nc integrator manual
Contents
1. PR BITS M Function Bit 32 Bit 3 Bit2 Bit1 Bit0 Read An Offset Don t Care 0 0 1 Write An Offset Don t Care 0 1 1 No Command pending in PC Don t Care D C D C 0 Command is pending in PC Don t Care D C DC 1 Beep PC Speaker Don t Care 1 0 0 Table 1 Telling PMAC NC What Offset to Read or Write The DPRAM location in PMAC DDFE 60DFE for Turbo and 0x37F8 for a PC Offset contains a DWORD that PMAC NC interprets when it receives a command for triggering the modification of an offset In PMAC the macro variable name PR COMMAND M M1 I is assigned at this location PR COMMAND M is a DWORD however it can be interpreted as two 16 bit WORDS concatenated together to form the DWORD The upper WORD reflects what type of offset can be set Table 2 indicates how the upper 16 bits of PR COMMAND M is interpreted when it receives a trigger command from PR BITS M The lower 16 Bits of PR COMMAND indicate for what tool number to interpret the command In tool offsets the PR COMMAND M upper word is 40 48 or 50 58 and in cutter compensation the PR COMMAND M upper word is 2 or 3 For work offsets there is a special interpretation of the lower 16 bits In G54 the value for the low 16 bits should have a base 20 plus the axis number where the axis number can be 1 2 3 4 5 6 representing X Y Z A B C respectively PR COMMA2. Motor Feedback Travel Limits Machine Input Output USB INPUT Spec 1 1 2 0 UMAC QMAC ESTOP NC Contact OU O AC Power Input 110v 230 V 50 60 Hz Dual Power Supply Adv 810 shipped with three cables ESTOP with NC Normally connect AC Power Input and USB cable Ei Diagram 1 Machine Tool Sample Connection Diagrams 33 Integrator User Manual NC System Interface Sample Block Diagram using ACC24E2A TB1 Top ACC 24E2A 0000 1u013 n m R6 RTN f PLIM MLIM HoMF USER TB1 Bottom 15V Supply GND 15V 15V Remove E85 E87 and E88 for External Power Supply Amplifier Float Shield ecm 15V TTE Float Shield AGND Neg Limit 1 m MEME Home Flag Servo Motor V Pos Limit Float Shield This is a general example of a system with sourcing flags and normally open amplifier enable output from the ACC 24E2A For opto isolation an external power supply is used and E85 E87 and E88 have been removed from the ACC 24E2A Diagram 2 Sample Connect
3. partsTotal dword 00000000 U Registry Editor Registry Edit View Favorites Help ze ig Tos REG DW OFD DsDononona iui zj Bb Hy amp amputa pi HEEN LOCAL MACHINE SYS TEAS RCPS lSs tool Services PAT Devies oo Wed ETATEH Screen 4 Parts Total Parts Required This value is used for setting the number of machined parts required When the parts count reaches this value a machine tool builder specific function may occur 22 How to Make a Custom Tool Offset Page NC Integrator User Manual Parts Count This value is incremented by 1 when a M02 M30 or a M code specified by the machine tool builder is executed In general this value may be reset when it reaches the number of parts required However a machine tool builder program specific function may occur EY PHAC NC Control Machine Life Totals Cycle Totals Hr Mn Sec Cycle Time 00 00 00 Cutting Time 00 00 00 Days Hr Mn Sec culling Parts Count Ea Cutting T Parts Required Running E PowerU Parts Count fo Machine Running Machine p Timer 00 00 00 Parts Count Parts Required 0 Parts Count 0 Parts Total 0 Time 12 33 27 PM Date 1 10 2000 Screen 5 Parts Count Setting To modify the parts required or parts count press F1 for the settings page then select F3 Parts Ctr Integrators Function PMAC NC DPRAM command words CS COMMAND6 Mand CS STATUS Mocontain bits that a
4. Arc Programmed Path Tool Center Pd Path Tool Center j e E n m Line to Line Line to Arc cc2 A al y Spira Programmed Arc D Path Tool Center Path Tool Center szaz E ka Arc to Line Arc to Arc Note The behavior for lead in moves is different from changing the compensation radius from zero to a non zero value while compensation is active An arc move is always added at the corner regardless of the setting of Isx99 This ensures that the lead in move never cuts into the first fully compensated move 12 Cutter Compensation NC Integrator User Manual Treatment of Inside Corners Inside corners are still subject to the blending due to the TA and TS times in force default values set by coordinate system I variables Isx87 and Isx88 respectively The longer the acceleration time the larger the rounding of the corner The corner rounding starts and ends a distance F TA 2 from the compensated but unblended corner The greater the portion of the blending is S curve the squarer the corner will be When coming to a full stop e g Step Quit or DWELL at the corner at an inside corner Turbo PMAC will stop at the compensated but unblended corner point Inside Corner Cutter Compensation Line Programmed Path Programmed Path Tool Center Hd Path _____y Line Line 7 x Tool Center r Path j at v Line to Line Line to Arc Line Program
5. Begistry Editor Registry Beit View Favorites Help Tem Dan RER ET CALCU REG I COWINNTUESTEWGIZICAI C EXE Screen 7 Registry Editor Launch CALCULATOR from NC In the registry editor create userButtonNamel which is a type string Edit this key and add CALCU which is the name of the user button displayed in NC This button can be found under PROG F12 The name of the button should be no more than six characters In the registry editor create userButtonFilel another type string Edit this key and add the executable file path as C WINNT S YSTEM32 CALC EXE To add another userButton increment the number from 1 to 2 Up to seven applications can be launched 28 How to Add and Display Error Messages NC Integrator User Manual MODIFYING WORK AND TOOL OFFSETS FROM PMAC PMAC NC contains bits in DPRAM as well as words that allow changing the tool and work offset database within PMAC NC In addition a floating point location resides there that is used to exchange floating point data Triggering PMAC NC to Read or Write an Offset The DPRAM location in PMAC DDFD 60DED for Turbo and 0x37F4 for a PC Offset contains bits that PMAC NC monitors for triggering the modification of an offset In PMAC the macro variable name PR BITS M M16 0 is assigned to this location Table 1 indicates how bits in PR BITS M trigger various commands Once the command has been executed Bit 0 will be cleared by PMAC NC
6. Programmed Path Arc N Tool Center Vl Path Line Line to Line Line P Line Programmed Path Arc wes Arc Tool Center q Path 4 Arc to Line Programmed Path Tool Center E NN Path Line Line to Arc Arc Programmed CYRUS Arc Tool Center Path 1 Arc to Arc Outside Corner Cutter Compensation Shallow Angle cos O gt Isx99 Line to Line Cutter Compensation 14 NC Integrator User Manual Shallow Outside Corner If the cosine of the change in directed angle is greater than Isx99 which means that the corner is flatter than the specified angle the moves will be directly blended together without an added arc The added arc prevents the compensated corner from extending too far out on the outside of a sharp corner However as an added move it has the minimum time of the acceleration time which can cause a slowdown on a very shallow angle While the default value for Isx99 of 0 9998 cos1 causes an arc to be added on any change in angle greater than 1 many will set Isx99 to 0 707 cos45 or 0 0 cos90 so arcs are only added on sharp corners When coming to a full stop e g Step Quit or DWELL at an outside corner with an added arc Turbo PMAC will include the added arc move before stopping When coming to a full stop at an outside corner without an added arc Turbo PMAC will stop at the compensated but unblended corner point Treatme
7. USER MANUAL NC Integrator IN DELTA TAU Ny Data Systems Inc NEW IDEAS IN MOTION Single Source Machine Control Power Flexibility Ease of Use 21314 Lassen Street Chatsworth CA 91311 Tel 818 998 2095 Fax 818 998 7807 www deltatau com Copyright Information 2003 Delta Tau Data Systems Inc All rights reserved This document is furnished for the customers of Delta Tau Data Systems Inc Other uses are unauthorized without written permission of Delta Tau Data Systems Inc Information contained in this manual may be updated from time to time due to product improvements etc and may not conform in every respect to former issues To report errors or inconsistencies call or email Delta Tau Data Systems Inc Technical Support Phone 818 717 5656 Fax 818 998 7807 Email support deltatau com Website http www deltatau com Operating Conditions All Delta Tau Data Systems Inc motion controller products accessories and amplifiers contain static sensitive components that can be damaged by incorrect handling When installing or handling Delta Tau Data Systems Inc products avoid contact with highly insulated materials Only qualified personnel should be allowed to handle this equipment In the case of industrial applications we expect our products to be protected from hazardous or conductive materials and or environments that could cause harm to the controller by damaging compone
8. 2 Edit the ERRORS DAT and add a message under the MessageBox section PLCMessageBoxErr0 Do you want to switch OFF the POWER 3 Define the bit number as macro in the header file define Msg box1l 65 The PLC will look like IF Switch Press 1 SET_ON ES_PLCMSGBOX_M Msg boxl ENDIF 26 How to Add and Display Error Messages NC Integrator User Manual ll IF ES_PLCMSGBOX_M 65536 User responds YES POWER_OFF ENDIF IF ES_PLCMSGBOX_M 65536 User responds NO CONTINUE ENDIF How to Add Modify User G M or T Code User G codes and existing T codes can be modified in the MILL G or MILL T files The NC software will download these G codes but will not display them on the screen under Active G codes The user G codes can be written from G60 1 to G79 1 Make sure the Motion application NCRegistry application has following settings iim m ot m Screen 6 Code Tab Adding G60 1 in MILL G file To add G60 1 to the MILL G file 1 Open the MILL G file in the editor 2 Add label N60100 and write the code under this label 3 Follow the same procedure for other user G codes How to Add and Display Error Messages 27 Integrator User Manual How to Launch a Different Application from NC Delta Tau NC allows launching different applications To accomplish this the integrator must add a registry entry in the window registry using the windows registry editor
9. Program Files Common Files Delta Tau Shared address h file The following list explains the association between the type of the error and macro name to be used in PLC or in G M T code 64 messages are possible in each category One M variable can display 32 error messages Display PLC or G M or T Code Fatal Error ES ERR FATAL M S ERR FATAL2 M Error ES ERR STOP M S ERR STOP2 M Warning ES ERR WARN M ES ERR WARN2 M General Message ES ERR MSG M ES ERR MSG2 M Message Box ES PLCMSGBOX M To Set or Reset the Message Decide how many messages and types of messages Edit the ERRORS DAT file for different messages in the editor Notepad or any editor Find out the bit address for the message Define the bit number as a macro To set the error use 9 SET ON Message Address Bit Number macro in the PLC To Reset the error use 9 SET OFF Message Address Bit Number macro in the PLC Qt PB Dmr For example The error message No Air Pressure Check is displayed if there is no air pressure 1 Edit the ERRORS DAT and add a message under STOP PLCStopErr64 0064 tPLC t No Air Pressure Check 2 Define the bit number as a macro in the header file define ERROR_AIR 80000000 Bit 32 3 In the PLC check for air pressure Input and set the error message PLC will look like How to Add and Display Error Messages 25 Integ
10. TB1 or TB2 AFAULT AFAUILT AE No DAC1B DAC1B 25V Amplifer Enable Diagram 5 4 15V Supply GND 15V 15V TB3 Amplifier Logic GND ASV i5v Ampliler Enable Sample Connection Diagrams 37 Integrator User Manual Sample Diagram for Connecting UMAC QMAC Machine Flags for ADV810 ACC 24E2A ACC 24E QMAC Sinking Flags Block Diagram Electrical Equivalent Diagram 24V Supply 24 V and FLG_RTN_1 ov 24V 5 FLG_RTN_1 Opto Isolator TB1 4 HOME1 Fone ih Ne MLIM1 x N C 3 1 Neg E gt PLMI Pos 7e MLIM1 1 User Flags HM PLIM NLIM User 0v ACC 24E2A ACC 24E QMAC Sourcing Flags Block Diagram Electrical Equivalent Diagram 24V Supply 24 V OV 24V 5 FLG RTN 1 Opto Isolator N 4 HOME1 Home EN MLIM1 x N C 3 Neg PLIM1 TVA 2 Pos MLIM1 1 ser Flags HM PLIM NLIM User l T 0 V and FLG RTN 1 Diagram 6 Sample Diagram for Connecting UMAC QMAC Machine Flags for ADV810 ACC 24E2A ACC 24E QMAC Sinking Flags Block Diagram Electrical Equivalent Diagram 24V Supply 24 V and FLG_RTN_1 OV 24V 5 FLG RTN 1 Opto Isolator TB1 4
11. ov 24V l1 v AGND Device J1 or J2 Bottom for Outputs 24V Supply ov Sensor coooog D Connector as a Option ooooooc TB1 or TB2 TOP for Inputs Sourcing Inputs 24V Supply ov 24V TB3 Top Rea Ret 2 Rei Device osma Sinking Inputs 24V Supply ov Sensor 24V Supply Input 12 Sensor J1 or J2 TOP for Inputs 24V Supply ov 24V Ld Sensor voodoo 5 0 9c 95 D Connector as a o6 Option 96 o o9 99 Diagram 4 Sensor 24V Supply OV 3 Sensor 36 Sample Connection Diagrams NC Integrator User Manual Sample Diagram for Connecting UMAC AMPLIFIER FAULT for ADV810 ACC 24E2A Sinking Amplifier Fault 15V Supply GND 15V_ 15V TB3 DB15 Option TB1 or TB2 15V Supply GND 15V_415V TB3 45V 4 15V Supply GND 15V 15V Amplifier AAV AASV AAGND Logic GND AAGND ARAB AsV AAGND aasisy EE AAAASV AFALILT AASV AFAULT Amplifer Fault AFAULT AE NO AFAULT AE COM AE NO AF
12. s inverse kinematic calculations are used the conversion from tip coordinates to joint coordinates takes place before lookahead calculations segment by segment for LINEAR and CIRCLE mode moves Therefore Turbo PMAC can execute the lookahead calculations in joint space motor by motor even if the system has been programmed in tip coordinates Once the lookahead function has been set up the lookahead function operates transparently to the programmer and the operator No changes need to be made to a motion program to use the lookahead Turbo PMAC Lookahead Function 1 Integrator User Manual function although the programmer may choose to make some changes to take advantage of the increased performance capabilities that lookahead provides Quick Instructions Setting Up Lookahead The following list quickly explains the steps required for setting up and using the lookahead function on the Turbo PMAC Greater detail and context are given in the subsequent section 1 2 ea eo PF nd 11 12 13 14 15 Assign all desired motors to the coordinate system with axis definition statements Set Ixx13 and Ixx14 positive and negative position limits plus Ixx41 desired position limit band in counts for each motor in the coordinate system Set bit 15 of Ixx24 to 1 to enable desired position limits Set Ixx16 maximum velocity in counts msec for each motor in the coordinate system Set Ixx17 maximum acceleration in cou
13. 5 Notes 1 Tests performed on 80 MHz Turbo PMAC 2 Tests performed at default 2 25 kHz servo update rate 3 Tests performed with no PMAC motor commutation or current loop closure 4 Higher block rates can be done but segmentation will smooth out features Note Subject to these constraints the length of the lookahead is subject only to memory limitations in the Turbo PMAC In general the Isx13 segmentation time is set to the largest value that meets user requirements in each of the above three concerns However it is seldom set larger than 10 msec Calculating the Required Lookahead Length In order for the coordinate system to reach maximum performance it must be looking ahead for the time and distance required for each motor to come to a full stop from maximum speed Because the lookahead buffer stores motion segments this lookahead length must be expressed in segments To calculate this value first compute the worst case time required to stop for each motor in the coordinate system This value can be obtained by dividing the maximum motor velocity by the maximum motor acceleration In terms of Turbo PMAC parameters Ixx16 Ixx17 StopTime m sec Now take the motor with the longest stop time and divide this time by 2 because the segments will come in at maximum speed which takes half the time of ramping down to zero speed Next convert this value to a number of segments by dividing by
14. Note If bit 14 of Ixx24 is also set to 1 the program does not stop at the limit Instead it will continue with the offending motor saturating at the limit value When stopped on a desired position limit within lookahead the program is only suspended not aborted The action is effectively equivalent to issuing a quick stop command It is possible to retrace the path coming into the limit or even to resume forward execution after changing the limit value An abort command must be issued before another program can be started Turbo PMAC Lookahead Function 3 Integrator User Manual Note If an actual position limit is also tripped during the deceleration to a stop at the desired position limit the program is aborted so retracing and resuming are not possible For this reason if the possibility of retracing and resuming is important Ixx41 should be set to a large enough value so that the actual position limit is never tripped during a desired position limit stop This technique permits these software position limits to be placed just within the hard stops of the machine Without the desired position limits the software position limits cannot be detected until the actual trajectory passes the limit This requires that these limits be placed far enough within the hard stops so that the motors have enough distance to stop after they pass the limits When a motor hits a software position limit without lookahead the decelera
15. etse ibt E eset te pee pets E laevum ades sees E sedere od 14 Shallow Outside Comnen i eiecti te ble se drea eset obe disse N desu cipe E stunt etaed iun 15 Treatment of Pull Reyersalis ne ett ete Re ep SI HERR ae epe E pe tede deae du ute E e veu Tete duo 15 Note ou Full Circles s se sedes ep Reti beat donde xe dete ue ee out vg adesuearetehausdeansedaeolgeyetee epe Dep ud eb Vue EIN 15 Speed of Compensated Moves esee eese eene enne ennt nete entere nne teste tnet ne enee tr ennetee nennen eene teen trennen 16 Changes in COMPCNSAHON useisiin iniesta ai neinei a eiea n ienien eiss er iaeiiai 16 How Turbo PMAC Removes Compensation ssssesseseeeeeeereneen een ene nren trennen reet nr en eren enne rennes 18 Inside COV CT RR TR 18 Q tside QUILT REC 18 Failures in Cutter Compensation eese teen enne saena eE E r ea reiner treten tren e E EEEE a e enne n nenne nenne 19 Inability to Calculate Through Corner eese eese nennen nennen rene ene eene neen nenne 19 Inside Corner Smaller than Radius eee eee eese esee teen tenente treten tnen trennen etre neteen rene te entes 20 Inside Arc Radius Smaller than Cutter Radius eee esee eene nne nre enne trennen 20 HOW TO MAKE A CUSTOM TOOL OFFSET PAGE e eeeeeeeee eene en sente sen tosta sns tn seta sse ta sensn sensns ss en 21 Howto Set Parts Counter iie reticere tiere ro re E REESE r ASESOR NE I BER iei ee VETERE E
16. to be followed The lookahead algorithm may reduce the speed along the path but it will not change the path Run the motion program and let the lookahead algorithm do its work Turbo PMAC Lookahead Function NC Integrator User Manual Detailed Instructions Setting up Lookahead A few steps are required to calculate and set up the lookahead function Typically the calculations only have to be done once in the initial configuration of the machine Once configured the lookahead function operates automatically and invisibly Defining the Coordinate System The lookahead function checks the programmed moves against all motors in the coordinate system The first step is therefore to define the coordinate system by assigning motors to axes in the coordinate system with axis definition statements This action is covered in the Setting up the Coordinate System section of the User Guide Lookahead Constraints Turbo PMAC s lookahead algorithm forces the coordinate system to observe four constraints for each motor These constraints are defined in I variables for each motor representing maximum position extents velocities and accelerations These I variables must be set up properly in order for the lookahead algorithm to work properly Position Limits Variables Ixx13 and Ixx14 for each Motor xx define the maximum positive and negative position values respectively that are permitted for the motor software overtravel limits Thes
17. 59 Set lower 16 bits to 61 based on table 3 so PMAC sets the G56 X work offset PR COMMAND M PR BITS M 80000 61 PR BITS M 3 3 Set bits 0 and 1 to trigger PMAC to read the data placed in the data location 30 Modifying Work and Tool Offsets frum PMAC NC Integrator User Manual 4 Type the following in PEWIN32 M162 30 8 M161 80000 61 M160 M160 3 5 To change G54 1 P48 X value to 48 1 type the following PR_DATA M 48 1 PR_COMMAND_M A0000 941 note that A is 10 in hex PR_BITS_M PR_BITSM 3 6 Type the following in PEWIN32 M162 48 1 M161 A0000 941 M160 M160 3 ii a Tool Offset To set the Z axis tool Geometry for offset number 8 to 10 0 type the following PR DATA M 10 0 PR COMMAND M 2D0000 8 note that 2D is 45 in hex PR BITS M PR BITS M 3 2 Type the following in PEWIN32 M162 10 0 M161 2D0000 8 M160 M160 3 Reading a Work Offset Set upper 16 bits of command to 8 based on table 2 so that PMAC NC reads a work offset in the range G54 G59 2 Set the lower 16 bits to 61 based on table 3 so PMAC reads the G56 X work offset PR COMMAND M 80000 61 3 Set bit 0 to trigger PMAC NC to write the data we want in the data location PR BITS M PR BITS M 1 PR DATA M should now contain the G56 X axis work offset 4 Type the following in PEWIN32 M161 80000 61 M160 M160 1 M162 lt Will respond with the G56 X axis work offset gt Modifying Work a
18. HOME1 Home I 3 MLIM1 Neg N C l 2 PLIM1 Pos p MOMI rie Flags HM PLIM NLIM User ov ACC 24E2A ACC 24E QMAC Sourcing Flags Block Diagram Electrical Equivalent Diagram 24V Supply 24 V oV 24V L 5 FLG_RTN_1 Opto Isolator A 4 HOME1 Home O TS 3 MLIM1 Neg ae PLIM1 y 2 Pos 1 MLIM1 User Flags HM PLIM NLIM User am TBI gs 0 V and FLG_RTN_1 Diagram 7 38 Sample Connection Diagrams NC Integrator User Manual Sample Diagram for Connecting QMAC OUTPUT Sink Only TB8 Load 250 mA Max Sample Diagram for Connecting QMAC INPUT TB6 or TB7 Sourcing Inputs 24V Supply ov 24V s 9 Sensor 1 TB6 or TB7 Sinking Inputs 24V Supply ov 24V 10 9 Sensor 1 TB6 or TB7 Diagram 8 Sample Connection Diagrams 39
19. ND M Value for Bit Value for Bit 31 16 15 0 Cutter Comp Geometry Offset 2 Tool Number Cutter Comp Wear Offset 3 Tool Number Work Offset G54 G59 8 See Table 3 Work Offset G54 1 P1 P48 10 See Table 3 Five Axis Tool Length 11 Tool Number Rotation G68 12 See Table 4 A Axis Tool Geometry Offset 40 Tool Number B Axis Tool Geometry Offset 41 Tool Number C Axis Tool Geometry Offset 42 Tool Number X Axis Tool Geometry Offset 43 Tool Number Y Axis Tool Geometry Offset 44 Tool Number Z Axis Tool Geometry Offset 45 Tool Number U Axis Tool Geometry Offset 46 Tool Number V Axis Tool Geometry Offset 47 Tool Number W Axis Tool Geometry Offset 48 Tool Number A Axis Tool Wear Offset 50 Tool Number B Axis Tool Wear Offset 51 Tool Number C Axis Tool Wear Offset 52 Tool Number Modifying Work and Tool Offsets from PMAC 29 Integrator User Manual X Axis Tool Wear Offset 53 Tool Number Y Axis Tool Wear Offset 54 Tool Number Z Axis Tool Wear Offset 55 Tool Number U Axis Tool Wear Offset 56 Tool Number V Axis Tool Wear Offset 57 Tool Number W Axis Tool Wear Offset 58 Tool Number Table 2 For example To modify the G54 X offset the low 16 bits should be 21 To modify G54 Y the low 16 bits should be 22 To modify the G54 Z value the low 16 bits should be 23 For G55 the base is 40 G56 the base is 60 G57 the base is 80 G58 the base is 100 and for G59 then base is 120 For the extended work o
20. NG AF COM DACIB AE NC DACIB DACIB DACIA DACIB DACIA DACIA DACIA ACC 24E2A Sourcing Amplifier Fault TBS DB15 Option Amplifier Logic GND TB1 or TB2 DAC1A 15V Supply GND 15V 15V AAGND SV i5v Amplifer Fault ACC 24E2A Normally Open Amplifier Enable TB3 DB15 Option Amplifier Logic GND 48V Amplifer Fault 15V Supply GND 15V 18V AASV ARTS AAGND AAGND TB3 AASV AASV AFAULT AE NO AE COM AE NC DACIB DAC Ba DACIA DACIA AFAULT 4 4 Amplifier Logic GND 48V 15v Amplifer Fault 4 15V Supply GND 45V 15V AAABV AALISV AFALIT AFAULT AF NO AF COM AF NG DACIR DACIB DACIA DACIA TB1 or TB2 TB3 7 ARABI Amplifier ARAS Amplifier ARGND Logic GND AAGND Logic GND 5V AREY AV 15V AAI 5v AFAULT FAULTS Amplifer Enable Amplifer Enable 4 15V Supply GND 5V 15V AAGND ACC 24E2A Normally Closed Amplifier Enable TB 3 DB15 Option Amplifier AA 18V Logic GND ABV AA 15V AE COM AE NG DAC1A DAC1A
21. RE 22 Paris Total ise iei iei poete seedtigecerachs dacteate reste vauns taiacenack tese ine E im feo nU esee E havacueatecrts 22 Paris Required sitire extinct oats euis pl CU RC E m 22 PONS COUN so dos tetti etre iteM exemit mtem adt D messes LL M cue Eu ed 23 Integrators Function eese sees eese eene eene thee en tentent intent tnnt en tese testen testen ss iedreen niekeen 23 HOW TO ADD AND DISPLAY USER MESSAGES eerie eee nentes een testen suse ta sns ta sens tns ta sens enses toss es sse ta suus 25 To Setor su MC M 25 Clearing Messages pu 26 Table of Contents i Integrator User Manual Messate BOK mM 26 Displaying Messages c ccscccessscessceensecessceessecesceeessecseneeessececeeessecseneeenseceeeeeaaecsneeeaaecescecsaeceeaeeeeaaeceeaeeesaeceeneeenaeens 26 How to Add Modify User G M or T Code sse eene entente nnne trennen nennen innen 27 Adding G60 1 in MILL G file esee eese teen enne trennen nennen etes ne enne trennen eterne trennen 27 How to Launch a Different Application from NC essere teen enne nennen nenne tee rennen enne 28 Launch CALCULATOR from NN rtt reete ter enni ko ebd eee ae iae e plena Lieb ehe Dae baee ani sbaee 28 MODIFYING WORK AND TOOL OFFSETS FROM PMAC eeeeee senes eene neta sensn senatu seta su seta sensns ta sune n 29 Triggering PMAC NC to Read or Write an Offse
22. ad in move and the first fully compensated move with the line from the programmed point to this compensated endpoint being perpendicular to the path of the first fully compensated move at the intersection Note A few controllers can make their lead out move a CIRCLE mode move This capability permits releasing contact with the cutting surface very gently important for fine finishing cuts Inside Corner If the last fully compensated move and the lead out move form an inside corner the lead out move starts directly from this point to the programmed endpoint When the lead out move is a LINEAR mode move the compensated tool path will be at a diagonal to the programmed move path When the lead in move is a CIRCLE mode move the compensated tool path will be a spiral Removing Compensation Inside Corner Line Programmed Path cco Programmed Path Tool Center D Path oe Line Line pd Arc d EN ToolCenter Line Path ic Line to Line Line to Arc Line cco Programmed Path cco Programmed Path Tool Center Arc Tool Center Path Spirals Spirals x S x S Arc to Line Arc to Arc Outside Corner If the last fully compensated move and the lead out move form an outside corner the last fully compensated move ends at a point one cutter radius away from the intersection of the last fully compensated move and the lead out move with the line from the programmed
23. ad three additional parameters controlling the dynamics of the lookahead operation Isx21 Isx22 and Isx23 In the current versions of the firmware these values are fixed at 3 6 and 7 respectively and the variables have been removed Isx21 now permits direct control of the lookahead state of operation Defining the Lookahead Buffer In order to use the lookahead function in a Turbo PMAC coordinate system a lookahead buffer must be defined for that coordinate system reserving memory for the buffer This is done with the on line coordinate system specific DEFINE LOOKAHEAD command Because lookahead buffers are not retained through a power down or reset this command must be issued after every power up or board reset There are two values associated with the DEFINE LOOKAHEAD command The first determines the number of motion segments for each motor in the coordinate system that can be stored in the lookahead buffer At a minimum this must be set equal to Isx20 If this value is set greater than Isx20 the lookahead buffer stores historical data This data can be used to reverse through the already executed trajectory If reversal is desired the buffer should be sized to store enough back segments to cover the desired backup distance There is no penalty for reserving more memory for these synchronous M variable assignments than is needed other than the loss of this memory for other uses The room reserved for the segment data in the looka
24. ath Path Line Line Tool Center Line i Ta TS Jo rogramm d i Line i Paih d Na gsi CONSIGUE Exgeuted Inside Corner Smaller Than Arc Radius Smaller Than Cutter Radius Cutter Radius If Turbo PMAC cannot find the next move in time it will end the current move as if the intersection with the next move would form an outside corner If the next move when found does create an outside corner or continues straight on compensation will be correct On an outside corner an arc move is always added at the corner regardless of the setting of Isx99 However if the next move creates an inside corner the path will have overcut into the corner In this case Turbo PMAC will then move to the correct intersection position and continue with the next move leaving the overcutting localized to the corner Inside Corner Smaller than Radius Second if the compensated path produces an inside corner with one of the moves shorter than the cutter radius the cutter compensation will not work properly This situation results in a compensated move that is in the opposite direction from that of the uncompensated move and there will be overcutting at the corner Inside Arc Radius Smaller than Cutter Radius Third if the program requests an arc move with compensation to the inside and the programmed arc radius is smaller than the cutter radius then no proper path can be calculated In this case Turbo PMAC ends the program at the end
25. ath will be a spiral Introducing Compensation Inside Corner Line P d ie ete Programmed i Tool Center eee nae Path oy Line Line r x Arc iine ToolCentery f fa Path CC2 Moe v Line to Line Line to Arc Line Foren ied Programmed Tool Center etal Path ______y Line gt s PAM N Arc rd Spiral Tool Centers Path i cee cee y Arc to Line Arc to Arc Cutter Compensation 11 Integrator User Manual Outside Corner Introduction If the lead in move and the first fully compensated move form an outside corner the lead in move first moves to a point one cutter radius away from the intersection of the lead in move and the first fully compensated move with the line from the programmed point to this compensated endpoint being perpendicular to the path of the lead in move at the intersection When the lead in move is a LINEAR mode move this compensated tool path will be at a diagonal to the programmed move path When the lead in move is a CIRCLE mode move this compensated tool path will be a spiral Then a circular arc move with radius equal to the cutter radius is added ending at a point one cutter radius away from the intersection of the lead in move and the first fully compensated move with the line from the programmed point to this compensated endpoint being perpendicular to the path of the first fully compensated move at the intersection Introducing Compensation Outside Corner
26. ble to give Turbo PMAC a program sequence in which the cutter compensation algorithm will fail not producing desired results There are three reasons the compensation can fail Inability to Calculate Through Corner First if Turbo PMAC cannot see ahead far enough in the program to find the next move with a component in the plane of compensation before the present move is calculated then it will not be able to compute the intersection point between the two moves This can happen for several reasons There is a move with no component in the plane of compensation i e perpendicular to the plane of compensation as in a Z axis only move during XY compensation before the next move in the plane of compensation and no CCBUFFER compensation block buffer declared e There are more moves with no component in the plane of compensation before the next move in the plane of compensation than the CCBUFFER compensation block buffer can hold There are more than 10 DWELLs before the next move in the plane of compensation e Program logic causes a break in blending moves e g looping twice through a WHILE loop Cutter Compensation 19 Integrator User Manual Failures in Cutter Compensation A uu uu ee D e P gt PA ty LN j at Failure No Overcut J Programmed Path E Line Failure to See Through Failure to See Through Inside Corner Outside Corner Tool Center Line Line Programmed Arc P
27. drate becomes a constraint instead of a command programmed acceleration times are used only to define corner sizes and minimum move block times Turbo PMAC will control the speed along the path automatically but without changing the path to ensure that axis limits are not violated Lookahead calculations are appropriate for any execution of a programmed path where throughput has been limited by the need to keep execution slow throughout the path because of the inability to anticipate the few sections where slow execution is required The lookahead function s ability to anticipate these problem areas permits much faster execution through most of the path dramatically increasing throughput Because of the nature of the lookahead calculations trajectory calculations are done well in advance of the actual move execution and moves are kept within machine limits by the automatic adjustment of move speeds and times they are not appropriate for some applications Any application requiring quick reaction to external conditions should not use lookahead In addition any application requiring precise synchronization to external motion such as those using PMAC s external time base feature should not use lookahead When the lookahead function is enabled Turbo PMAC will scan ahead in the programmed trajectories looking for potential violations of its position velocity and acceleration limits If it sees a violation it will then work backward thr
28. e variables are defined in counts and are referenced to the motor zero or home position often called machine zero Even if the origin of the axis for programming purposes has been offset often called program zero the physical position of these position limits does not change they maintain their reference to the machine zero point Turbo PMAC checks the actual position for each motor as the trajectory is being executed against these limits if a limit is exceeded the program is aborted and the motors are decelerated at the rate set by Ixx15 Variable Ixx41 for each Motor xx defines the distance between the actual position limits explained above and the desired position limit that can be checked at move calculation time even in lookahead That is if the calculated desired move position is greater than Ixx13 Ixx41 or less than Ixx14 Ixx41 this will constitute a desired position limit violation Desired position limits are only checked if bit 15 of Ixx24 is set to 1 In this mode if the lookahead algorithm while scanning ahead in the programmed trajectory determines that any motor in the coordinate system would exceed one of its desired position limits it will suspend the program and force a stop right at that limit It will then work backwards through the buffered trajectory segments to bring the motors to a stop along the path at that point in the minimum time that does not violate any motor s Ixx17 acceleration constraint
29. ents expected during the time for lookahead There is no penalty for reserving more memory for these synchronous M variable assignments than is needed other than the loss of this memory for other uses Note The buffer reserved in this manner for synchronous M variables under lookahead is distinct from the fixed size buffer used for synchronous M variables without lookahead For example the command amp 1 DEFINE LOOKAHEAD 500 50 creates a lookahead buffer for Coordinate System 1 that can store 500 segments for each motor assigned to the coordinate system at that time plus 50 synchronous M variable assignments 8 Turbo PMAC Lookahead Function NC Integrator User Manual CUTTER COMPENSATION Cutter Radius Compensation Turbo PMAC provides the capability for performing cutter tool radius compensation on the moves it performs This compensation can be performed among the X Y and Z axes which should be physically perpendicular to each other The compensation offsets the described path of motion perpendicular to the path by a programmed amount automatically compensating for the size of the tool This permits the user to program the path along the edge of the tool letting Turbo PMAC calculate the tool center path based on a radius magnitude that can be specified independently of the program Cutter radius compensation is valid only in LINEAR and CIRCLE move modes The moves must be specified by F feedrate not TM
30. ffsets G54 1 Pn where n can range from 1 48 the base value is n 1 20 See table 3 below Offset Base Value for Value for Value for Value for Value for Value for Type Bits 15 0 to Bits 15 0 to Bits 15 0 to Bits 15 0 to Bits 15 0 to Bits 15 0 to Set X Axis Set Y Axis Set Z Axis Set A Axis Set B Axis Set C Axis G54 20 21 22 23 24 25 26 G55 40 41 42 43 44 45 46 G56 60 61 63 63 64 65 66 G57 80 81 82 83 84 85 86 G58 100 101 102 103 104 105 106 G59 120 121 122 123 124 125 126 G54 1 Pl 0 1 2 3 4 5 6 G54 1 P2 20 21 22 23 24 25 26 G54 1 940 941 942 943 944 945 946 P48 Table 3 Offset X Center Y Center Z Center XY Rotation YZ Rotation ZX Rotation Type of Rotation of Rotation Of Rotation Angle Angle Angle G68 1 2 3 4 5 6 Table 4 Where PMAC NC Returns Data from a Read or Write of an Offset The DPRAM location in PMAC DDFF 60DFF for Turbo and 0x37FC for a PC Offset contains a floating point value that PMAC NC uses for setting the modification of an offset or feeding data to the PMAC from PMAC NC In PMAC the macro variable name PR DATA M M1 2 is assigned at this location that is of the type DPRAM floating point format ipi a Work Offset Type the following to set a work offset PR DATA M 30 8 2 Set the upper 16 bits of command to 8 based on table 2 so that PMAC NC sets a work offset in the range G54 G
31. head buffer is dependent on the number of motors assigned to the coordinate system at the time of the DEFINE LOOKAHEAD command If the number of motors assigned to the coordinate system then changes the organization of the lookahead buffer will be wrong and the program will abort with a run time error on the next move after the coordinate system is changed If the coordinate system must be changed during an application that uses lookahead the lookahead buffer must first be deleted then defined again after the change The following motion program code shows how this could be done Turbo PMAC Lookahead Function 7 Integrator User Manual DWELL 10 Stop lookahead execution CMD amp 1 DELETE LOOKAHEAD Delete buffer CMD amp 1 4 gt 100C Assign new motor to C S 1 CMD amp 1 DEFINE LOOKAHEAD 1000 100 Redefine buffer DWELL 10 Make sure commands execute The second value associated with the DEFINE LOOKAHEAD command determines the number of synchronous M variable assignments e g M1 1 for the coordinate system that can be stored in the lookahead buffer Synchronous M variable assignments in the motion program delay the actual assignment of the value to the M variable until the start of actual execution of the next move in the motion program Therefore these actions must be held in a buffer pending execution This size of the buffer for these assignments must be at least as great as the largest number of assignm
32. ion Diagrams NC Integrator User Manual Sample Diagram for Connecting UMAC Analog AMPLIFIER ADV810 Connections ACC 24E2A DAC Torque Velocity Mode 15V TB3 15V TB3 Supply Supply GND 45V 15V GND 45V 15V Amplifier Amplifier 2 t4 ger oe AA 15V 15V AFAULT uu AFAULT Ar NO Amplifer Enable Amplifer Enable AE NC Float Float mem Shield Shield _ DACIA E it A A DACIA t i 1 7 Shield ji TB1 orTB2 DB15 Option Sample Diagram for Connecting UMAC QMAC Digital AMPLIFIER ADV810 Connections ACC 24E Direct Digital PWM Mode Digital Amplifier Like GEO Drive 36 Pin Mini D Connector This is a standard 36 pin cable compatible with most of the Direct Digital Amplifier manufacturers Delta Tau Amplifier version is GEO Drive If GEO drive is not used check the Pin out in the manual Sample Diagram for connecting QMAC Analog AMPLIFIER ADV810 Connections pa Analog Amplifier B GND 2 10v Command input 1 GND Me AMP 1 DB9 S Option A required Diagram 3 Sample Connection Diagrams 35 Integrator User Manual Sample Diagram for Connecting UMAC INPUT OUTPUT ACC 65 E TB1 or TB2 Bottom for Outputs Sinking Outputs TB3 Bottom 24V Supply Sourcing Outputs oye TB3 Bottom AGND aono v AGND 24V Supply
33. ion time is used instead This results in a speed less than what was programmed The lookahead function can further slow these moves but it cannot speed them up Acceleration Limits Variable Ixx17 for each Motor xx defines the magnitude of the maximum acceleration permitted for the motor These variables are defined in the raw PMAC units of counts per millisecond squared so a quick conversion must be calculated from the user units e g in sec or g s If the algorithm while looking ahead in the programmed trajectory determines that any motor in the coordinate system is being asked to violate its acceleration limit it will slow down the trajectory at that point just enough so that no limit is violated It will then work backwards through the buffered trajectory segments to create a controlled deceleration along the path to this limited speed in the minimum time that does not violate any motor s Ixx17 acceleration constraint Calculating the Segmentation Time Turbo PMAC s lookahead function operates on intermediate motion segments calculated from the programmed trajectory An intermediate point for each motor is computed once per segment from the programmed path and then a fine interpolation using a cubic spline to join these segments is executed at 4 Turbo PMAC Lookahead Function NC Integrator User Manual the servo update rate The user settable segmentation time is therefore an important parameter for optimization of the
34. le has been skipped Typically while this is the result of sloppy programming an outside corner with a full circle causes an overcut into the circle many machine designers may want to permit slight cases of this Coordinate system parameter Isx97 defines the shortest arc angle that may be executed the longest arc angle is 360 plus this angle Cutter Compensation 15 Integrator User Manual The default value of Isx97 sets a minimum arc angle of one millionth of a semi circle enough to account for numerical round off but sometimes not enough for compensated full circles To handle these cases Isx97 should be set to a somewhat larger value Failure When Compensation Extends Full Circle Tool Center Path Compensated Circle Skipped Programmed 2 Full Circle Speed of Compensated Moves Tool center speed for the compensated path remains the same as that programmed by the F parameter On an arc move this means that the tool edge speed the part of the tool in contact with the part will be different from that programmed by the fraction Rtgoj Rare Changes in Compensation Radius Magnitude Changes Changes in the magnitude of compensation new CCR values made while compensation is active are introduced linearly over the next move When this change is introduced over the course of a LINEAR mode move the compensated tool path will be at a diagonal to the programmed move path When this change is i
35. llow the machine builder to program specific functionality for the parts counter The bit CS PARTS COUNT in CS COMMAND6 M allows the parts count and parts total field on the parts counter screen to increment by 1 The bit CS PARTS RESET in CS COMMAND M allows the parts count to be reset to 0 In addition the bit CS PARTS RESET in CS STATUS6 M indicates the parts count has reached the parts required Example M2 M30 code inside the file MILL M N2000 N30000 Cause parts counter PLC to do its work PARTS COUNT 1 RETURN How to Make a Custom Tool Offset Page 23 Integrator User Manual Example Parts counter PLC OPEN PLC 12 CLEAR IF PARTS_COUNT 1 Cause Parts count and parts total to increment SET_ON CS_COMMAND 6_M CS_PARTS_COUNT Wait for increment command to complete WHILE ON CS_COMMAND6_M CS_PARTS_COUNT ENDW Check to see if the parts count has reached the parts required IF ON CS_STATUS6_M CS_PARTS_RESET TO DO User may want to have special action at this location Such as set an output to a BEACON to indicate that the programmed required parts have been reached Reset Parts count Q8SET ON CS STATUS6 M CS PARTS RESET ENDIF PARTS COUNT 0 CS COMMAND6 M CS PARTS COUNT Setting this bit in PLC causes the parts count and parts total to increment by 1 This bit is cleared automatica
36. lly once PMAC NC 32 has incremented the parts total and parts count CS STATUS6 M CS PARTS COUNT This is set by PMAC NC 32 while incrementing the parts total and parts count This bit is cleared once PMAC NC 32 has incremented the parts total and parts count CS COMMAND6 M CS PARTS RESET Setting this bit in PLC causes the parts count to reset to 0 Once the parts count has reset to 0 the CS PARTS RESET bit in CS STATUS6 Mis cleared CS STATUS6 M CS PARTS RESET This is set by PMAC NC 32 when the parts count reaches the parts required set previously on the settings page 24 How to Make a Custom Tool Offset Page NC Integrator User Manual HOW TO ADD AND DISPLAY USER MESSAGES There are four different types of user messages possible Fatal Error Error Warning and Message box These messages are displayed in NC with different colors indicating different actions The user messages are written in the ERRORS DAT file Fatal Errors are displayed as INDY and can be edited under the FATAL section in ERRORS DAT file Errors are displayed as JNjst0538 and can be edited under the STOP section in ERRORS DAT file Warnings are displayed as WARNING and can be edited under the WARNING section in ERRORS DAT file Messages are displayed as WISSE and can be edited under the MESSAGE section in ERRORS DAT file To set or reset these messages set the bit of one of the pre defined M variable macros These are found in C
37. lookahead function Variable Isx13 for each Coordinate System x defines the time for each intermediate segment in the programmed trajectory in milliseconds before it is possibly extended by the lookahead function Isx13 is an integer value if a non integer value is sent Turbo PMAC will round to the next integer If Isx13 is set to 0 the coordinate system is not in segmentation mode no intermediate segments are calculated and the lookahead function cannot be enabled Several issues must be addressed in setting the Isx13 segmentation time These include its relationship to the maximum block rate the small interpolation errors it introduces and its effect on the calculation load of the Turbo PMAC Each of these is addressed in the following sections Block Rate Relationship In most applications the Isx13 segmentation time will be set so that it is less than or equal to the minimum block programmed move time Put another way the segmentation rate defined by Isx13 is usually set greater than or equal to the maximum block rate For example if a maximum block rate of 500 blocks per second is desired the minimum block time is 2 milliseconds and Isx13 is set to a value no greater than 2 This relationship holds because blocks of a smaller time than the segmentation time are skipped over as Turbo PMAC looks for the next segment point While this does not cause any errors there is no real point in putting these programmed points in the mo
38. med Path Programmed Path f V i Tool Center Path y i v Arc to Line Arc to Arc Treatment of Outside Corners For outside corners Turbo PMAC will either blend the incoming and outgoing moves directly together or it will add an arc move to cover the additional distance around the corner Which option it chooses is dependent on the relative angle of the two moves and the value of I variable Isx99 The relative angle between the two moves is expressed as the change in directed angle of the motion vector in the plane of compensation If the two moves are in exactly the same direction the change in directed angle is 0 if there is a right angle corner the change is 90 if there is a complete reversal the change in directed angle is 180 Isx99 specifies the boundary angle between directly blended outside corners and added arc outside corners It is expressed as the cosine of the change in the directed angle of motion cos0 1 0 cos90 0 0 cos180 1 0 at the boundary of the programmed moves The change in directed angle is equal to 180 minus the included angle at the corner Cutter Compensation 13 Integrator User Manual Sharp Outside Corner If the cosine of the change in directed angle is less than Isx99 which means the corner is sharper than the specified angle then an arc move will be added around the outside of the corner Outside Corner Cutter Compensation Sharp Angle cos 0 lt Isx99
39. move time Turbo PMAC must be in move segmentation mode Isx13 gt 0 to do this compensation Isx13 gt 0 is required for CIRCLE mode anyway Note In CIRCLE mode a move specification without any center specification results in a linear move This move is executed correctly without cutter radius compensation active but if the compensation is active it will not be applied properly in this case A linear move must be executed in LINEAR mode for proper cutter radius compensation Defining the Plane of Compensation Several parameters must be specified for the compensation First the plane in which the compensation is to be performed must be set using the buffered motion program NORMAL command Any plane in XYZ space may be specified This is done by specifying a vector normal to that plane with I J and K components parallel to the X Y and Z axes respectively For example NORMAL K 1 by describing a vector parallel to the Z axis in the negative direction specifies the XY plane with the normal right left sense of the compensation NORMAL K1 would also use the XY plane but invert the right left sense This same command also specifies the plane for circular interpolation NORMAL K 1 is the default The compensation plane should not be changed while compensation is active Other common settings are NORMAL J 1 which specifies the ZX plane for compensation and NORMAL I 1 which specifies the YZ plane These three settings of the
40. nd Tool Offsets from PMAC 31 Integrator User Manual Reading a Tool Offset 1 To read a tool offset type the following PR COMMAND M 2D0000 8 2 Set bits 0 and 1 to trigger PMAC to read the data placed in data location PR BITS M PR BITS M 1 PR DATA M should now contain the Z axis tool geometry offset 3 Type the following in PEWIN32 M161 2D0000 8 M160 M160 1 M162 PMAC will respond with the Z axis tool geometry offset for tool number 9 Implementation Issues in PLC and Motion Program Code When performing these functions in PLC or a motion program code the programmer should check to make sure that PR BITS M bit 0 is cleared before relying on the data in PR DATA M to insure that PMAC NC has successfully completed the transaction For example To set tool offset 8 and 9 consecutively enter the following PR DATA M 10 0 PR COMMAND M 2D0000 8 PR BITS M PR BITS M 3 WHILE PR BITS M amp 1 0 wait for PC to finish ENDWHILE PR DATA M 11 0 PR COMMAND M 2D0000 4 9 PR BITS M PR BITS M 3 WHILE PR BITS M amp 1 0 wait for PC to finish ENDWHILE Production software would of course have a timeout in the while statement and create an error message if the 0 Bit of PR BITS M was not cleared 32 Modifying Work and Tool Offsets from PMAC NC Integrator User Manual SAMPLE CONNECTION DIAGRAMS ADV 810 Basic Connection Amplifier Connection
41. normal vector correspond to RS 274 G codes G17 G18 and G19 respectively If implementing G codes in Turbo PMAC program 1000 incorporate them in PROG 1000 N17000 NORMAL K 1 RETURN N18000 NORMAL J 1 RETURN N19000 NORMAL I 1 RETURN Defining the Magnitude of Compensation The magnitude of the compensation the cutter radius must be set using the buffered motion program command CCR data Cutter Compensation Radius This command can take either a constant argument e g CCRO 125 or an expression in parentheses e g CCR P10 0 0625 The units of the argument are the user units of the X Y and Z axes In RS 274 style programs these commands are often incorporated into tool data D codes using Turbo PMAC motion program 1003 Cutter Compensation 9 Integrator User Manual Negative and zero values for cutter radius are possible Note that the behavior in changing between a positive and negative magnitude is different from changing the direction of compensation See the Changes in Compensation section of this manual In addition the behavior in changing between a non zero magnitude and a zero magnitude is different from turning the compensation on and off See the appropriate sections of this manual Turning on Compensation The compensation is turned on by buffered motion program command CC1 offset left or CC2 offset right These are equivalent to the RS 274 G Codes G41 and G42 respectively If implementing G Code subr
42. nt of Full Reversal If the change in directed angle at the boundary between two successive compensated moves is 180 1 the included angle is less than 1 this is considered a full reversal and special rules apply If both the incoming and outgoing moves are lines the corner is always considered an outside corner and an arc move of approximately 180 is added If one or both of the moves is an arc Turbo PMAC will check for possible inside intersection of the compensated moves If such an intersection is found the corner will be treated as an inside corner Otherwise it will be treated as an outside corner with an added 180 arc move Reversal In Cutter Compensation lt n Line N x Dus rammed Path arcY e o Ling lt H Arc d M o joie P Tool Center Arc ATA Tool Center Center Pai gt Path Right Path Left Line to Line Line to Arc Inside and Outside Tool Center 3 Path Arc Programmed Path ACS Tool Center At Path gt Arc to Arc Outside Arc to Arc Inside Note on Full Circles If a full circle move is executed while in cutter compensation and one or both of the ends produces a shallow outside corner that is directly blended no added arc see the previous section Treatment of Outside Corners the compensated arc move will be extended beyond 360 and Turbo PMAC may produce just a very short arc 360 shorter than what is desired making it appear that the circ
43. ntroduced over the course of a CIRCLE mode move the compensated tool path will be a spiral Compensation Direction Changes Changes in the direction of compensation between CC1 and CC2 made while compensation are generally introduced at the boundary between the two moves However if there is no intersection between the two compensated move paths the change is introduced linearly over the next move 16 Cutter Compensation NC Integrator User Manual Cutter Compensation Change of Direction CC1 N Line cc2 Line Programmed H P Path Tool Center Tool Center P4 Path Path m E Line i Line to Line Line to Arc Are Pro x grammed E CC1 S C62 Pah cee gt Arc V H Programmed i Path lt t CC2 Line TS n aN Tool Center Tool Center Path Path M ELI oco Y CC1 Arc to Line Arc to Arc Cutter Compensation Change of Direction No Intersection Programmed Tool Center Path ne gt Change Through a Line Change Through an Arc Tool Center Path Cc2 Programmed Path CC1 CC1 Programmed Line Path Change Through a Line Change in Reversal Cutter Compensation 17 Integrator User Manual How Turbo PMAC Removes Compensation Turbo PMAC gradually removes compensation over the next LINEAR or CIRCLE mode move following the CCO command that turns off compensation This lead out move starts at a point one cutter radius away from the intersection of the le
44. nts msec for each motor in the coordinate system Set Isx13 segmentation time in msec for the coordinate system to minimum programmed move block time or 10 msec whichever is less Compute maximum stopping time for each motor as Ixx16 Ixx17 Select motor with longest stopping time Compute number of segments needed to look ahead as this stopping time divided by 2 Isx13 Multiply the segments needed by 4 3 round up if necessary and set the Isx20 lookahead length parameter to this value If the application involves high block rates set the Isx87 default acceleration time to the minimum block time in msec set the Isx88 default S curve time to 0 If the application does not involve high block rates set the Isx87 default acceleration time and the Isx88 default S curve time parameters to values that give the desired blending corner size and shape at the programmed speeds Store these parameters to non volatile memory with the SAVE command to make them an automatic part of the machine state After each power up reset send the card a DEFINE LOOKAHEAD 4 of segments H4 of outputs command for the coordinate system where of segments is equal to Isx20 plus any segments for which backup capability is desired and of outputs is at least equal to the number of synchronous M variable assignments that may need to be buffered over the lookahead length Load the motion program into the Turbo PMAC The motion program defines the path
45. nts or causing electrical shorts When our products are used in an industrial environment install them into an industrial electrical cabinet or industrial PC to protect them from excessive or corrosive moisture abnormal ambient temperatures and conductive materials If Delta Tau Data Systems Inc products are directly exposed to hazardous or conductive materials and or environments we cannot guarantee their operation NC Integrator User Manual Table of Contents INTEGRATOR GUIDELINES csssscsscssssscescssseecessncssssnssccsssssescsssnessssncsscssssossessessosssssnsssssnessessssossnsssssseseoses 1 TURBO PMAC LOOKAHEAD FUNCTION sessesosssessesosososseseseososososoesosoosososossesessocesosocoesesososoosessosesssoesoseesosssossoss 1 AERO GUC TOM E 1 Quick Instructions Setting Up LEookahead 2 2 5 1 teosesse eee re Have obe Ope Sp biked noes EEE A Sa 2 Detailed Instructions Setting up Lookahead sess nennen nennen enne nne 3 Defining the Coordinate System 5 eter Data pice eepebel Poe euet cheque trant one bab dnt are iienaa aa saae prep eua Dun 3 Hr e TESTED TAE 3 Positiot Pip e HR 3 Velocity TUMUS T E tes 4 HT mobi s TE tye 4 Calculating the Segmentation Time eese eee enne eene aei trennen trennen eren ren eene EEES 4 Dore SSOITAT AIITEM 5 Calculatton ImplicattOR
46. of the previous move with a run time error setting the internal run time error code in register Y 002x14 to 7 20 Cutter Compensation NC Integrator User Manual HOW TO MAKE A CUSTOM TOOL OFFSET PAGE The default tool page comes with Z Geom Z Wear CC Wear CC Geom etc More columns can be added for other axes in this tool page by changing registry settings Use the registry editor to go to the Tool Offset Key See Screen 1 a Registry Editor Registry Edit View Favorites Help E gp TEA E Eg Eater a aiora C Filo Henagar 5 T E Persmerers zila My ComputerXHKEY CURRENT USER Software Delta Tau NCUI 32XTool offsets E Screen 1 Tool Offset Key There are two keys toolOffset and toolOfsAxisType In the figure Z represents the axis name and R represents the radius The number of characters digits must be same in these two keys Currently there are four characters digit in these keys Up to seven types can be assigned to the axis The table below shows the settings possible ToolOfsAxis letters and associated function ToolOfsAxisType Function ToolOfsAxis 0 Geometry XYZ 1 Wear X Y Z 2 Length L 3 Orientation X Y Z 4 Cutter R Compensation 5 Pocket P 7 Cutter Comp wear R To add Geom for X axis change the registry to toolOfsAxis ZZRRX toolOfsAxisType 01470 The modified registry will look like G Registry Edito
47. ough the pre computed buffered trajectories slowing down the parts of these trajectories necessary to keep the moves within limits The calculations are completed before these sections of the trajectory are actually executed Turbo PMAC can perform these lookahead calculations on LINEAR and CIRCLE mode moves The coordinate system must be put in segmentation mode Isx13 gt 0 to enable lookahead calculations even if only LINEAR mode moves are used The coordinate system must be in segmentation mode anyway to execute CIRCLE mode moves or cutter radius compensation In segmentation mode Turbo PMAC splits the moves into small segments automatically which are executed as a series of smooth splines to re create the programmed moves Turbo PMAC stores data on these segments in a specially defined lookahead buffer for the coordinate system Each segment takes Isx13 milliseconds when it is put into the buffer but this time can be extended if it or some other segment in the buffer violates a velocity or acceleration limit This technique permits Turbo PMAC to create deceleration slopes in the middle of programmed moves at the boundaries of programmed move or over multiple programmed moves whichever is required to create the fastest possible move that does not violate constraints All of this is done automatically and invisibly inside the Turbo PMAC the programmer and operator do not need to understand the workings of the algorithm If Turbo PMAC
48. outines in Turbo PMAC motion program 1000 simply incorporate them in PROG 1000 N41000 CC1 RETURN N42000 CC2 RETURN Turning off Compensation The compensation is turned off by buffered motion program command CCO which is equivalent to the RS 274 G Code G40 If implementing G Code subroutines in Turbo PMAC motion program 1000 incorporate them in PROG 1000 N40000 CCO RETURN How Turbo PMAC Introduces Compensation Turbo PMAC gradually introduces compensation over the next LINEAR or CIRCLE mode move following the CC1 or CC2 command that turns on compensation This lead in move ends at a point one cutter radius away from the intersection of the lead in move and the first fully compensated move with the line from the programmed point to this compensated endpoint being perpendicular to the path of the first fully compensated move at the intersection Note A few controllers can make their lead in move a CIRCLE mode move This capability permits establishing contact with the cutting surface very gently important for fine finishing cuts 10 Cutter Compensation NC Integrator User Manual Inside Corner Introduction If the lead in move and the first fully compensated move form an inside corner the lead in move goes directly to this point When the lead in move is a LINEAR mode move the compensated tool path will be at a diagonal to the programmed move path When the lead in move is a CIRCLE mode move the compensated tool p
49. point to this compensated point being perpendicular to the path of the fully compensated move at the intersection Turbo PMAC then adds a circular arc move with radius equal to the cutter radius ending at a point one cutter radius away from the same with the line from the programmed point to this compensated endpoint being perpendicular to the path of the lead out move at the intersection 18 Cutter Compensation NC Integrator User Manual Finally Turbo PMAC gradually removes compensation over the lead out move itself ending at the programmed endpoint of the lead out move When the lead out move is a LINEAR mode move this compensated tool path will be at a diagonal to the programmed move path When the lead in move is a CIRCLE mode move this compensated tool path will be a spiral Removing Compensation Outside Corner Line Programmed Ate Path ae Tool Center Path E Tool Center RAPI i NONE Line M Line to Line i D i I 3 I i 1 rd N Line la 7 Spiral s Programmed gor sare Path Tool Center s Path Tool Center Arc to Line Arc to Arc Note This behavior is different from changing the magnitude of the compensation radius to zero while leaving compensation active An arc move is always added at the corner regardless of the setting of Isx99 This ensures that the lead out move will never cut into the last fully compensated move Failures in Cutter Compensation It is possi
50. r Help 3 ay NOU ae 2 Name Typa 53 Eonar a a FEG Sz EZRRX ca Fila Meresgor ab iscl fs e Typen BE 3z 01470 i 53 Per Biimlerz zs My ComputerXHKEY CURRENT USER Software Delta Tau NCUI 32XTool Offsets Screen 2 Setting Tool Offset How to Make a Custom Tool Offset Page 21 Integrator User Manual The modified tool page will look like i m Tool Geste TUD Z Gom Z Wear CC Gasm CC Waar X Geom 1m 0600 mom oowoo 00000 06000 aggin GO mma Oce600 a r 4 ARARA 16 9000 16 9000 IL NEUE oc gowo OD0ODO0 DOO Dowo 200 i 0000 000i n 0000 X 00000 00000 OO DOO ani va LLL vv LE tcx 000 ouw 00m0 oco 3 1000 3 AAA 3 1000 aes D o000 0 0000 1 m m 00000 3 1000 Wy 06000 00000 O 6 ooo gaggi e oo0n C0000 Dowo aco 2 0000 0 0000 Lt DOO 0000 06000 6 0000 j 00009 86 6000 16 9000 0 0000 1 O00 c oowoo oowoo nox n0xeo ooo im We eh En j f A ARAR A AARAA AAAA P 20000 o co 0 0000 Dowo O0O0ODU 0000 0 0000 0 0000 o ooo cooo ooms nowe aoon AAA f AARAA 0 0000 0 0000 0 000 C0000 i QU V V l Y Y UU Block Heii Screen 3 Modified Tool Page How to Set Parts Counter Parts Total This value is incremented by 1 when a M02 M30 or M code specified by the machine tool builder is executed Usually this value represents how many parts have been made by the machine since its last rebuild This value cannot be set on the screen but is set through the following registry entry
51. rator User Manual IF INPUT AIR 0 QGSET ON ES ERR STOP2 M ERROR AIR ELSE GSET OFF ES ERR STOP2 M ERROR AIR ENDIF Clearing Messages To clear just this message type QsET OFF ES ERR STOP2 M ERROR AIR To clear all messages at once type ES ERR STOP2 M 0 Use this as an example and display other messages Message Box With the Delta Tau NC POP UP Windows can be added using message box type messages through a PLC The PLC can then take action based on the response There are two types of message boxes available e Message Box with OK button Messages ranging from 1 64 are reserved for this type e Message Box with YES and NO buttons Messages ranging from 65 128 are reserved for this type A message box is displayed from a PLC by setting variable ES PLCMSGBOX M The messages are stored in ERRORS DAT this file under the MessageBox section e The message box with an OK button will return 0 e The message box with a YES button will return 1 Check 65536 MSB word Bit 1 in PLC e The message box with a NO button will return 1 check 65536 Bit 1 MSB word Bit 1 in PLC Displaying Messages To display messages 1 Set ES_PLCMSGBOX_M 1 in PLC for MsgBox 0 2 Set ES PLCMSGBOX M 65 in PLC for MsgBox 64 To display the message box l Type either Yes or No when prompted at the Do you want to switch OFF the POWER prompt
52. s i e seiten erp db ee ute ees p b b tutu ied su vine aod ual ave uode 5 Calculating the Required Lookahead Length eee eee eese nennen tenente eene trennen enne 6 LEookahead Length Paranieter e tars tete E tee ER e tee Sup ondeekes a a esee ne bees opidiondean ens te 7 Defining the Lookaheud Buffer tette t titor ont be irent e epe es irte entend ap tense 7 CUTTER COMPENSATION S 9 Cutter Radius Compensation oen coe De e Debt tre toe D Ie de tenis eA he eee 9 Defining the Plane of Compensation eese sees nree then nest nr en rennen ren eene tne enne nnne 9 Defining the Magnitude of Compensation eese nennen nee trennen eren neret enne enne 9 Turning on COMPENSATION iater I eee iiianoe Oy Ha nea veu Eae udine Deua edu VR DU e ag PER RN eue eue ub Sue TEENS ENERO 10 Turning off Compensation M 10 How Turbo PMAC Introduces Compensation eeseeseseeeeeeeeeneenen eene nennen nennen enne nennen trennen ener enr enne 10 Inside Corner Introduction i e et ite eed egere Eo cbe etre tov bee peteeto vue riae ope beta De en 11 Outside Corner Introduction 2 unt dere t estem tene dese pe teet peto de usted tege dtu obese Ron 12 Treatment of Inside COTHEES ise o te t ua Eee Sep E Une e toes Mte tes tase ty teh eode stre E 13 Treatment Of Outside COTMOTS sci ec ies eee Sees aeu ehe dece Er beste pad E Saar E 13 SharpOulside COFREF 3a
53. t ener nennen nren enne eene nee 29 Telling PMAC NC What Offset to Read or Write eesesesseeeseeeeeeee eene ener enne innen eene reinen 29 Where PMAC NC Returns Data from a Read or Write of an Offset nennen 30 Setting A Work Offset XC 30 Aag HAGO 31 Reading TRIPS T M 3l Reading TOOL Off a 32 Implementation Issues in PLC and Motion Program Code eee nennen 32 SAMPLE CONNECTION DIAGRAMS eere cesses enses enses tuse tasse ta sens enses ense tasse ta sens enses enata sesso sees suse ts en aestus 33 ii Table of Contents NC Integrator User Manual INTEGRATOR GUIDELINES The Delta Tau NC is an open architecture controller with standard machine software G M T and PLC that can be modified and with available features that can be added The instructions discussed in this manual should be followed by an integrator who knows PMAC well Integrator Guidelines Integrator User Manual Integrator Guidelines NC Integrator User Manual TURBO PMAC LOOKAHEAD FUNCTION Introduction Turbo PMAC can perform highly sophisticated lookahead calculations on programmed trajectories to ensure that the trajectories do not violate specified maximum quantities for the axes involved in the moves This permits the writing of the motion program simply by describing the commanded path Vector fee
54. the coordinate system segmentation time StopTime m sec Ixx16 2 IsxI3 m sec s seg 2 Ixx17 Isx13 LookaheadLength segs This is the number of segments in the lookahead buffer that must be always properly computed ahead of time Because the Turbo PMAC does not recalculate fully the lookahead buffer every segment actually it must look further ahead than this number of required segments 6 Turbo PMAC Lookahead Function NC Integrator User Manual Lookahead Length Parameter Variable Isx20 for the coordinate system tells the algorithm how many segments ahead in the program to look This value is a function of the number of segments that must always be correct in the lookahead buffer SegmentsNeeded The formula is 4 Isx20 SegmentsNeeded 3 Setting Isx20 to a value larger than needed does not increase the computational load although it does increase the time of heaviest computational load while the buffer is filling However it does require more memory storage and it does increase the delay in having the program react to any external conditions Setting Isx20 to a value smaller than needed does not cause the limits to be violated However it may cause Turbo PMAC to limit speeds more severely than the Ixx16 limits require in order to ensure that acceleration limits are not violated In addition a saw tooth velocity profile may be observed Note Preliminary versions of the Turbo PMAC firmware h
55. tion of motors is controlled by Ixx15 not Ixx17 and deceleration is not necessarily along the programmed path Velocity Limits Variable Ixx16 for each Motor xx defines the magnitude of the maximum velocity permitted for the motor These variables are defined in the raw PMAC units of counts per millisecond so a quick conversion must be calculated from the user units e g millimeters per minute If the algorithm while looking ahead in the programmed trajectory determines that any motor in the coordinate system is being asked to violate its velocity limit it will slow down the trajectory at that point just enough so that no limit is violated It will then work backwards through the buffered trajectory segments to create a controlled deceleration along the path to this limited speed in the minimum time that does not violate any motor s Ixx17 acceleration constraint Note During the initial move block calculations before move data is sent to the lookahead function a couple of factors can result in commanded velocities lower than what is programmed First if the vector feedrate commanded in the motion program with the F command exceeds the maximum feedrate parameter Isx85 then Isx85 is used instead Second if the move block time either specified directly with the TM command or calculated as vector distance divided by vector feedrate is less than the programmed acceleration time the larger of TA or 2 TS the programmed accelerat
56. tion program if the controller is going to skip over them However some inherit old motion programs with points closer together than is actually required these users may have reason to set the segmentation time larger than the minimum block time Note The programmed acceleration time sets a limit on the maximum block rate The move time for a programmed block even before lookahead is not permitted to be less than the programmed acceleration time The programmed acceleration time is the larger of the TA time TA Isx87 by default and twice the TS time TS Isx88 by default In high block rate lookahead applications the TA time is typically set equal to the minimum desired block time and the TS time is typically set to because it squares up corners Calculation Implications While smaller Isx13 segmentation times permit higher real maximum block rates and permit more accurate interpolation they increase the Turbo PMAC computational requirements particularly when lookahead is active The following table shows the result of benchmarking tests on the Turbo PMAC and the minimum segmentation times that can be used for a given number of axes executing lookahead calculations Turbo PMAC Lookahead Function 5 Integrator User Manual Number Maximum Block Minimum Segmentation of Axes Rate blocks sec Time msec 2 2000 1 200 3 1000 1 4 500 2 5 500 2 6 500 2 8 333 3 12 250 4 16 200
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