the laser inspection process use the Metrology software to analyze the surface roughness take measurement and assess the quality of machined parts The Laser Inspection Tab is displayed in Figure 7 32 Control Panel Scanning Pattern Predefined User Defined v Start Point x 0 0 Y 0 0 End Point X 11 0 Y 1 0 Step Over mm 0 005 Sample Spacing in Scanning Dir mm 0 005 Data File Setting Directory File Name Sampling Rate Hz 500 Figure 7 32 Laser Inspection Tab Laser scans can be performed in one of four predefined scanning patterns or in a user created scanning pattern The predefined scanning patterns will be the easiest and most useful scanning solutions for typical users Scanning Using a Predefined Scanning Pattern 1 Mount the laser distance sensor to the Z stage remove the spindle if necessary Open the Laser Inspection Tab within the CNC Control Panel 3 Select the Predefined Scanning Pattern selection circle Figure 7 32 From the drop down menu select the desired
62. aa EEEa 75 Auto Sensing Multiple Tools for a Job using the Microlution mMT Control Software cceccceeees 75 Manual Operation Mode A aaa 76 Implementation in an NC Program ccccccccccccecsesssececececsesseaeseeececsesesseseesescseseeaeseesceseeseeaeseeeesseeseaaees 76 Z Axis Fixture Probing G123 Cycle cscscccccccssssssnsecececsesessneeseceesenesneasseceescsesseassesecessessnasaesecsesesasanaeseesss 77 SOTA and Parameters cies sacise E sensed ecesdectun ai 77 Fixture Probing Example iii ceda da 77 Workpiece Proba A E 78 X Y Z single surface measurement G65 P9811 conoonccnnncccnccooucnnononanononnonocononononononcnnnnnnnconnnnnnnnnnnnccinnss 79 Table of Contents September 2011 Microlution i Table of Contents Pallet ID function G65 PORO cir ci ei i ia edades 81 Error COdeiNAexitable iia drid shea fens e A E A da E 84 EXP A LES 85 Subroutines and Macro Program Calls cccconccocoonncncnnnononnnnnnnnnnnononnnnnnncnnnnnnonnnnnnnnnnnononnnnnnnnannnnncnnnnnnnos 87 SECUP ANG OFGANIZATIONN ca A eden acia 87 Syntaxcand PAM A a acia 87 Subprogram Parameter Variables ccccoconoooooconccononennnnnncnnnonennnnnnncnnnnnonnonnnnnnnnnnnnonnnnnnnannnonnnnnnnnos 88 Subprogram Examples cin e aid 89 RARA 90 Data Setting Group Descripti0NS cocococococonnnonononononononononononononono nono no nono nn nono nono nono nono nono rn nn rn nono rn Raak ina ka 90 Data Setting Examples n e ieee
63. achine unless the protective lid is closed Rotating cutting tools can cause severe injury When a program is running the X Y and Z stages as well as the spindle can move rapidly at any time in any direction e The Emergency Stop button also known as an Emergency Power Off button is the large circular red switch located on the handheld pendant see Hardware Introduction section Pressing the Emergency Stop button will shut off power to the X Y and Z stage motors as well as the spindle Use the Emergency Stop button only in emergencies to avoid crashing the machine e All machine panels should be closed and secured at all times except during installation and servicing During installation and servicing only qualified personnel should have access to the machine When power is supplied to the machine some components operate at high temperatures Therefore extreme caution is required Once the machine is installed the control cabinet must be secured and only opened by qualified service personnel e DO NOT modify or alter this equipment in any way If modifications are necessary all such requests must be handled by Microlution Inc Any modification or alteration of any Microlution milling machine could lead to personal injury and or mechanical damage and will void your warranty e It is the machine supervisor s responsibility to make certain that all who operate or service the machine are thoroughly acquainted with the installation operation
64. b Also be sure to open the tool changer door and leave it open until adjustments are complete The top rear panel of the machine may need to be removed to gain better access as well When adjusting the position of the gripper on the tool wheel side of travel use the outer side X actuator travel stop and the top side rotary actuator travel stops for horizontal and vertical adjustment respectively Note vertical adjustments may affect horizontal position slightly Fig 7 13 shows the adjustment locations and corresponding gripper travel for aligning at the tool wheel side AA X Adjustment Figure 7 13 Alignment at the tool wheel side With the tool wheel homed adjust the gripper so that the closed gripper is centered on the nearest tool position on the wheel To adjust the tool changer gripper on the spindle side extend the tool changer arm to the spindle position and close the gripper around a tool Make sure the spindle collet is open and empty and Kill and retract the Z stage Adjust the vertical and horizontal position of the tool gripper so that the tool slides smoothly in and out of the open collet Fig 7 14 shows the adjustment of the tool changer gripper on the spindle side 72 Operation September 2011 Microlution VIII Operation AN Tool Collar Setting using Bohan Tool Setter There are two means to ensure reliable tool collar setting Many tool vendors will offer tools with pre set tool collars Also a specializ
65. board can be dragged anywhere on the screen After pressing this button the next time the screen is touched a right click will be simulated After the right click occurs this button is no longer enabled and any subsequent touch of the screen will result in a normal left click e A Switch Allows the user to switch the keyboard keys to a different character set Language Currently English is the only language available Menu Right Click Hides the keyboard from view The keyboard can be unhidden by pressing the button in the lower right of the screen that shows up while the keyboard is hidden Hide Turns off the keyboard The easiest way to reopen the keyboard after Power AN turning it off is through the Start menu Figure 4 2 On screen keyboard 15 Software Introduction September 2011 Microlution IV Software Introduction AN Menu Buttons Additional panel tabs are located at the top of the main Start up screen as labeled in Figure 4 1 Clicking on the icon brings up the panel Setup A The Setup menu button is located in the upper left corner of the main interface window at startup The Setup Window Figure 4 3 is used for initial motor homing motion setup and may contain customized setup software see Appendix A for customized setup instructions Upon machine power up the motors must be phased See the Software Startup and Homing the Motors sub section under the Operation section of this
66. box will display the feedrate from the G code The Override box is used to scale Feedrate the G code feedrate commands Override will increase or decrease the displayed feedrate by the percentage displayed in the Override text box This can be useful to slow down a program and monitor all operations to ensure they are completed as anticipated or speed up the program to l determine optimum feedrates The maximum override is 200 of the displayed feedrate verride Note Changing the Override will not change the feedrate displayed in the Feedrate Text Box However the displayed feedrate is scaled by the percent listed in the Override Text Box The true feedrate is the scaled override value of the displayed feedrate in the Feedrate Text Box Turns the air supply to the air bearings in the spindle on When the spindle is enabled the Enable Spindle speed can be set and the spindle started and stopped the tool release is also disabled so that a tool cannot be released while in motion The RPM Text Box displays the desired spindle speed The spindle must be enabled to modify the RPM text box Click the Set button to set the spindle speed to the displayed value The spindle must be enabled and on to adjust spindle speed The buttons will increase or decrease the spindle speed by the displayed increment RPM Laser Inspection Tab LT 9000 Confocal Laser Option Required The Laser Inspection Tab see Figure 4 12 allows the us
67. by step amount The scan will then decrement the angle until the start angle is reached This process repeats until the end value of radius and angle is reached Circular Area Arc Scan 10 11 12 13 14 Choose the X and Y program coordinates where the scan will start and stop refer to Figure 7 32 for button locations For circular scan patterns choose the X and Y program coordinates of the center of the scanning arc circle and the radii of the start and stop arcs circles The scan path will progress based on the selected scanning pattern Choose the Step Over distance The Step Over distance is the distance the laser moves after completing one line of scanning It is recommended to set the Step Over distance equal to the Sample Spacing Choose the desired Sample Spacing The Sample Spacing is equivalent to the distance between each data point in the scanning direction Choose the Sample Rate The Sampling Rate decides how many data points are taken each second The computer computes the necessary feedrate based on the Sample Spacing and the Sampling Rate Use the Browse button to choose the directory the file is saved to Name the file using the File Name box Press the Enable Laser button to turn the laser on Press the Setup button to prepare the laser Press the Start button to start scanning A dialog box will appear to inform the user when the scan is finished The Stop button can be pressed at any time to sto
68. by the step amount and the scan will proceed along the new radius until reaching the start radius This process repeats until the end value of radius and angle is reached The scan will move along an arc starting with a radius equal to the start radius and angle equal to the start angle The angle will increment until the end angle is reached The radius will then be incremented by step amount The scan will then decrement the angle until the start angle is reached This process repeats until the end value of radius and angle is Rectangular Area X Scan Pulldown Menu Rectangular Area Y Scan Pulldown Menu Circular Area R Scan Pulldown Menu Circular Area Arc Scan Pulldown Menu 25 Software Introduction September 2011 Microlution IV Software Introduction HA reached Allows the user to load a G code program to control the scan useful for User Defined Scanning Program i y more complex scans or sequentially completing multiple types of scans Sample Spacing in Scanning Dir Distance between samples Data points will be collected every time the mm distance traveled increases by this number Sampling rate desired on laser system This is used in conjunction with sample spacing to determine feed rates Fast sampling rates however can cause data points to be missed 1 kHz is recommended sampling speed but up to 2 kHz is typically reliable Sampling Rate Hz Load
69. can be included in the main program file as shown in the subprogram example These subprograms should be noted by starting the code with the subprogram number i e O and ending the code with a M99 call The four number format is required for this to work properly Secondly the subprograms can be stored as separate files in the same folder as the main program These programs must be named with only the subprogram number in the four digit format and be of the same file type as the main program Lastly the subprograms can be stored in the communal subprogram folder C Program Files Microlution Subprograms These also need to be named with only the subprogram number in the four digit format and be of the same file type as the main program If there is no subprogram found for a subprogram call an error will result Ensure that the main program also has a four digit format program number Subprograms numbered 1 8999 are available for user access Subprograms are 9000 9999 are for internal access NOTE It is possible to have different subprograms in all 3 places Ensure that the correct subprogram is in correct place The main program will first look at the bottom of its own file then in the same folder and then finally in the communal folder NOTE Subprograms are loaded into controller memory upon the Load G Code button click If any subprogram files are modified after the Load G Code button is clicked those changes will not
70. ce sensing 130 Appendix A September 2011 Microlution Xl Appendix A AN The workpiece sensing function uses a laser displacement sensor attachment to measure the thickness of the workpiece at a particular location Manual Operation Mode Below are the steps to use the workpiece sensor manually using the touch screen interface Stop spindle if rotating Remove tool from spindle Disable spindle using the Disable Spindle button Remove spindle Install laser Move machine to desired X Y position Close lid Press Workpiece Sensing button located in the User Tab of the Input Panel Ensure laser is on The laser will move toward the workpiece until it reaches the appropriate measurement range The laser sensing is complete when the laser turns off and the stage retracts 10 The workpiece thickness offset is automatically saved to the G54 workpiece offset register The offset will also be displayed in the text box next to the Workpiece Sensing button a ee Ee a Operation in an NC Program Workpiece sensing is executed using G122 The syntax for this code is as follows G122 Wx Where x is the worpiece offset number between 1 6 to which the measurement will be saved If this parameter is set to 1 the measurement is saved to the G54 registers if set to 2 the measurement is saved to G55 registers and so on Standard implementation within an NC program might look like this below is a description of each step M5 MO
71. correct pockets for milling using the Set Pockets button browse to the correct program file through the Browse button and then load the program by clicking the Load Program button Press Cycle Start to begin 42 Software Introduction September 2011 Software Introduction Microlution AN Figure 4 28 User Tab Mandrel 43 Software Introduction September 2011 Microlution V Hardware Introduction HARDWARE INTRODUCTION Coordinate Axes Coordinate Axes The coordinate system for the 363 S is a right handed system set up with the positive x axis extending to the right when facing the machine the positive y axis extending up and the positive z axis extending toward the front of the machine as seen in Figure 5 1 Figure 5 1 Coordinate axes 44 Hardware Introduction September 2011 Microlution V Hardware Introduction AN Pallet and Spindle Mounting Figure 5 2 X Y Z stage introduction The following items reference Figure 5 2 X Y Stage The X Y stage moves in the X Y plane and has 2 48 63 mm of travel in each direction Pallets see Work Piece Mounting System Section for an introduction to pallets are mounted to the Erowa pallet mounting system located on the X Y stage Erowa Pallet Mounting System The Erowa pallet mount system allows pallets to quickly and easily be changed with sub micron repositioning repeatability The mounting system uses a pneuma
72. e LO Recommended Air Vacuum Setup to Prevent Dust Ingress Overview The air blast and vacuum system work together to remove machined particles from the work area and keep them from ingressing into the internals of the machine The figures below show the proper setup of the sytem The vacuum hose attachment is attached and sealed to the chip chute The vacuum nozzle is installed beneath the work zone This nozzle is held in place using four magnetic feet and can be removed for cleaning maintenance Caution must be used when removing the vacuum nozzle to prevent any contact with a sharp tool tip The air blast line is attached to the spindle mount and MUST be oriented to point downward to the tool tip and toward the vacuum nozzle This is because the air blast strongly influences the direction of debris The air blast line can be bent or adjusted achieve the proper air flow direction VACUUM NOZZLE VACUUM HOSE ATTACHMENT IMPORTANT AIR BLAST SHOULD POINT DOWNWARD TOWARD TOOL AND VACUUM NOZZLE Figure 8 2 Air blast vacuum setup 111 Cleaning Maintenance September 2011 Microlution VIII Cleaning Maintenance AN Chip Cleanup A wet dry vacuum is the most effective way to remove stray chips in and around the machine The machine can also be wiped down with a shop towel or fine bristled brush DO NOT use air blast to blow away chips Protective Lid and Chip Hood Cleaning Clean the clear p
73. e micron per rotation increment X10 moves each stage ten microns per rotation increment and X100 moves each stage 100 microns per rotation increment 4 Emergency Stop Button The Emergency stop button shuts off the power to the spindle and stage motors Note To return the machine to normal operation after pressing the E stop twist the E Stop clockwise to disengage it Next the linear motors need to be in closed loop mode Refer to the MDI tab segment of this manual for more information about the Close button and closed loop mode The spindle must also be restarted The machine is ready to continue normal operation Enable the spindle within the Program Run tab and click the Cycle Start button to start machining Figure 5 6 Handheld pendant 52 Hardware Introduction September 2011 Microlution V Hardware Introduction AN Machine Regulators CB X Y stage Counterbalance Pressure Regulator Suspends the X Y stage to decrease the workload of the Y axis linear motors Pressure will vary based on the weight on the workpiece Adjust the pressure until the X Y stage is suspended and stationary 1 Regulator 1 Tool Collet Pressure Regulator Airbearing Spindle optional Regulates the pressure used during tool changes on automatic tool changing spindles Aux 1 can also be used to supply air to the air bearing spindle options Suggested air pressure is approximately 0 6 MPa 2 Regulator 2 Spindle Co
74. e then stored in program 300 Any number less than 1000 can be used as the program number Note The file size should be less than 300kb larger programs can still be run on the 363 S but must utilize the rotary buffer in the CNC Control Panel For programs larger than 300kb always use the CNC control panel s Program Run Tab After downloading the program to the controller set the desired spindle speed and start the spindle refer to the Program Run Tab segment of this manual Run the program by opening the Terminal Tab and type the run command into the Terminal Entry Line The run command is executed by typing b r into the Terminal Entry Line where is the program number For example typing b300r would run program 300 Any program loaded into the controllers memory can be run using the Terminal Tab The program can be stopped at any time using the Stop button 106 Operation September 2011 Microlution VIII Operation AN Automatically Running a Program by Using the Combine Tab and the Program Tab Microlution 363 S Position mm Offset mm To Go mm Load y CAMERA ERRoR status 00 0000 00 0000 00 0000 LASER warnine STATUS 00 0000 00 0000 00 0000 00 0000 00 0000 00 0000 000000 Active G codes M codes G1 1 G18 G20 G40 G43 G54 1 G90 G94 G99 M00 MOS M07 Current Tool lt D 2 TU o 5 Do TOO
75. ed tool collar setting machine can be acquired for more accurate tool collar setting Below describes one option of tool collar setter along with the procedure for using it This tool collar setter was purchased from Bohan Engineering Limited Machine Lever Tool Collar Setter Tool Collar Remover Collar Holding Bar Collar Collection Bin Tool Collar Set Length Gauge Tool Collar Setting Insert a tool tip down into the tool collar setter and a collar into the collar holding bar as shown in figure 7 15 Rotate the machine lever downward until tool collar set length gauge is at the appropriate reading Slowly release the machine lever and remove tool with collar from the tool collar setter Tool Collar Removal Figure 7 15 Tool Collar Setting Insert tool with collar tip down with the collar resting in the collar holding bar Rotate the machine lever downward Make sure to hold the tool so that it does not fall from the machine and break Once tool is free from collar slowly release the machine lever The collar will fall into the collar collection bin for easy retrieval Figure 7 16 Tool Collar Removal 73 Operation September 2011 VIII Operation Tool Collar Setting using Two Piece Setting System 1 Set desired set length a Loosen set screws 1 and 2 b Slide one of the included length standards into part 1 of the ring setter Back out the adjustment screw far enough to allow the collar of the length sta
76. ember 2011 Microlution LO VIII Operation The G10 command can be used for data setting tool offset tool compensation and workpiece offset values It can also be used to set user variables Offset compensation setting commands data setting group numbers 2 20 10 12 11 13 are non modal and so only affect the line they are on User variable setting commands data setting group number 50 are modal each following line is an additional data setting command and can only be turned off using the G11 command The current coordinate system mode absolute or incremental affects the behavior of data setting groups 2 20 10 12 11 and 13 If in absolute mode these groups will overwrite the current offset compensation value with the parameter value If in incremental mode these groups will add the parameter value to the current offset compensation value Data Setting Group Descriptions Group Number Description Required Parameters Optional Parameters Fixed atiset data setting group Enables updating occ oiai X Keerde offset value 2 workpiece offsets Parameter P denotes the offset E EE E Y Y axis offset value with range 1 6 referring to G54 G59 p Z Z axis offset value Additional offset data setting group Enable l X X axis offset value updating additional workpiece offsets Parameter P P Workpiece offset 20 Y Y axis offset value denotes the offset with range
77. eptember 2011 Microlution VIII Operation AN Application The function measures posts at specified locations to identify the pallet number for the current pallet Based on the output appropriate machining or measurement code can be used on the machine The measurement assumes that the posts are located along an horizontal line beginning at point X Y and subsequent posts are at a spacing of Bb each along the positive X direction The Z height of the post also needs to be specified as a compulsory input The program runs in the currently active work offset Measurement system The measurement is done in the binary system For measurement with more than 1 post the left most post represents the most significant bit MSB and the right most post representing the least significant bit LSB The weightage of each post from the right is obtained by multiplying the weightage of the post to the right of it by 2 By definition the weightage of the right most post is 1 Hence by definition the weightage of the post to the left of it is 2 and one left to that is 4 and so on Consider the example below with 3 posts Weightage of the posts 1 4 Output in binary system 101 To obtain the output in the decimal system multiply the value of the post by its individual weightage Hence the output for this case in decimal system is 1 4 0 2 1 1 5 The program outputs the above pallet number in the decimal system in variable Q4325 0 1 2 i
78. er to scan a part using a built in scan path or by using a user defined scan path Table 4 4 lists the applicable buttons and their functions for the Laser Inspection Tab Refer to the Operation section of this manual for a step by step set of instructions for using the Laser Inspection Tab 24 Software Introduction September 2011 Microlution IV Software Introduction HAN Control Panel Scanning Pattern Predefined User Defined v Data File Setting Directory File Name Sampling Rate Hz 500 Figure 4 12 Laser Inspection Tab Table 4 4 Laser Inspection Tab buttons and their functions Button Function Predefined Scanning Pattern Select pattern to use Sets the scan to proceed from the start X and Y position to the end X position After reaching the end X position the Y position is incremented towards the Y end position by the step amount and scans from the end X value to the start X value This process repeats until the end value of X and Y is reached Sets the scan to proceed from the start X and Y position to the end Y position After reaching the end Y position the X position is incremented towards the X end position by the step amount and scans from the end Y value to the start Y value This process repeats until the end value of X and Y is reached The scan will move radially starting at the start radius and start angle until the end radius is reached The angle will be incremented
79. erheat Inside Control Unit Internal temperature of the control unit too high A3 Over Load Motor torque load exceeding safe limits A4 Emergency Stop Emergency stop system activated A5 Over Air Pressure Over air supply Table 5 2 Spindle Error Codes Error Code Problem Area Trouble El Excess Current Motor current beyond safe limits E2 Over Voltage Motor voltage beyond safe limits E3 Motor Sensor Trouble with the sensor signal in the motor E4 Control Unit Overheat Internal temperature of the control unit too high E5 Brake Circuit Trouble Trouble with the motor brake circuit E6 Rotor Lock Motor stalled for more than 3 seconds E7 daria Inadequate air supplied for more than 4 seconds during rotation or inadequate air supply when motor start commanded E8 Torque Overload Torque limits exceeded for too long a period of time To Intercept communication with selector unit NE212 Only if using E9 Communication Interception NE211 to connect to the system EA External Control Signal Error External control sequencing problem EC Internal Memory Error Trouble with memory EEPROM EE Emergency Stop Error Safety relay has been activated and the emergency stop system has stopped the motor EH Over Speed Rotating speed is beyond set speed for too long EL Incompatible Motor Incompatible motor is connected to the system 135 Appendix A September 2011 Microlution Xl Appendix A AN Part Pattern Tab The Part Pattern Tab see Figure 4 11 allows a G code p
80. escribed below Table 7 4 Connector 1 DB 25 breakout pinout Pin Description Software Access Variable 1 NC 2 Digital Input 2 M26 3 NC 4 Digital Input 4 M30 5 Digital Input 6 M28 6 Digital Output 2 P2022 7 Digital Output 4 P2024 8 Digital Output 6 P2026 9 Digital Ouptut 8 P2028 10 Analog Input 1 M5064 11 Analog Input 2 M5063 12 Analog Output 2 M802 13 NC 14 Digital Input 1 M27 15 Digital Input 3 M25 16 NC 17 Digital Input 5 M29 18 Digital Output 1 P2021 19 Digital Output 3 P2023 20 Digital Output 5 P2025 21 Digital Output 7 P2027 22 Analog Input 1 M5064 23 Analog Input 2 M5063 24 Analog Output 1 M702 25 COM OV 145 Appendix A September 2011 Microlution Xl Appendix A AN Table 7 5 Connector 2 DB 9 breakout pinout Pin Description Software Access Variable 1 User Flag 1 M117 2 User Flag 2 M217 3 User Flag 3 M317 4 User Flag 4 M417 5 NC 6 User Flag 1 M117 7 User Flag 2 M217 8 User Flag 3 M317 9 User Flag 4 M417 Digital Inputs The digital inputs accept 24V single ended input signals The digital inputs can be accessed in the controller by accessing the appropriate M variable see Delta Tau User Manuals GeoBrick Turbo PMAC User Manual and Software Reference for more information shown in the table above Digital Outputs The digita
81. escribes proper installation and transportation steps precautions and techniques Following the Installation Transportation section is the Operations section The Operations section provides step by step instructions for operating the machine and using the software Finally the Cleaning Maintenance section describes the correct procedure for cleaning and maintaining the machine Note The black highlighted titles differentiate sections The grey highlighted titles breakup the sections into sub sections and are therefore referred to as sub sections Underlined headings within sub sections are referred to as segments 5 Introduction Using This Manual September 2011 Microlution i ll Safety SAFETY Reap Berore OPERATING THis MAcHINE e Only authorized personnel should work on this machine Untrained personnel present a hazard to themselves and the machine and improper operation will void the warranty e Check for damaged parts and tools before operating the machine Any part or tool that is damaged should be properly repaired or replaced by authorized personnel Do not operate the machine if any component does not appear to be functioning correctly Contact your shop supervisor e Use appropriate eye and ear protection while operating the machine ANSI approved impact safety goggles and OSHA approved ear protection are recommended to reduce the risks of sight damage and hearing loss e Do not operate the m
82. ffset This process can be repeated for a total of up to 6 offsets To save all six offsets to a file click the Save To File button and type the name of the file in the dialog box that appears DQO COMBINE OFFSET Absolute O Relative mX 0 0 mm 1 mm Z 0 0 mm Jog Speed Baggi mm min lt Figure 7 30 Jog Tab JOG COMBINE OFFSET TERMINAL SENSOR USER SE E active EEEE A NEOIDOSN AH Input Panel aa eae ee Save To File Retrieve From File Figure 7 31 Offset Tab 108 Operation September 2011 Microlution VIII Operation AN All 6 offsets will be saved to a tab delimited file that can be read back from the file later Saving to a file is the only way to save the program offsets when the machine is powered down When the machine is powered up all offsets are set to their default values of 0 Note Shutting down the Microlution 363 S CNC Control Software does not delete the current saved offsets The offsets that were saved before the program was shut down will be restored the next time the program is started Recall Saved Location from a File 1 Click the Retrieve From button in the Offset Tab of the software Figure 7 31 2 Select the file where the offset locations are stored 3 The 6 saved offsets will be loaded into the 6 G codes These offsets can be previewed by selecting the
83. g Vout 10V Mx02 810 Example Set Analog Output 1 to 5 5V M702 5 5V 10V 810 445 5 User Flags The user flags are wired through an interface circuit to the user input flags for each motor on the GeoBrick controller The flags accept 24VDC logic The flag input voltage can be wired with either positive or negative polarity with respect the descriptions in Table 2 Note the User Flag 1 User Flag 2 User Flag 3 and User Flag 4 inputs are not common Please refer to the Delta Tau GeoBrick User Manual and Delta Tau Software Reference Manual for more information on how to use flags 147 Appendix A September 2011
84. gram M6 executes a tool change operation The syntax for this command is as follows Txx M6 where xx is the tool number to be loaded Standard implementation within an NC program might look as follows below is a description of each step T2 M6 S10000 M3 1 T2 M6 Tool Change This command will unload the current tool in the machine return it to the tool carousel and load the specified tool in the spindle in this case Tool 2 will be loaded In addition this command has built in functionality to stop spindle rotation before unloading the current tool so an M5 command preceding this command is optional but not required 2 S10000 M3 Start spindle rotation This command will start spindle rotation in the clockwise direction at the specified speed In this case the spindle speed is set at 10 000 rpm Tool Changer Alignment The automatic tool changer can be re aligned if tool placement into the tool wheel or spindle begins to function with error The position of the tool gripper can be adjusted in both vertical and horizontal directions using the end stops on the main X axis and rotary pneumatic actuators Fig 7 12 shows the horizontal X and vertical Y adjustment locations Figure 7 12 Tool changer position adjustment locations 71 Operation September 2011 VIII Operation Before adjusting the position of the tool changer gripper arm it is important to first run a home sequence from the tool changer software ta
85. gram coordinate system The graph has units of mm and 0 0 refers to the machine origin The red lines indicate the axes maximums and thus define the working volume of the machine The user can click hold and drag a box on either graph to zoom in Zooming out is achieved by right clicking and selecting Un Zoom or Undo All Zoom Pan Right clicking the graphs with the mouse displays such options as copy save and print This feature is useful for monitoring the utilization of the working volume During setup this feature can be used to adjust the fixturing of the workpiece so that it falls within the working volume To verify the workpiece is within the working volume move the stages ensure stages are killed refer to Table 4 5 for more information on killing stages around the edges of the workpiece and watch the Machine Tool Status to confirm the workpiece falls within the working volume The Clear Part Pattern Array button will clear any part pattern array that is displayed on the Machine Tool Status Graph 30 Software Introduction September 2011 Microlution IV Software Introduction LO G CODE AXIS CAMERA STATUS LASER View Panel Part Pattern Y mm Figure 4 15 Axis Tab showing the Machine Tool Status CameraTab Camera Option Required The Camera Tab displays the image from an optional camera This is useful for visual tool settings and other operation moni
86. h Register required use tool number of tool to be measured S Spindle Speed optional defaults to 5000 use O for no rotation X Radial Offset for Length Measurement optional defaults to 0 0mm Z Axial Offset for Diameter Measurement optional defaults to 0 5mm J Additional Length Offset optional defaults to 0 0mm Length Measurement Examples Example 1 T1M6 Load tool 1 G120 B1 H1 Length only measurement for tool 1 measured at 5 000rpm Example 2 T2M6 Load tool 2 G120 B3 H2 30000 Length and diameter measurement for tool 2 measured at 30 000rpm Calculation of X and Z parameters X and Z are used to change the measurement position for the laser measurement cycle The X parameter should be used when measuring the length of tools larger than 1 5mm in diameter and the Z parameter should be used when the standard axial position 0 5mm from the tip will not measure the correct diameter such as for very small diameter endmills or endmills with corner radii The figure below shows how to calculate X and Z for larger tools For small tools where Z 0 5 is too large use Z length of cut 2 or Z 0 1 whichever is larger X D 2 corner rad 0 5mm Z corner rad 0 5mm Auto Sensing Multiple Tools for a Job using the Microlution mMT Control Software 1 Inthe Tool Changer Tab Press SELECT TOOLS 2 Select the individual tools that will be used for the job tools should highlight green when selected 3
87. he tool is selected Home Resets the tool carousel to ensure that it is in the correct position Pause Tool Changer Pauses the tool change Can be resumed by pressing the button a second time 28 Software Introduction September 2011 Microlution IV Software Introduction HAN View Panel Starting the software automatically opens the View Panel as seen in Figure 4 14 View Panel is used for the user to see feedback information from the 363 S mMT and its peripheral devices The tabs included in this panel are G Code Axis Camera Laser Error Status Warning Status Tool Offsets and Workpiece Offsets G CODE AXIS CAMERA ERROR STATUS TOOL OFFSETS WKP OFFSETS as WARNING STATUS View Panel PROGRAM NAME SUB ABSOLUTE 1 DATE DD MM YY 16 02 10 TIME HH MM 22 11 N100 G21 N102 GO G17 G40 G43 G80 G30 05 FLAT TOOL 2 DIA OFF 2 LEN 2 DIA 1 27 N104 T2 M6 N106 GO G90 G54 X 15 Y 15 535000 M3 Program SUB ABSOLUTE 1 NC Figure 4 14 View Panel GCode Tab G Code Tab The G Code Tab in the View Panel shown in Figure 4 14 displays the current program that is loaded and ready to be run The program can be searched scrolled through using the buttons to the right described in Table 4 6 The program can be loaded and unloaded using the Combine Tab in the Input Panel Once a program is successfully loaded it can be executed with the Cycle Start button in the Program Tab
88. ic Mount Type cc cccccssscccsssseceessseeceessececessseeecsssseceesseeeceessececesseeeesaeeeceeaas 129 Removing the Spd ere a E a E E E a a E ea E a REEE 129 Installing thE Spine a ii Ana 130 WOK ONTE E Ne ii E AE T AT 130 Manual Operation MOde e aida ARo ELEA E AAEE EE EEE ENESE 131 Table of Contents September 2011 Microlution i Table of Contents Operation a EES TES AET 131 Spindle Control Unit resen ena AS AR 133 Part Pattern Taiana ide da EN E A A E A o E 136 Creating a Part Pattern sissano a a a a i a i a i E a aaa 138 Legacy Cleaning Maintenance ccccccssccssssesssecssscecssecesscecseccsececssecssscecseccsascecaeecsaseeeseeceaseecseecsseeecseeceas 141 Laser Inspection LT 9010 Confocal Laser Option Required oococooccccononnnoconcnnnnonannccnnnannccnnnnnnonnnnncnnn 142 Scanning Using a Predefined Scanning Pattern cccconococoonnnnccnnononnnnnnnonnnnnonnnnnnncncnnnononnnnnnnccnnnnnnonos 142 Scanning Using a User Defined Scanning Pattern cccocccocconcnncconononnnnnnncnnnononnnnnnnoncnnnnnonnonnnnccnnnnonnnnos 143 User I O Option required ccccccscccsssccescecsssceeseecsseceessccsscecseecsseccessecsssceeseecssscecssecsaseeeaeecsaseeeseecsseeecaeeceas 145 Digital Input aaa EEA E ceed cedueomue cad Fass canes neniana EE 146 DigitaltO ut puts i ceive iiite i A ede E EEE RE Ea AARRE EEE EATE EE EEEn ese ccees la 146 EOT PUES ui E E EEE E E E EE E EE ceevevtetes 146 Filtered PWM Ana
89. ider ceda 61 Tool Changing Manual Collet 80 000 RPM Electric Air Bearing ccccccccccssscesssecsseceeseecsseceeeeecsseceseeees 62 A O ON 62 A O NN 63 Tool Changing Manual Collet 160 000 RPM Air Turbine Air Bearing oooococonnnonnnononononnnonananonnnonnacnnnnons 64 Tool Installation Erre TA io 64 TOO Removal Figure Tibia ini 65 Tool Changing Automatic Collet ccconccocoonncnccanononoancnnccnonnononnnnncnnnnnononnnnnnnnnnnononnnnnnnnonnnnnnnnnnnncnnnnnennnnos 66 AAA NN 66 NAAA NN 67 Tool Changing Automatic Tool Changer ccccccccccccscssssssecccscsesessssecececeeseseesececscseseseaeeseescessesesaeseeseseeeeaaees 68 Mandal Operation Modez e ss A A A Ai 68 Operation in an NC program eiiceci csssesscelivesdlasevesdiesivesdsshadesnsedivesdlessdnaddesdsnndandadnseded vesdsessanndseadsandacgecdzas 71 Tool Changer Alignment eran a a coaseecuks cddecsdslenseadiacdechestwassaasedsassastyecess 71 Tool Collar Setting using Bohan Tool Setter ccccccccccccssssssscesececeeseseeeesececesseeeeeseesceseesnsaeseesessseseeaees 73 Tool Collar Setting using Two Piece Setting SySteIM ccconccooccnncnccononoonnnncnncnnnnnnnonnnncnnnnnonnnnnnncnnnnnononnos 74 Tool Sensing G120 Cicle eesosa reres eeni ii ae ia E EEEE i EE AASE aS DREE iE aE e 75 Syntax and Para Me TEO dees re ra a Hes do 75 Length Measurement EXIM E a iach nani Ad a a dias 75 Calculation of X and Z parameters no serena se a eie a iea E a Aa E a ii
90. ike swarf Depending on the workpiece material appropriate care for example vacuum swarf removal must be taken to properly handle the swarf Consult material manufacturer for additional information The machine must be periodically cleaned to remove residual swarf The user is responsible for establishing a cleaning process and schedule as required by material removal rates workpiece material and other factors 7 Safety September 2011 Microlution II Safety DAN Hazardous voltage inside Remove power before servicing Laser radiation DO NOT STARE INTO BEAM Class 2 laser product 8 Safety September 2011 Microlution 111 Machine Information AA MACHINE INFORMATION Warning Read this section before operating machine Failure to do so can result in machine malfunction and or operator injury General Machine Specifications Table 3 1 General Machine Specifications Height 135 cm 53 Width 71 cm 28 Depth 64 cm 25 Footprint 0 45 m 4 86 ft Weight 340 kg 750 Ibs without accessories Maximum Feed Rate 8000 mm min 314 9 IPM Machine Travel 63 mm x 63 mm x 63 mm 2 48 x 2 48 x 2 48 Resolution 0 05 microns 0 0000008 Positioning Accuracy 2 0 microns 0 00008 Ko Machine Information September 2011 Microlution ll Machine Information LN Machine Requirements Table 3 2 Machine Requirements Minimum of 170 liters min 0 7 MPa 6
91. ing back cover of the stand in looking into the clear filter vessel If an excessive amount of chips have accumulated within the filter vessel then the vessel should be cleaned out and the filter replaced Filter Replacement 1 Remove the back cover of the coolant system stand 2 Loosen the screws that hold the coolant filter vessel to the back of the stand 3 Remove the coolant filter vessel from the stand with both coolant lines still attached 4 Unplug the coolant line from the output of the filter vessel Place a receptacle underneath the vessel while doing this to catch any coolant that flows out of the line or vessel 5 Pour some of the coolant out of the filter vessel and into the receptacle through the output port Pour until you can see the level of the coolant through the clear vessel 6 Unscrew the clear part of the filter vessel from the top 7 Remove the old filter 8 Dump out the rest of the coolant that is inside the vessel and clean out any old chips 9 Insert a new filter into the vessel contact Microlution for order information about replacement filters 10 Reattach the bottom of the filter vessel to the top and plug in the output coolant line 11 Turn on the flood coolant through the software to test for any leaks in the housing It may take a moment for the coolant to start flowing out of the coolant nozzle while the filter vessel refills 12 If there are no leaks reattach the filter housing to the stand and
92. ion will stop Machining cycle will stop Spindle rotation will stop Machining cycle will stop Machine will move to safe position 33 Software Introduction September 2011 Microlution IV Software Introduction HAN G CODE AXIS CAMERA ERROR STATUS TOOL orrsers Workpiece Probing Error X axis Fatal Following Error Limit Exceeded Tool Length Measurement Error Y axis Fatal Following Error Limit Exceeded Tool Diameter Measurement Error Z axis Fatal Following Error Limit Exceeded Tool Breakage Error X axis Amplifier Fault Tool Dirty Error Y axis Amplifier Fault E Stop Tripped Z axis Amplifier Fault X axis Software Limit Exceeded X axis Warning Following Error Exceeded Y axis Software Limit Exceeded Y axis Warning Following Error Exceeded Z axis Software Limit Exceeded Z axis Warning Following Error Exceeded Positioning Fault Lid Open Fault System Pressure Fault Robot Fault Error Recovery Figure 4 18 Error Status Tab Warning Status Tab The Warning Status Tab displays the status of warning alarms on the 363 S shown if Figure 4 19 If the indicator next to an alarm is green then that alarm functioning properly If the indicator is red then a fault has been registered and the alarm must be cleared before proceeding with many of the functions on the machine Table 4 8 gives a description of each of the alarms Table 4 8 Warning Alarms on the 363 S Recovery Cause s Sys
93. ition is true Turbo PMAC will execute all subsequent statements on following lines down to the next ENDIF If the condition is false it will skip to the ENDIF and continue execution there In a PLC program compound conditions can be extended onto multiple program lines with subsequent AND and OR statements There is no limit on nesting of IF conditions and WHILE loops other than total buffer size in fixed motion and PLC programs Supported comparators l gt lt I lt I gt Examples IF P1 gt 10 M1 1 IF M11 0 AND M12 0 M2 1 M3 1 IF M11 0 AND M12 0 M2 1 M3 1 ENDIF See also user variable description for list of accessible usable variables 92 Operation September 2011 Microlution VIII Operation DAN While condition action condition consists of one or more sets of expression comparator expression joined by logical operators AND or OR action is a program command This statement allows repeated execution of a statement or series of statements as long as the condition is true It is Turbo PMAC s only looping construct It can take two forms Valid in motion program only With a statement following on the same line it will repeatedly execute that statement as long as the condition is true No ENDWHILE is used to terminate the loop WHILE condition action Valid in motion and PLC programs With no statement following on the same line it will execute statements on subse
94. ition without a loss of positioning repeatability The pallets are held in place an Erowa pallet mounting system as shown in Figure 7 17 The holding force is provided by a pneumatic chuck This system allows each pallet to mount in the same position every time it is placed on the 363 S Figure 7 17 Pallet attachment point 95 Operation September 2011 Microlution VIII Operation _AAL Removing the pallet Jog the Z stage away from the pallet at least 40mm Turn off the spindle Verify that the tool is clear of the part and pallet Also verify that the spindle is off Open the protective lid Grab the pallet to prevent it from falling when the pneumatic chuck is released Press the release pallet button in the MDI Tab 6 Slowly pull the pallet up and out of the working area MAA i Dd Warning Tool bits are sharp Never touch the tool bit Figure 7 18 Pallet and machinable fixture plate during removal replacement of pallet 96 Operation September 2011 Microlution VIII Operation AN Installing the pallet Move tool and spindle away from pallet mounting area Disable spindle Open protective lid Hold pallet in front of mounting area with spigot placed inside the pneumatic chuck The round notch shown in Figure 5 3 on the pallet should face the floor Press the Clamp Pallet button in the MDI Tab Check that the pallet is seated firmly and does not move with light pressure ADM
95. itional add on features that have not been purchased will be disabled The Default and Admin users are permenant and cannot be deleted 18 Software Introduction September 2011 Software Introduction Microlution AN User Setup ES Ea E El UserName Default Password default Show unavailable controls Hide unavailable controls Admin Default test test2 y Positio RAA A Contro ERER SA Microlution 363 S EA Menu Items Setup New Open Admin n Panel Position Velocity Offset Panel Program Tab x Feedrate control Figure 4 6 Administration window for user account setup Y Update The Update menu button will open a new window shown in Figure 4 7 where a 25 digit access code can be entered to enable any 363 S mMT add on features Popular add on features include a laser distance sensor a tool changer a camera vision system and several different spindle options to name a few Upon purchasing one of these add on features an access code will be supplied by Microlution which can be entered in this window to unlock the corresponding software controls Confirmation that the upgrade was successful will be given upon entering a correct access code In order to use the newly available software controls they must be activated in the user account setup window for each user 19 Software Int
96. ive lid Remove the hex screw with 3 32 hex wrench Place the collet pin in the hole where the hex screw was removed Place M5 1 wrench on the collet Standing in front of the machine turn clockwise until loose Remove the wrench from the collet Loosen the collet nut further with fingers Remove the tool from the collet Remove the collet pin from the spindle Close the protective lid LOO SO ONS US hbhepbp WNRO 65 Operation September 2011 Microlution VIII Operation AN Tool Changing Automatic Collet This section describes how to install and remove tools from spindles equipped with an automatic collet Figure 7 7 Figure 7 7 Automatic tool changing collet Tool Installation 1 Jog the Z stage away from the pallet Ensure that the spindle is disabled in the Input Panel Jog Tab 3 Verify that the spindle is clear of the workpiece and pallet Also verify that the spindle is off IN Note Tool will be expelled from collet by air pressure when tool is released Hold the tool in place when releasing or clamping the tool to prevent damage to the tool 4 Release the collet using the Release Tool button on the Jog Tab of the Input Panel Figure 7 8 JOG COMBINE OFFSET MDI TERMINAL SENSOR USER Input Panel Xx 0 0 mm Y mm Open Loop Move to Zero zoo m B A Jog Speed Bgg mm min lt amp E
97. l make only two parts End Index le Je Start Starts the part patterning program Stop Stops the part patterning program Pause Pauses the pattern program 137 Appendix A September 2011 XI Appendix A Creating a Part Pattern Position Panel Ais c Laser Pad Vasa oa 04 la Changer View Panel Part Tool P Laser rogram pattem Changer Control Panel Patam Pareme 2 Onga F Use Program Origin Define in Machine Coord No of Rows M 10 x 0 0 No of Columns N 10 Y 00 X Spacing mm 4 0 Y Spacing mm 4 0 MDI Combine Terminal Offset User I Panel Start Row 1 Column 1 o Browsen Add To Queue Remove End Row 1 Column 1 Figure 7 27 Part Pattern Tab within the Control Panel The Part Pattern Tab Figure 7 27 allows the user to execute programs in the same way as the Program Run Tab but with the added feature of running the program multiple times with different program origins to create an array of parts To load NC programs into the program click the Browse button to open a dialog box and find the G code file The file name will appear in the box above the Browse button By clicking the Add button that file name will appear in the box below the Add button multiple files can be added sequentially to this box After adding the desired files click the Combine button which will take the text of the listed files and append them to each
98. l outputs are open collector sinking outputs They require an external positive voltage supply that has its common tied to the machine common Pin 25 of Connector 1 Each output has a maximum sink current of 100mA The digital outputs are controlled by a multiplexing circuit within the Microlution 363 S The states of the outputs are updated with each execution of a multiplexing PLC approx 100ms A partial schematic of the output circuit is shown below Thermal Resettable Fuse 0 1A User Digital Output Internal Circuit Figure 34 Digital output partial schematic Analog Inputs Analog inputs are wired directly to Analog Inputs 3 and 4 on the GeoBrick controller Each input accepts 5V single ended or differential inputs The voltage can be read using the proper software variables see Table 1 using the scaling factor below See the Delta Tau GeoBrick User Manual for more details Scaling Vin M506x 5V 32 768 Example M5063 14500 User Analog Input 1 Vin 14 500 5V 32 768 2 213V 146 Appendix A September 2011 Microlution Xl Appendix A AN Filtered PWM Analog Outputs The analog outputs are wired directly to analog outputs 3 and 4 on the GeoBrick controller The outputs are 10V single ended The output voltage can be set by setting the proper software variable see Table 1 using the scaling factor below See Delta Tau GeoBrick User Manual for more details about the Analog Outputs Scalin
99. llet The notch 9 seen at the bottom of the pallet indicates the correct mounting orientation The notch should face towards the floor when mounted to the machine The backside of the pallet has the Erowa pallet mounting system This system permits easy and repeatable mounting of the pallet workpiece to the X Y stage 6 Erowa Pallet Mounting System The Erowa pallet mounting plate ensures accurate and repeatable pallet placement on the X Y stage 7 Threaded Mounting Holes These four holes allow the interface plate and or the machinable fixture to be securely mounted to the pallet 8 Non Threaded Mounting Holes The non threaded mounting holes allow for quick and secure mounting of the machinable fixture plate to the pallet 9 Notch There is a notch in the pallet and machinable fixture plate to indicate the correct mounting orientation notches should be aligned When mounted on the machine the notch should face towards the floor 2 Spigot The spigot rigidly holds the pallet to the X Y stage The Erowa plate on the back of the pallet ensures that the spigot positioning is very accurate 3 Pallet with Spigot Attached This shows the correct orientation of the spigot and the pallet 4 Machinable Fixture Plate The aluminum machinable fixture plate offers a smooth surface upon which to mount the workpiece The plate also functions as a sacrificial surface for machining a through feature 5 Complete Pallet System Picture five
100. log Outputs ccccccccessscecccecsesssssceceeececseeeaeseeeesssesaeseeececeeseeaeseseesceeeaaeaeeeeseeeeea 147 USER eT A ai tt 147 Table of Contents September 2011 Microlution Introduction Using This Manual AAA INTRODUCTION USING THIS MANUAL Thank you for purchasing the Microlution Inc 363 S micro milling machine tool This instructional manual will introduce the 363 S its specifications components software and other aspects of the machine Before operating the 363 S this manual should be read thoroughly and in its entirety After the manual has been completely read keep it as a reference for later use Please read this manual from beginning to end starting with the Safety section Following the Safety section is the Machine Information section with machine specifications requirements operating conditions and other useful information Following the Machine Information section is the Software Introduction section The Software Introduction is where the machine software is introduced and all the buttons functions and windows are explained Note A step by step set of instructions for operating the machine and navigating the software is located in the Operation section of this manual Following the Software Introduction is the Hardware Introduction The Hardware Introduction introduces the exterior components of the machine and their functionality Next the Installation Transportation section d
101. luded with the machine This cycle is called by placing a G201 command in a program The I O timing for this sequence and a written description of the sequence is provided below G201 TIMING CHART SIGNAL 1 Of VARIABLE ROBOT ENABLED OUT5 M7105 PRELOAD REQUEST OUT6 M7106 LOAD REQUEST OUT4 M7104 MANDREL RELEASED OUT7 M7107 LOAD COMPLETE IN4 M7124 MANDREL RELEASE REQUEST IN5 M7125 ROBOT OK IN2 M7122 3 OPEN ROBOT DOOR 4 MOVE MACHINE TO G28 REFERENCE POSITION 5 CHECK MACHINE AT HOME POSITION AND DOOR OPEN 6 SEND LOAD SIGNAL TO ROBOT 7 WAIT FOR MANDREL UNCLAMP REQUEST Ea 8 MANDREL UNCLAMPED PRE LOAD SIGNAL RELEASED MANDREL UNCLAMPED SIGNAL SET TO HIGH _ 9 WAIT FOR MANDRELCLAMP REQUEST S y O 12 CLOSE ROBOT DOOR 13 RESET OUTPUTS 101 Operation September 2011 VIII Microlution Operation AN Tool Setting Camera The zero plane for the Z axis can be set manually to any surface of the part or fixture Itis useful to set the surface of the workpiece as the zero plane for the Z axis because most machining operations and programs assume that the surface of the workpiece is the zero plane The following is a step by step list of instructions that will guide the user through the process of setting the zero plane for the Z axis 1 Start with
102. lution IX Supported G and M Codes AN G10 Data Setting Format G10 L or G10 L P X Y Z or G10 L P R Required Inputs L Data setting group number Optional Inputs P Data register R Data value X X axis offset Y Y axis offset Z Z axis offset Note This command will only work in one of the above formats There are no defaults for this command Note If data setting is done while in absolute mode the current offset will be over written If data setting is done while in incremental mode the value will be added to the current offset G11 Data Setting Modal End Format G11 Required Inputs Optional Inputs G17 X Y Plane Designation Format G17 Required Inputs Optional Inputs G18 Z X Plane Designation Format G18 Required Inputs Optional Inputs G19 Y Z Plane Designation Format G19 Required Inputs Optional Inputs G20 Metric to English mm to in Unit Conversion Format G20 Required Inputs Optional Inputs G21 English to Metric in to mm Unit Conversion Format G21 Required Inputs Optional Inputs G28 Return to Machine Reference Position Format G28 X Y Z Required Inputs Optional Inputs Default X Move destination along X axis current location Y Move destination along Y axis current location Z Move destination along Z axis current location Note The recommended form is listed below 119 Supported G and M Codes September 2011 Microlutio
103. m from the drop down box and the origin will display in the text boxes above the drop down box 4 Apply the desired offset by selecting the desired drop down box and clicking the Apply Saved button Set Known Location as Program Origin 1 Within the Offset Tab Figure 7 31 click the X Y and or Z buttons in the middle of the tab to select the axes whose origin should be reset 2 Type the origin into the text boxes next to the selected axes Click the Set New Program button to make the new origin active This will update the active origin shown in the Dashboard and in the Offset Tab If this origin should be saved select the desired save location from the drop down box G54 G59 Click Save Active Origin This will take the current program origin and save it to the selected G code offset This process can be repeated for a total of up to 6 offsets Click the Save To File button and type the name of the file in the dialog box that appears En NOW SP 109 Operation September 2011 Microlution VIII Cleaning Maintenance DAN CLEANING MAINTENANCE Proper cleaning and maintenance is essential for continued error free operation of the 363 S Make sure you read and follow all cleaning maintenance guidelines before operating the machine Additional Machine Guarding to Prevent Dust Ingress Overview This section outlines additional dust strip made of felt material that must be added to the machine to prevent plastic dust i
104. n IX Supported G and M Codes AN G91 G28 ZO G91 G28 XO YO G28 1 Machine at Reference Position Check Format G28 1 Required Inputs Optional Inputs Default G40 Tool Radius Cutter Compensation Off Format G40 Required Inputs Optional Inputs G41 Tool Radius Cutter Compensation Left Format G41 D Required Inputs D Tool number Optional Inputs G42 Tool Radius Cutter Compensation Right Format G42 D Required Inputs D Tool number Optional Inputs G43 Tool Length Offset Apply Format G43 H F Z Required Inputs H Tool number Optional Inputs Default F Feedrate previously used feedrate Z Move destination along Z axis current location Note This offset is in addition to the current offset It will take into account the previously applied offset not overwrite them Note G43 can be used in conjunction with G01 in specialized format below G01 G43 Z H F G49 Tool Length Offset Remove Format G49 Required Inputs Optional Inputs Note This command will only work if the last offset commanded was a tool length offset G43 G54 Workpiece Offset 1 Format G54 Required Inputs Optional Inputs Note This offset will overwrite the current offset G54 1 Additional Workpiece Offsets Format G54 1 P Required Inputs P Additional Workpiece Offset Number 120 Supported G and M Codes September 2011 Microlution IX Supported G and M Codes AN Optional Inputs N
105. n is not changed during patterning Note The patterning sequence proceeds from left to right and then top to bottom Table 4 3 Part Pattern Tab buttons and their functions 136 Appendix A September 2011 Microlution Xl Appendix A AN Button Function No of Rows M Specifies the number of rows of parts in the pattern No of Columns N Specifies the number of columns of parts in the pattern X Spacing x The desired distance between the centers of adjacent parts in the x direction Y Spacing y The desired distance between the centers of adjacent parts in the y direction Origin Enter the location of the top left corner of the pattern Use current program 8 zero or define new coordinates Applies the five pattern parameters above to the program and visualization The Set ieee aes E E visualization of the array will be displayed in the Axis Tab Allows pattern to be started from locations other than the Top Left part This is useful when a program needs to be stopped after making several parts to change a tool for example without throwing away the remaining material or altering the pattern Start Index Is Js Specifies which part to stop the program on patterns always proceed from left to right and then top to bottom For example a start index of 1 1 and end index of 2 1 will make one entire row of parts plus the 2 1 part however a start index of 1 1 and end index of 1 2 wil
106. ndard to rest against the ring setter c Tighten the set screw 1 to hold the standard tightly d Rotate the adjustment screw until it comes to rest against the length standard Tighten set screw 1 to fix the adjustment screw s position 2 Pressing on a tool collar a Slide a tool shank first into Part 1 of the ring setter until it is touching the adjustment screw Tighten set screw 1 to hold the tool in place b Slide a tool collar into the pocket in Part 2 of the ring setter c Press the two halves of the ring setter together Pull apart the two halves d Loosen set screw 1 to release the tool 3 Removing a tool collar a Slide the removal pin into Part 1 of the ring setter Tighten set screw 1 to hold the pin in place b Slide the tool into Part 2 of the ring setter c Press the two halves of the ring setter together Pull apart the two halves Set Screw 2 Adjustment Screw 74 Operation September 2011 Microlution VIII Operation AN Tool Sensing G120 Cycle The tool sensing function uses a Renishaw NC 4 non contact tool setter measure tool length and diameter The tool sensor is attached to the machine at the factory Do not attempt to remove Consult factory if modification is necessary Syntax and Parameters G120 B H S X Z J B Measurement Type required 1 Length only 2 Length and single sided diameter measurement 3 Length and double sided diameter measurement H Tool Lengt
107. ng Canned Cycle Format G82 X Y R Z P F K Inputs Center location of hole along X axis Center location of hole along Y axis Clearance plane of Z axis Total depth of tool point Dwell in seconds at the bottom of the drill cycle Feedrate Number of repeats AMTMTMUN gt OS lt gt G83 Deep hole Drilling Canned Cycle Format G83 X Y R Z P Q 1 J K F K Inputs Center location of hole along X axis Center location of hole along Y axis Clearance plane of Z axis Total depth of tool point Dwell in seconds at the bottom of the drill cycle Feedrate mm min Incremental distance of each peck Depth of first peck Peck reduction for each peck after first Number of repeats AC OTUND lt x G90 Absolute Mode Format G90 Required Inputs Optional Inputs G91 Incremental Mode Format G91 Required Inputs Optional Inputs G98 Canned Cycle Initial Level Return Format G98 Required Inputs Optional Inputs G99 Canned Cycle R Level Return Format G99 Required Inputs Optional Inputs G120 Tool Sense Format G120 B H J S X Z Required Inputs B Tool sense type H Tool number 122 Supported G and M Codes September 2011 Microlution IX Supported G and M Codes AN Optional Inputs Default J Additional length offset 0 0mm S Desired spindle speed 5000 rpm X Radial location of length measurement 0 0mm Z Axial location of diameter measurement
108. ngress into the machine The steps documented below are mandatory for the Optomill as of 5 20 11 and highly recommended for other 363 S machines that regularly machine plastic Machines shipped 5 20 11 and later have this dust strip added prior to shipment Follow the steps below to add or repair this strip Required Material 1 1 8 3 175mm thick adhesive backed felt strip soft grade F13 or similar 1 25 4mm wide This material can be obtained through an industrial supply company e g McMaster Carr p n 87555K122 or from Microlution Installation procedure 1 Remove the stationary top cover from the machine by removing the 9 M3 fasteners using a Phillips screwdriver 2 Lay the stationary top cover on a work surface as shown in the figure below Cut the felt strips into three sections remove the cover layer for the adhesive and attach the strips to the top cover as shown below to form a perimeter around the U shaped notch in the part 3 Re attach the stationary top cover to the machine Ensure that all spacers between the top cover and the machine are replaced properly 4 Move the X Y stage around by hand to make sure that the stage still moves freely without significant additional friction If additional friction is present contact Microlution for further instructions Figure 8 1 Application of adhesive backed felt strip 110 Cleaning Maintenance September 2011 Microlution VIII Cleaning Maintenanc
109. ngs if equipped 3 Click the Start button to enable the air supply to the turbine and set the target speed in the RPM text box see Figure 7 4 mM 60 Operation September 2011 Microlution VIII Operation Microlution 363 S Position mm Offset mm To Go mm Load G CODE CAMERA ERROR STATUS 00 0000 00 0000 00 0000 TOOL OFFSETS WKP OFFSETS LASER _ warninestatus View Panel 00 0000 00 0000 00 0000 00 0000 00 0000 00 0000 Active G codes M codes G1 1 G18 G20 G40 G43 G54 1 G90 G94 G99 M00 MOS M07 Current Tool Workpiece Probing Error axis Fatal Following Error Limit Exceeded Tool Length Measurement Error Y axis Fatal Following Error Limit Exceeded Tool Diameter Measurement Error Z axis Fatal Following Error Limit Exceeded Tool Breakage Error X axis Amplifier Fault Spindle Control TOOL Tool Dirty Error CHANGER Y axis Amplifier Fault PROGRAM LASER Control Panel Feedrate On Feedrate mm min Flood Coolant O Off O Override Arcont O O X axis Software Limit Exceeded X axis Warning Following Error Exceeded Y axis Software Limit Exceeded Y axis Warning Following Error Exceeded Z axis Software Limit Exceeded o o Oo o E Stop Tipped Zavs Amplifier Fault o Oo Z axis Warming Following Error Exceeded Oo El Single Block C Tool Changer Fault Lid Open Fault Op
110. nput Panel Execute BERR eee Ct A O 0 E JOG Figure 4 23 MDI Tab The Combine Tab is used to find queue load and rewind G Code files The Combine Tab is located in the Input Panel as shown in Figure 4 24 below Table 4 12 below lists the buttons and functions of the Combine Tab Figure 4 24 Combine Tab Table 4 12 Combine Tab buttons Button Function os Gcod Loads all the G Code files from the queue to memory and displays the code in the G Code text box of the View Panel Also downloads all subprograms Makes the first line of the program active This can be used after a pause Rewind command or stop command The program will not begin executing until Cycle Start is pressed close Geode Removes the current G code program from memory and clears the text box displaying the code Save Gcode Takes the currently displayed Gcode and save it to a file of the user s choosing 39 Software Introduction September 2011 Microlution IV Software Introduction HA Browse and find G Code files After finding a file it will show up in the queue box Browse Remove Removes the selected G Code file from the queue Terminal Tab The Terminal Tab located on the Input Panel opens a Terminal which allows commands to be sent to the controller one line at a time Figure 4 25 shows the Terminal Commands are entered in the text box at
111. nputs Optional Inputs M207 1 Robot Part Released Output On Format M207 1 Required Inputs Optional Inputs M207 2 Robot Part Released Output Off Format M207 2 Required Inputs Optional Inputs M208 1 Robot Output 8 On Format M208 1 Required Inputs Optional Inputs M208 2 Robot Output 8 Off Format M208 2 Required Inputs Optional Inputs M209 1 Robot Output 9 On Format M209 1 Required Inputs Optional Inputs M209 2 Robot Output 9 Off Format M209 2 Required Inputs Optional Inputs M210 1 Robot Output 10 On Format M210 1 Required Inputs Optional Inputs M210 2 Robot Output 10 Off Format M210 2 Required Inputs Optional Inputs M211 1 Robot Output 11 On Format M211 1 Required Inputs 127 Supported G and M Codes September 2011 Supported G and M Codes Microlution LAN Optional Inputs M211 2 Robot Output 11 Off Format M211 2 Required Inputs Optional Inputs M212 1 Robot Output 12 On Format M212 1 Required Inputs Optional Inputs M212 2 Robot Output 12 Off Format M212 2 Required Inputs Optional Inputs 128 Supported G and M Codes September 2011 Microlution Xl Appendix A AN APPENDIX A LEGACY CUSTOM ORDER This section contains instructions on legacy and specialized components that may be specific to a customer s machine Please disregard this section if this information does not pertain to your machine Spindle
112. obot Enable Load On robot option required M205 2 Robot Enable Load Off robot option required M206 1 Robot Pre Load On robot option required M206 2 Robot Pre Load Off robot option required M207 1 Robot Part Released Output On robot option required M207 2 Robot Part Released Output Off robot option required M208 1 Robot Output 8 On robot option required M208 2 Robot Output 8 Off robot option required M209 1 Robot Output 9 On robot option required M209 2 Robot Output 9 Off robot option required M210 1 Robot Output 10 On robot option required M210 2 Robot Output 10 Off robot option required M211 1 Robot Output 11 On robot option required M211 2 Robot Output 11 Off robot option required M212 1 Robot Output 12 On robot option required M212 2 Robot Output 12 Off robot option required 117 Supported G and M Codes September 2011 Microlution IX Supported G and M Codes AN Common G Codes M Codes and their syntax G00 Rapid Move Mode Format GOO X Y Z Required Inputs Optional Inputs Default X Move destination along X axis current location Y Move destination along Y axis current location Z Move destination along Z axis current location G01 Linear Move Mode Format G01 X Y Z F Required Inputs Optional Inputs Default X Move destination along X axis current location Y Move destination along Y axis current location Z Move destination along Z axis current loca
113. of the Input Panel It can be executed from any line in the G Code window Note take care when starting from the middle of the program to ensure all offset etc are setup correctly While a program is running the line of code the program is currently executing is highlighted in the G Code Tab Table 4 6 G Code Window Buttons Item Button Functionality Begin TE Buren Moves the G Code cursor to the beginning of the G Code program 29 Software Introduction September 2011 Microlution IV Software Introduction AAN P U RA Moves the G Code cursor up one page of the G Code program Button Line Up 7 Moves the G Code cursor up one line of the G Code program Button Edit Button Eat Enables the user to edit the currently selected line of G Code text Opens a find replace window allowing the user to quickly search for replace text Note Find Button use caution when using the replace all functionality Replacing many lines in a large file can be very slow Line Down Moves the G Code cursor down one line of the G Code program Button Page Down Ben Moves the G Code cursor down one page of the G Code program End Button Moves the G Code cursor to the end of the G Code program Axis Tab The Axis Tab in the View Panel opens the Machine Tool Status Graph shown in Figure 4 15 This is a graphical representation of the current position of the cutting tool The blue lines indicate the pro
114. oling Air Pressure Regulator Regulates the spindle motor cooling air pressure Suggested air pressure is approximately 0 3 MPa 3 Regulator 3 Coolant Blast Air Regulator Regulates coolant air applied directly to the work piece Suggested air pressure is approximately 0 2 MPa 4 Regulator 4 Pallet Unclamp Regulator Regulates air pressure of kinematic pallet unclamp action Suggested air pressure is approximately 0 55 MPa 5 Regulator 5 Pallet Air Purge Regulator Regulates air pressure of pallet cleaning air purge Suggested air pressure is approximately 0 5 MPa 6 Regulator 6 Tool Sensor Purge Air option required Regulates air pressure of tool sensor purge Suggested air pressure is approximately 0 4 MPa 7 Regulator 7 Tool Changer Air Regulator option required Regulates air to the pneumatic actuators on the tool changer Suggested air pressure is approximately 0 6 MPa 8 Regulator 8 Tool Clamp Air Regulator option required Regulates air to provide clamping force to the spindle collet HF45 spindle option required Suggested air pressure is 0 2 MPa 9 Regulator 9 Configurable Auxiliary Regulator Contact Microlution 10 Regulator 10 Configurable Auxiliary Regulator Contact Microlution Note Regulators may have different functions depending on the options chosen for the machine Please contact Microlution for the correct regulator function map if yours do not match what is shown above 53
115. olycarbonate of the protective lid and chip hood with a mild soap or cleaner 112 Cleaning Maintenance September 2011 Microlution VII Cleaning Maintenance Maintenance Preventative Maintenance Schedule Description Interval For Additional Information Spindle With air on wipe spindle with cloth to remove chips Daily Spindle User Manual General Clean chips from machining zone using brush vacuum Daily Microlution User Manual Spindle Remove collet clean spindle taper check collet for wear Weekly Spindle User Manual Pneumatics Inspect filter bowls for liquid Drain if necessary Weekly Microlution User Manual Pneumatics Check that incoming air pressure is 90 100psi Weekly Microlution User Manual Pneumatics Check tubing for kinks or wear Replace if worn Monthly Microlution User Manual Cooling Fans Inspect filters for dust Clean or replace if dirty Monthly Microlution User Manual General Dust ingress check See instructions in User Manual Monthly Microlution User Manual Additional Descriptions for Selected Items Coolant Filter Inspection The coolant filter is located inside the coolant system stand It can be accessed by removing the back cover of the coolant system stand The coolant filter should be inspected at least once a month under typical use Under heavy use or in processes that create a large quantity of chips the filter should be inspected more frequently The filter can be inspected by simply remov
116. on platform on it During transportation the axes should be prevented from moving during transport Proper bracing should be placed between the Z axis and pallet area to keep the axes from shaking or colliding Note When transporting machine via the wheels ensure that the leveling feet are completely lowered Failure to do so may result in damage to the leveling feet Note For questions regarding transport please contact the factory at 773 282 6495 58 Installation Transportation March 2010 Microlution VIII Operation _AAL OPERATION Power On Procedure Verify E Stop button is pressed on the handheld pendant Verify that all cable connections listed in the Installation section have been made Plug in the machine power cord to a 120 VAC outlet Supply air and adjust supply regulator to 100psi Adjust counter balance pressure so that the x y stage is suspended floating See Machine Regulators in the Hardware Introduction for more information Turn on machine power by flipping switch on back panel Reset the E Stop button by twisting clockwise Start up the computer If the machine is equipped with a chiller or additional auxiliary devices make sure that these are also powered on and functioning properly Oo OND Power Down Procedure Press the E Stop button on the handheld pendant Save any important offsets or open programs Close the Microlution mMT Control Center software
117. onal Inputs M03 Start Spindle Clockwise Format M03 Required Inputs Optional Inputs M05 Stop Spindle Format M05 Required Inputs Optional Inputs M06 Tool Change Format M06 Required Inputs Optional Inputs Note Before this command a T command must be issued with the appropriate tool number T01 M06 M07 Air Blast Coolant On Format M07 Required Inputs Optional Inputs Mos Flood Coolant On Format M08 Required Inputs Optional Inputs M09 All Coolant Off Format M09 Required Inputs Optional Inputs M30 End of Program Flag Rewind NC code Format M30 Required Inputs Optional Inputs M98 Subroutine Call Format M98 P L Required Inputs P Subroutine Number Optional Inputs L Number of Subroutine Repeats M101 Pallet Clamp Format M101 Required Inputs Optional Inputs 124 Supported G and M Codes September 2011 Microlution IX Supported G and M Codes AN M102 Pallet Unclamp Format M102 Required Inputs Optional Inputs M103 Machine Light On Format M103 Required Inputs Optional Inputs M104 Machine Light Off Format M104 Required Inputs Optional Inputs M106 Tool Guard Retract Format M106 Required Inputs Optional Inputs M107 Tool Guard Extend Format M107 Required Inputs Optional Inputs M110 1 Robot Door Open Format M110 1 Required Inputs Optional Inputs M110 2 Robot Door Close Format M110 2 Required Inputs Optional Inputs
118. ote This offset will overwrite the current offset P parameter inputs can only be 1 394 Any others will be discarded and no offset will be applied G55 Workpiece Offset 2 Format G55 Required Inputs Optional Inputs Note This offset will overwrite the current offset G56 Workpiece Offset 3 Format G56 Required Inputs Optional Inputs Note This offset will overwrite the current offset G57 Workpiece Offset 4 Format G57 Required Inputs Optional Inputs Note This offset will overwrite the current offset G58 Workpiece Offset 5 Format G58 Required Inputs Optional Inputs Note This offset will overwrite the current offset G59 Workpiece Offset 6 Format G59 Required Inputs Optional Inputs Note This offset will overwrite the current offset G65 Macro Call Format G65 P A B C D E F G H 1 J K L M Q R S T U V W X Y Z Required Inputs P Macro Program Number Optional Inputs A M Q Z Macro Parameters G80 Canned Cycle Cancel Format G80 Required Inputs Optional Inputs G81 Drilling Canned Cycle Format G81 X Y R Z F K Inputs X Center location of hole along X axis Y Center location of hole along Y axis R Clearance plane of Z axis Z Total depth of tool point 121 Supported G and M Codes September 2011 Microlution IX Supported G and M Codes AN F Feedrate K Number of repeats G82 Spot Drilli
119. other in the order they are listed the contents of the combined program are then shown in the G code Tab of the View Panel Scroll through the code to verify that the correct sequence is loaded This code will be executed once for each part in the array The array parameters can be set using the Pattern Parameters in the upper left corner of the Part Pattern Tab Hitting Set stores the values and updates the display below The Start Index and Stop Index are adjusted at the bottom right Details on the functionality of each button within the Part Pattern Tab can be found in the Part Pattern Tab segment of this manual Clicking the Start button will start the program execution at the part listed in the Start Index After the program finishes execution on the End Index part the program will stop Pressing the Stop button will also halt program execution 138 Appendix A September 2011 Microlution Appendix A AN xI Example The pattern in Figure 7 28 is desired on the surface of a part imm 3mm X F N XXX 6mm Figure 7 28 Example Part Pattern Assume the NC program makes each X in two parts First the program creates the first diagonal and then it makes the second diagonal Each X is 3mm tall and 2mm wide the spacing between the features is 1mm in the horizontal direction and 3mm in the vertical direction Each feature is 0 25mm deep and will be machined with a flat end mill 0 25mm wide which is the width of the
120. other shape as the height difference between a post corresponding to 0 input and a post corresponding to 1 input The figure below illustrates the various parameters associated with the posts A A Retract plane while measurement Surface corresponding to 1 input Zol re S Surface corresponding to 0 input Value 1 0 1 Pallet orientation The pallet identification ID function also works as a pallet orientation function If the pallet is attached rotated on the machine the pallet identification function will not execute completely if the surface in the measuring zone is at a different height than expected by the function On the other hand a surface at the same height as the Z parameter for the pallet identification will not terminate the function and might output a false pallet id Hence to use the function as a pallet orientation function as well it is necessary that the measuring posts be at a height different from the height of the rest of the surface A tighter control for the measuring band can be provided with the help of parameter Ee as explained below which governs the clearance height from where the measurement begins This helps reduce the possibility of a false trigger and hence a false pallet ID output As a better practice it is advised not to use that least and the highest value numbers as valid pallet IDs e g For a 3 post measurement consider 0 0 0 and 1 1 1 as invalid pallet IDs 81 Operation S
121. p the scanning process if necessary Scanning Using a User Defined Scanning Pattern 14 3 Appendix A September 2011 Microlution xl Appendix A AN 1 Select the User Defined Scanning Pattern selection circle displayed in Figure 7 33 Control Panel Scanning Pattem Predefined User Defined Data File Setting Directory File Name Sampling Rate Hz 500 Figure 7 33 User Defined Scanning Program within the Laser Inspection Tab 2 Press the Load Program button to open a user created G code scanning pattern Choose the Sampling Rate The computer determines the sample spacing based on the G code specified feedrate and the user specified sampling rate Press the Browse button and select which directory to save the scan to Name the file using the File Name text box Press the Setup button to prepare the laser and load the G code Press the Start button to start scanning A dialog box will appear to inform the user when the scan is finished The Stop button can be pressed at any time to stop the scanning process if necessary 2 O PS Oy UL 144 Appendix A September 2011 Microlution Xl Appendix A AN User I O option required The User I O option provides 6 digital Inputs 8 digital outputs 2 Analog Inputs 2 Filtered PWM Analog Outputs and access to 4 User Flags Table 7 4 and Table 7 5 show the pinout of the two user I O breakout boards A description of each type of input is d
122. pindle accuracy within 2 microns The spindle can be operated at a maximum RPM of 60 000 if a liquid chilled spindle block is used to house the spindle Please contact Microlution for more details 100 000 Jaeger Z33 D11100 02S2Y RPM Ceramic Hybrid Ball Bearing Spindle with Automatic Tool Changing Capability Ideal for larger Diameter tools up to 0 125 3 175 mm These spindles are driven by an electric brushless motor The motor spindle combination is connected to a spindle control unit which controls the spindle speed The brushless motor provides a long service life excellent durability and high reliability This spindle utilizes an air operated collet to easily change tools and high precision bearings to obtain spindle accuracy within 2 microns Please contact Microlution for more details 80 000 RPM Electric Motor Driven Spindles NRA 5080 Ideal for use with tools up to 0 050 1 27 mm in diameter for the air bearing option and 0 125 3 175 mm in diameter for the ceramic bearing option These spindles use an electric brushless motor to drive different spindles The brushless motor provides a long service life excellent durability and high reliability The motor spindle combination is connected to a spindle control unit which controls the spindle speed There are two different bearing options for the 80 000 RPM Electric Motor Driven Spindle These two bearing options are air bearings and ceramic bearings The air bearing spindle
123. pindle options The cycle will first perform a linear move to the measurement start location if X Y or Z passed Next the machine moves slowly in the Z direction until a trigger is detected The machine moves away from the fixture a small amount and repeats the triggering move Once the trigger is detected again the Z axis moves 10mm away from the triggering location and the work offset registers are updated Syntax and Parameters G123 W H X Y Z J W Work offset to update required O current offset 1 G54 2 G55 3 G56 4 G57 5 G58 6 G59 H Tool Length Register required use tool number of active tool X X axis start location for measurement optional defaults to current location Y Y axis start location for measurement optional defaults to current location Z Z axis start location for measurement optional defaults to current location WARNING CHANCE FOR COLLISION IF IMPROPER VALUE PASSED USE ONLY IF YOU KNOW THE APPROXIMATE WORK OFFSET J Additional Z axis Offset optional defaults to 0 0mm Fixture Probing Example T1M6 Load tool 1 tool must have been measured previously using G120 G54 G43 H1 Apply work and tool offsets use if approximate offset is known G123 W1 H1 Measurement cycle updates the Z axis register of G54 77 Operation September 2011 Microlution VIII Operation DAN Workpiece Probing This section of the manual describes the functioning of the
124. produces extremely low heat and vibration and has a very long service life because of low friction and wear The air bearing provides exceptional spindle accuracy of within one micron The ceramic bearing spindle has a spindle accuracy within one micron and requires an oil mist air flow for lubrication 160 000 RPM Air Turbine Air Bearing Spindle ABS 1600 48 Hardware Introduction September 2011 Microlution V Hardware Introduction AN Ideal for use with small tools up to 0 02 0 508 mm in diameter Air turbine spindles use an air turbine instead of an electric motor to drive the spindle The air turbine air bearing spindle has a maximum spindle speed of 160 000 rpm which is much higher than electric motor driven spindles Additionally the air turbine air bearing spindle uses an air bearing which produces extremely low heat and vibration and has a very long service life because of low friction and wear The air bearing provides a spindle accuracy within one micron Figure 5 4 One spindle option 50 000 RPM Electric Motor Driven Automatic Tool Changing Spindle with mounting system 49 Hardware Introduction September 2011 Hardware Introduction Microlution AN 50 Hardware Introduction September 2011 Microlution V Hardware Introduction AN Front of the Machine Figure 5 5 displays the front of the 363 S The protective lid encloses the machining process and protects the user from chips
125. pulling on its handle 16 Discard the filter bag in the trash 17 Rinse filter housing with water to ensure no chips remain in the housing 18 Replace drain stopper after applying a thread tape to eliminate leaking 19 Discard the old coolant and rinse water in a safe location 20 Insert a new Microlution Inc supplied filter bag into the housing and make sure the bag makes full contact with the side of the housing 21 Add new coolant to the filter housing until the coolant level is about three quarters of an inch below the inlet hole 22 Replace the housing lid Coolant Change The coolant should be replaced at least as often as the filter bag If the coolant begins to get foamy before the filter bag needs replacing the coolant can be changed independently To change the coolant follow these instructions Place a pan or bucket under the filter housing Unscrew the drain stopper at the bottom of the housing When all the coolant has drained add thread locking tape to the drain stopper and screw it back on 10 Remove the housing lid and add new coolant until the coolant level is approximately three quarters of an inch below the inlet hole 11 Replace the housing lid Do N Protective Rubber Boot Inspection Frequently check the protective rubber boots for rips and cracks If a rip or crack is found immediately discontinue use and contact Microlution Inc for a replacement set CAUTION Operating the machine with
126. quent lines down to the next ENDWHILE statement WHILE condition statement statement ENDWHILE Examples WHILE P20 0 G4 P1 WHILE P7500 lt 100 G90 GO XO YO Y5 G4 P1 P7500 P7500 1 ENDWHILE See also user variable description for list of accessible usable variables GOTO data data is an integer constant or expression with a value from O to 99 999 This command causes the motion program execution to jump to the line label N specified in data with no jump back If data is a constant the path to the label will have been linked before program run time so the jump is very quick If data is a variable expression it must be evaluated at run time and the appropriate label then searched for The search starts downward in the program to the end and then continues if necessary from the top of the program down If the specified line label is not found the program will stop and the coordinate system s Run Time Error bit will be set Examples IF P7500 gt 0 GOTO750 93 Operation September 2011 VIII Operation ENDIF N740 N750 GOTO P7500 See also user variable description for list of accessible usable variables 94 Operation September 2011 Microlution Vill Operation LOM Manual Pallet Changing The Pallet mounting system is designed to be very repeatable This allows pallets to be removed cleaned inspected etc and then placed back on the machine in the same pos
127. r Yy y The surface position or size in mm or Zz z and Hh h Tool offset number storing the appropriate diameter for the measuring probe e g H1 will use the tool radius value stored for tool 1 Optional inputs Cc c Measurement mode Sets the measurement mode for the machine Value can be either O regular mode or 1 fine mode Default value 0 regular mode e g C1 will set the machine to fine measuring mode Ee e Experience Value Specify an experience factor value to be applied to the measurement Value can be either positive or negative Default value 0 79 Operation September 2011 Microlution Operation yo VIII e g E0 1 causes the measurement to be shifted by 0 1mm Ff f Feedback Percentage The percentage feedback that is used when updating an offset Enter a value between 0 and 2 0 and 200 Default value 1 Qq q Overtravel distance The probe overtravel distance for use when the default values are unsuitable The probe will then travel beyond the expected position when it searches for a surface Default value 2mm in fine mode and 3mm in regular mode Ss s The work offset number that will be set S1 to S6 G54 to G59 S101 to 494 G54 1 P1 to G54 1 P394 New work offset Existing offset value error Tt t The tool offset number to be updated Updates the tool radius comp for X and Y measurements and the tool length comp for Z measurement T1 to T36 Tool 1 to Tool 36 New tool
128. r limit exceeded Warning error limit exceeded X Axis Warning Error Y Axis Warning Error Z Axis Warning Error Software travel limit exceeded System pause Clean tool Correct cause of E stop trigger Motors de energized Spindle de energized Check for programming errors Jog axes to within travel limits Machine motion stopped Machine motion stopped Machine motion stopped All motors de energized All motors de energized All motors de energized Check for any restrictions to motion Re initialize machine All motors de energized All motors de energized All motors de energized Re initialize machine Check for any restrictions to motion Re initialize machine All motors de energized All motors de energized All motors de energized Attempt to start machining cycle or Machining cycle will sto Interlock Fault E P TE REE MIN E K p Close lid spindle with lid open Spindle rotation will stop Multiple Errors see software Tool Changer Fault p message RRRS Machine not in home position during Positioning Fault home check Issue performing an automatic pallet Robot Fault change System Pressure Loss Loss of system pressure Follow software message instructions Move machine to Home and restart program Check for robot issues and restart program Restore system pressure Reinitialize machine Machining cycle will stop Spindle rotation will stop Machining cycle will stop Spindle rotat
129. r the carousel arm to add remove individual tools or add remove entire carousels Open Close Gripper Manually opens or closes the tool grippers 69 Operation September 2011 VIII Microlution Operation LM Open Close Door Manually opens or closes the door separating the milling area from the tool changer compartment Ensure that the door is closed before executing machining sequences Selection of Tools Un Select All These buttons allow an operator to keep a visual record of tools loaded in the carousel as shown in Figure 7 11 Load Tool This button disables all tool buttons that are not selected and allows the operator to select which active tool to load Note When loading a tool the machine will first attempt to unload any tool in the spindle This tool will be returned to the carousel position from which the last tool was loaded Warning When machine power is cycled the software will not retain the current spindle tool number and the carousel will be homed Ensure correct tool carousel alignment with the Index Carousel button to prevent tool changer errors during spindle tool placement in the carousel Poan Part Tool g Pattern Changer Control Panel Figure 7 11 Selection of active tools active tools shown are highlighted in green 70 Operation September 2011 Microlution VIII Operation AN Operation in an NC pro
130. robe G54 X0 YO Apply correct work offset and go to start position G43 H1 Activate tool offset for particular tool G65 P9809 X 10 Y10 Z 20 A4 B3 D3 E4 Call pallet identification function continue with program Program will output the pallet number in the decimal system in variable Q4325 83 Operation September 2011 VIII Operation Error code index table If any of the probing functions fails to complete as commanded it may be due to one of many reasons If this were to happen the error flag Q801 will have a non zero value corresponding to the type of error that aborted the function The table below provides detailed description for each error number and the function in which the error appeared ERROR FLAG REASON CYCLE NUMBER 1 INSUFFICIENT PARAMETERS IN FUNCTION CALL 9811 2 INCORRECT USE OF S AND T PARAMETERS 9811 3 PROTECTED MOVE FAILED 9809 4 NO SURFACE DETECTED 9811 5 G31 FAILED TO INITIALIZE OR EXECUTE 9811 6 OFFSET UPDATE TYPE NOT ALLOWED 9811 7 OFFSET UPDATE MORE THAN UPPER LIMIT 9811 9 F INPUT OUT OF RANGE 9811 12 Q INPUT OUT OF RANGE 9811 13 S INPUT OUT OF RANGE 9811 14 H OR T INPUT OUT OF RANGE 9811 15 U INPUT OUT OF RANGE 9811 16 V INPUT OUT OF RANGE 9811 21 INSUFFICIENT PARAMETERS 9809 22 INCORRECT PARAMETERS IN FUNCTION CALL 9809 23 TRIGGER ERROR ON SURFACE 9809 84 Operation September 2011 VIII Microlution Operation AN
131. roduction September 2011 Microlution IV Software Introduction Microlution Please enter upgrade code provided by Microlution Inc Figure 4 7 Upgrade window 20 Software Introduction September 2011 Microlution IV Software Introduction HAN There are four panels in the main interface window of the Microlution 363 S CNC Control Software as shown in Figure 4 1 The panels are the Dashboard Control Panel View Panel and Input Panel Each panel except the Dashboard has several tabs where similarly grouped controls are contained Each tab can be accessed by pressing its corresponding botton at the top of its panel The remainder of this section describes in detail the tabs in each panel and the controls contained in each tab Dashboard Start up opens the Dashboard in the upper left corner as shown in Figure 4 8 This panel shows the current state of the machine The top sections shows the current location of the axes in program coordinates the current offset of the axes from its initial homing coordinates the distance to go to the commanded position each axis the load on each motor the vector feedrate and the spindle speed The bottom section shows the active G codes and M codes and the tool that s currently in the spindle X 00 0000 00 0000 00 0000 0000 Y 00 0000 00 0000 00 0000 Spindle 000000 PRA EN Active G codes M codes G1 1 G18 G20 G40 G43 G54 1 G90 G94 G99 M00 MOS M07
132. rogram to be patterned into an array The tab enables the user to set pattern size and visualize the array before starting the machining process Additionally the program allows the user to set the start and end indices of the array so that certain sections of the array can be machined without machining the whole array This feature is useful if the user wishes to machine the first part in the array and inspect it before machining the entire array Table 4 3 lists the buttons located in the Part Pattern Tab as well as the function of each button For a step by step list of instructions on using the Part Pattern Tab refer to the Operation section of this manual Control Panel Pattern Parameters Origin Set Use Program Origin Define in Machine Coord No of Rows M 10 No of Columns N 10 X Spacing mm 4 0 Y Spacing mm 4 0 Start Row 1 Column 1 End Row 1 Column 1 Figure 4 11 Part Pattern Tab Note Patterning works by automatically changing the program s X and Y axes zero position by the offset values specified and rerunning the loaded G code program The graphical representation of the pattern draws circles with their centers at the origin of that instance of the part Caution The graphical representation does not check the G code program in any way The user must verify that the X and Y spacing is large enough so that the individual parts within the array do not overlap The Z axis origi
133. roller COMBINE OFFSET TERMINAL SENSOR USER _ Input Panel o Absolute O Relative MI x 60 Jim ny mm D EMovetozero zoo ma B Usetozera Jog Speed Bgg mm min 1 E Gey Figure 4 22 Input Panel displaying the Jog Tab Jog Tab 37 Software Introduction September 2011 Microlution AN The Jog Tab is used for manually moving the axes and loading releasing tools manually The axes can be moved incrementally or to absolute positions and the handheld pendant can also be enabled to manually move the axes Figure 4 22 shows the Jog Tab and Table 4 11 lists the buttons and their functions Refer to the Operation section of this manual for a step by step set of instructions for using the Jog Tab IV Software Introduction Table 4 11 Jog Tab buttons and their functions Button Function Use the Move button to move the stages to absolute or relative coordinates Move according to the values specified by the text boxes Only the axes that are checked will be moved The jog speed text box displays the current jog speed for all three axes Moving Jog Speed a A the slider bar will adjust the jog speed accordingly Check All Apply action to all axes Clamp Unclamp Pallet Releases and clamps the pallet Pressing this button when it displays Clamp Pallet will clamp the pallet Pressing the button when it says Unclamp Pallet will unclamp the pallet Clamp Release Tool
134. s the program and verifies that a valid filename and directory have Setu P been entered Start Begins scanning Ends scanning and saves data if only a few degrees of a circular area R Stop Scan are desired the program can be stopped after the desired data has been collected Data File Setting Choose directory and filename for data to be saved Enable Laser Must be enabled for data to be collected Tool Changer Tab Automatic Tool Changer Option Required The Tool Changer Tab Figure 4 13 is functional on machines that feature the automatic tool changer system This tab allows users to interact with the tool changer There are 36 tool locations in the tool carousel Table 4 5 lists the applicable buttons and their functions Note The Tool Changer system will home at power up and remain at position zero until tool loading begins It is recommended that all tools are loaded into the wheel and removed from the spindle at power up to ensure proper operation 26 Software Introduction September 2011 Microlution Software Introduction li a Pressure 9 O Q Figure 4 13 Tool Changer Tab Table 4 5 Tool Changer Tab buttons and their functions Button Function Shows the user which tools have been selected and are available for tool Tool Buttons change The tool buttons can be highlighted through the Select Tools button Enables all tool buttons to allow
135. scanning pattern Table 7 3 describes the scanning patterns available in the drop down menu Y 142 Appendix A September 2011 XI Microlution Appendix A AN Table 7 3 Predefined Scanning Patterns Scan Type Description Sets the scan to proceed from the start X and Y position to the end X position After reaching the end X position the Y position is incremented Rectangular Area X Scan towards the Y end position by the step amount and scans from the end X value to the start X value This process repeats until the end value of X and Y is reached Sets the scan to proceed from the start X and Y position to the end Y position After reaching the end Y position the X position is incremented Rectangular Area Y Scan towards the X end position by the step amount and scans from the end Y value to the start Y value This process repeats until the end value of X and Y is reached The scan will move radially starting at the start radius and start angle until the end radius is reached The angle will be incremented by the step Circular Area R Scan amount and the scan will proceed along the new radius until reaching the start radius This process repeats until the end value of radius and angle is reached The scan will move along an arc starting with a radius equal to the start radius and angle equal to the start angle The angle will increment until the end angle is reached The radius will then be incremented
136. shows the correct completed pallet system 47 Hardware Introduction September 2011 Microlution V Hardware Introduction AN Spindle Introduction There are several different spindle options available for the Microlution 363 S These options include 160 000 RPM air turbine air bearing spindle ABS 1600 80 000 RPM electric motor driven spindles NRA 5080 and 40 000 NR 5041E ATC and 50 000 NR40 5100 ATC RPM electric motor driven spindles with automatic tool changing functionality 40 000 NR 5041E ATC amp 50 000 NR40 5100 ATC RPM Electric Motor Driven Spindles with Automatic Tool Changing Capability pictured in Figure 5 4 Ideal for larger Diameter tools up to 0 125 3 175 mm These spindles are driven by an electric brushless motor The brushless motor provides a long service life excellent durability and high reliability Both the 40 000 and 50 000 RPM spindles utilize an air operated collet to easily change tools Both spindles use high precision bearings to obtain spindle accuracy within 2 microns 50 000 IBAG HF45A60CP RPM Electric Motor Driven Spindles with Automatic Tool Changing Capability Ideal for larger Diameter tools up to 0 276 7 0 mm These spindles are driven by an electric brushless motor The brushless motor provides a long service life excellent durability and high reliability This spindle utilizes an air operated collet to easily change tools and high precision bearings to obtain s
137. sult data is displayed in the adjacent text box This data is automatically saved into the registers for the tool number listed in the textbox in the top right No experience value is used when performing a tool sense with this method The Select Carousel Tools button enables the user to detect which tools are present in the tool carousel The Sense Selected Tools button uses the highlighted tools in the Tool Changer Tab to change to and sense each tool See the Tool Sensing section of this manual for more information about the tool sensing routine If the workpiece probing option is available on the machine after a pallet identification routine the pallet number will be displayed in the Pallet ID textbox See the Workpiece Probing manual for more information about the workpiece probing COMBINE OFFSET 01 TERMINAL SENSOR USER _ Input Panel Tool Number 1 Pallet ID HE Length Offset Diameter mm Figure 4 27 Sensor Tab User Tab Options required The User Tab Figure 4 28 may vary depending on special options and equipment included on individual machines Typical options found here will be program array setup and manual operation of special pneumatic systems These system include tool guarding mandrel clamping and robot door actuation The program array setup can be used to repeat a loaded program at each spot on the array These locations are defined in the workpiece offset table offsets 1 12 Select the
138. surement diameter measurement length compensation and diameter compensation The description length compensation and diameter Tool Offset Table 36 Software Introduction September 2011 IV Software Introduction AN A ee The save to file button writes all the current tool offsets to a Save to File Button F E e we file and saves it to a user specified destination The receive from file button takes a user specified tool offset Retrieve from File Button file and replaces all the current tool offsets with the offsets from that file G CODE AXIS CAMERA ERROR STATUS WKP OFFSETS WARNING STATUS View Panel Previous Page _ Index To Tool 1 _Net Pase Tool Tool Description Measured Measured Length Radius Number Length mm Dia mm Comp mm Comp mm 1 19 9688 2 3047 0 0000 0 0000 18 9195 1 0257 0 0000 0 0000 28 9158 33 2691 0 0000 0 0000 32 9338 32 6174 0 0100 0 0000 27 7965 33 2691 0 0000 0 0300 28 7025 33 2691 0 1100 0 0000 30 8051 0 1842 0 0000 0 0000 31 6247 0 6825 0 0000 0 0000 28 8919 0 1361 0 0000 0 0000 28 7911 33 2691 0 0000 0 0000 29 1232 33 2691 0 0000 0 0160 28 0034 33 2691 0 0000 0 0000 Figure 4 21 Tool Offsets Tab Input Panel Starting the software automatically opens the Input Panel as seen in Figure 4 22 The Input Panel is used to perform manual operations program loading and direct interaction with the machine cont
139. t Use the dial marked X Y Z 4 5 6 to select the axis of movement Figure 7 23 Currently the 4 5 and 6 positions are inactive Use the increment selection dial to select the handwheel scaling factor Figure 7 23 X1 moves the selected stage 1 micron per rotation increment X10 moves the stage 10 microns per rotation increment and X100 moves the stage 100 microns per rotation increment 5 To disable manual movement using the handwheel click the Disable Handwheel button Figure 7 23 Handheld pendant 104 Operation September 2011 Microlution VIII Operation AN Executing a Program NC programs can be run on the 363 S in three different ways manually using the Text Editor and the Terminal Panel Figures 7 24 and 7 25 automatically using the Program Run Tab and as a part array using the Part Pattern Tab Manually Running a Program by Using the Terminal Panel Warning The Terminal Panel has the ability to directly address variables and functions in the Delta Tau CNC controller and therefore should be used with caution Changes to key operating variables can result in changes in machine accuracy erratic machine behavior damage to the machine and or personal injury Only personnel specially trained in the operation of the Terminal Panel functionality should use any commands in the Terminal Panel other than the run command The run command executes a program To use the run command type b r into
140. take effect until after the Gcode is closed with the Close G Code button and then re loaded with the Load G Code button Variable Definition Variables and constants can be defined with variable names These definitions are located in the C Program Files Microlution SubPrograms Macros txt file Definitions use the following syntax and cannot contain spaces DEFINE MACRO_NAME VARIABLE OR CONSTANT Example DEFINE A_PARAMETER Q101 DEFINE Z_RETRACT 10 By placing the example code into the C Program Files Microlution SubPrograms Macros txt file the user will now be able to write macros using the variable names A_PARAMETER and Z_RETRACT instead of variable Q101 and constant 10 Syntax and Parameters 87 Operation September 2011 VIII Operation Subroutines M98 P L P Subprogram number required L Subprogram repeats optional defaults to 1 Macros G65 P A M Q Z P Subprogram number required A M Q Z Macro call parameters Subprogram Parameter Variables Parameter Variable A Q101 Q102 Q103 Q104 Q105 Q106 Q107 I O mnm oOo oa wv Q108 Q109 Q110 Q111 Q112 Q113 Q116 Q117 Q118 Q119 Q120 Q121 Q122 Q123 Q124 Q125 N lt x E lt c a v 2 Ol v Zl x Q126 88 Operation September 2011 Microlution VIII Operation DAN
141. tating speed of the cutting tool when using an angle spindle not applicable to the 363 S or speed reducer Select the gear ratio by using the Speed Adjustment Buttons 10 When setting gear mode the gear ratio is displayed in the Digital Speed Indicator 11 7 Controller Button This button toggles spindle control between manual mode using the speed adjustment buttons 10 and automatic mode using the CNC Control Panel 8 Rotation Direction Button This button toggles between clockwise FWD and counter clockwise REV cutting tool rotation as seen when the tool is facing away from the operator 9 Start Button Starts and stops motor rotation 10 Speed Adjustment Buttons These buttons increase UP or decrease DOWN the motor speed between 5 000 60 000 min rpm 11 Digital Speed Indicator Preset speed actual speed warning and error codes are displayed to 2 digits When the motor is stopped the preset speed is displayed When the motor is rotating the actual speed is displayed The display also displays error and warning codes as well as the gear ratio while in gear mode 134 Appendix A September 2011 Microlution AN Xi Appendix A Table 5 1 Spindle Warning Codes Warning Code Warning Function Trouble AO Motor Code Motor cord or connector disconnected or misaligned Al Low Air Pressure Low air pressure A2 Ov
142. tem Response Procedure Check for loose Spindle motor disconnected Spindle will not start disconnected connections Spindle Motor Disconnected High spindle motor cooling air Check Warning pressure fault Code on Spindle torque overload warning Mos ti n Spindle Spindle motor current overload Controller warning Correct cause of Spindle over speed warning warning code Spindle Warning 34 Software Introduction September 2011 Microlution IV Software Introduction LO Spindle torque overload fault Spindle motor current overload fault Check Error Code Low spindle motor cooling air Spindle will stop on Spindle Spindle Error pressure fault Program will stop Controller Spindle over speed fault Spindle will not start Correct cause of Power cycled on controller box with error code spindle commanded to be spinning X Axis Velocity Error Velocity limit exceeded Y Axis Velocity Error Velocity limit exceeded Z Axis Velocity Error Velocity limit exceeded Machining cycle will stop Re initialize Spindle rotation will stop machine G CODE AXIS CAMERA error status TOOL OFFSETS WKP OFFSETS LASER WARNING STATUS View Panel Spindle Motor Connected X axis Velocity Limit Exceeded Spindle Warning Y axis Velocity Limit Exceeded Spindle Error Z axis Velocity Limit Exceeded Figure 4 19 Warning Status Tab Workpiece Offsets Tab The Workpiece Offsets Tab displays the values of all the workpiece
143. the Terminal Panel where is the program number For example typing b300r would run program 300 Damage to the machine caused by misuse of the Terminal Panel may void the factory warranty In addition programs 110 150 are reserved for factory use Do not use these program numbers Figure 7 24 Text Editor Panel MDI Combine Terminal Offset User Input Panel ow enter Figure 7 25 Terminal Tab 105 Operation September 2011 Microlution VIII Operation DAN Programs can be loaded to the controller directly from the built in text editor Figure 7 24 By saving programs to the controller they can be run by typing one command in the Terminal panel Figure 7 25 Programs that contain loops or jump commands can only be executed using the manual method because their entire contents must be in the controller memory in order to perform the jump commands Open the text editor using either the new or open menu buttons By clicking on the download button in the editor Figure 7 24 the program that is currently in the Editor window will be sent to the controller The program will be saved to the file currently open on the 363 S The first two lines of a program to be downloaded to the 363 S should look like close open prog 300 clear These lines will close the currently open program open program 300 and clear anything that is already stored in that location The remaining lines of the program ar
144. the bottom of the window and sent with the enter key Warning The Terminal Panel has the ability to directly address variables and functions in the Delta Tau CNC controller and therefore should be used with caution Changes to key operating variables can result in changes in machine accuracy erratic machine behavior damage to the machine and or personal injury Only personnel specially trained in the operation of the Terminal Panel functionality should use any commands in the Terminal Panel other than the run command The run command executes a program To use the run command type b r into the Terminal Panel where is the program number For example typing b300r would run program 300 Damage to the machine caused by misuse of the Terminal Panel may void the factory warranty COMBINE OFFSET TERMINAL SENSOR Input Panel Terminal Entry Line Figure 4 25 Terminal Tab 40 Software Introduction September 2011 Microlution IV Software Introduction Offset Tab The Offset Tab see Figure 4 26 is used to set save and load program origins workpiece offsets Table 4 13 describes the buttons located within the Offset Tab and their functions Refer to the Operation section of this manual for a step by step set of instructions for using the Offset Tab Figure 4 26 Offset Tab Table 4 13 Offset Tab buttons and their functions Button Function
145. tic chuck to position the pallet This connection assures repeatable positioning Protective Rigid Seals The protective rigid seals keep chips and fluid out of the machine motion and electronic components while still allowing motion of the stages Z Stage The Z stage moves in the Z direction and has a total travel range of 3 94 100 mm Available machining travel range depends on the spindle workpiece fixture and installed options such as an automated tool changer Spindles detailed in the Spindle Introduction and optional metrology equipment are mounted to the spindle mounts located on the Z stage Spindle Mount The spindle mount allows for quick spindle changes with highly repeatable positioning The spindle mounting system uses 6 bolts to rigidly hold the spindle block to the z axis stage 45 Hardware Introduction September 2011 V Hardware Introduction Work Piece Mounting System 1 Pallet Back and Front 2 Spigot 3 Pallet with Spigot Attached 4 Machinable Fixture Plate 5 Complete Pallet System The following items reference Figure 5 3 Figure 5 3 Pallet System Introduction 46 Hardware Introduction September 2011 Microlution V Hardware Introduction AN 1 Pallet The front face of the pallet is smooth with four threaded 7 and four unthreaded 8 mounting holes around the edges of the pallet The mounting holes enable the machinable fixture to be securely fastened to the pa
146. tion F Feedrate previously used feedrate Note G01 can be used in conjunction with G43 in specialized format below G01 G43 Z H F G02 Circular Move Mode Clockwise Format G02 X Y F 1 J or G02 X Y F R Required Inputs X Move destination along X axis Y Move destination along Y axis Optional Inputs F Feedrate l Arc move along the X axis from current location circle center to start J Arc move along the Y axis from current location circle center to start R Circle radius Note This command will not work if there is no I J or R specified Please use one of the formats listed above A single or J input will also work There are no defaults for this command G03 Circular Move Mode Counter Clockwise Format G03 X Y F 1 J or G03X Y F R Required Inputs X Move destination along X axis Y Move destination along Y axis Optional Inputs F Feedrate l Arc move along the X axis from current location circle center to start J Arc move along the Y axis from current location circle center to start R Circle radius Note This command will not work if there is no I J or R specified Please use one of the formats listed above A single or J input will also work There are no defaults for this command G04 Dwell Format G04 P or GO4X Required Inputs P Dwell time in seconds Optional Inputs Default X Dwell time in seconds 0 seconds 118 Supported G and M Codes September 2011 Micro
147. tional Stop O System Pressure Fault Spindle Control JOG COMBINE OFFSET Spindle 1 E ee MDI TeRMNAL Sensor USER mparans MC Tool Number 1 EE AD Pallet 10 MA Increment B o m vee Length Ofte oo a a oe a o Figure 7 4 Program Run Tab of the Control Panel The following instructions pertain to Figure 7 4 Changing the Spindle Speed 1 Entering a new RPM value into the text box and clicking the Set button will change the spindle speed to the new value 2 Using the buttons will increase or decrease the speed of the spindle by the amount shown in the textbox Disabling the Spindle Click the Stop button to stop the spindle from rotating Wait for the spindle to come to a complete stop Click the Disable Spindle button The spindle is now disabled and tools pallets or spindles can be changed by following the guidelines outlined in the Tool Changing Pallet Changing and Spindle Changing sections SI 61 Operation September 2011 Microlution Vill Operation AN Tool Changing Manual Collet 80 000 RPM Electric Air Bearing This section describes how to install and remove tools from the 80 000 RPM electrically driven spindle with air ceramic bearings and the manual collet Figure 7 5 Equipment 2 M10 Wrenches Tool Installation Jog the Z stage away from pallet Turn off the spindle Verify that the
148. tive offset although they can update any other work or tool offset Also ensure that the correct measuring probe is loaded into the spindle Measuring with a fluted tool is not recommended because the probing force can damage the work piece and or the tool If the measuring program fails to execute for some reason then an error is outputted which may help debug the error source and the program stops immediately Please return the stages to the start position before re running the code 78 Operation September 2011 Microlution VIII Operation AN X Y Z single surface measurement G65 P9811 Description The cycle measures a surface to establish the size or position Application With its tool offset active position the probe adjacent to the surface The cycle measures the surface and returns to the start position The measured surface can be considered in one of two ways 1 Asa size where the tool offset is updated in conjunction with the Tt input 2 Asa reference surface position for the purpose of adjusting a work offset using the Ss input The function supports single axis measurement moves only The appropriate probe length and diameter must be stored in tool number which is passed as parameter H This can be done by using the tool sensor and running a diameter and length measurement cycle Format G65 P9811 Xx or Yy or Zz Hh Cc Ee Ff Qq Ss Tt Uu Vv Where denotes optional inputs Compulsory inputs Xx x o
149. toring and real time inspection The contents of this tab will be slightly different depending on the type of camera that is purchased Fig 4 16 shows the controls for an EO 3112C Color USB Camera from Edmund Optics These controls shown here are the same as for the camera s software so consult the camera s user manual or online help for more information G CODE AXIS CAMERA STATUS LASER View Panel IntCamera Savelmage use DirectDraw Trigger mode Software Falling Rising use Memoryboard Figure 4 16 Camera Tab Laser Tab LT 9010 Confocal Laser Option Required 31 Software Introduction September 2011 Microlution IV Software Introduction LC The Laser Tab shown in Figure 4 17 shows the camera feedback from the Keyence LT 9010M or similar laser with a camera in the laser head This tab will only be available if your laser includes a camera G CODE AXIS CAMERA STATUS LASER View Panel Figure 4 17 Laser tab Error Status Tab The Error Status Tab displays the status of error alarms on the 363 S shown if Figure 4 18 If the indicator next to an alarm is green then that alarm functioning properly If the indicator is red then a fault has been registered and the alarm must be cleared before proceeding with many of the functions on the machine Table 4 7 gives a description of each of the alarms Table 4 7 Error Alarms on the 363 S

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