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Programming Knee Mill - Southwestern Industries, Inc.

1. Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 7 0 Program Mode 7 1 7 2 Getting Started amp Some General Information Programming Overview The ProtoTRAK SMX CNC makes programming easy by allowing you to program the actual part geometry as defined by the print The basic strategy is to first fill in the initial program information in the Program Header screen and then program the features of the part by selecting the soft key event types geometry and then follow all instructions in the Data Input Line When an event is selected all the prompts that need to be input will be shown on the right side of the screen The first prompt will be highlighted and also shown in the Data Input Line Input the dimension or data requested and press INC SET or ABS SET For X or Y dimension data it is very important to properly select INC SET or ABS SET For all other data either SET will do As data is being entered it will show in the Data Input Line When SET the data will be transferred to the list of prompts in the right side of the screen and the next prompt will be shown in the Data Input Line When all data for an event has been entered the entire event will be shifted to the left side of the screen and the conversation line will ask you to select the next event Enter Program Mode Press MODE select PROGRAM soft key The ProtoTRAK SMX CNC
2. Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 12 6 Service Codes These are special codes that may be entered into the ProtoTRAK SMX CNC to call up routines used in installation setting of preferences machine checkout and service WARNING Before using service codes be aware that some of the routines are very powerful and may change system settings in a way you don t want Some of the routines cause the servos to come on and move at rapid speed The Service Codes are divided into logical categories The table below summarizes the more important ones See the service manual for more information on using Service Codes Software Code Description Comment 33 Software and firmware version Displays current software versions and system settings 141 Load configuration file from Floppy A To load set up files from a disk in the floppy drive 142 Save configuration file to Floppy A To save the set up files for reloading later When a computer replacement is necessary saving the settings to a disk for reloading them later may be desirable 313 Display configuration file Displays certain values set through other service codes or machine parameters 316 Update Master Software Runs the routine that copies new master software from a disk to the ProtoTRAK system Use this routine to install new ProtoTRAK software T
3. Selectable two or three axis CNC three axis CNC models Color graphics with adjustable views Inch mm selectable Convenient modes of operation DRO Mode Features for Manual Machining Incremental and absolute dimensions Jog at rapid with override Powerfeed X Y or Z for three axis CNC models Do One CNC canned cycle Teach in of manual moves Servo return to 0 absolute Tool offsets from library Z Go To three axis CNC models only Program Mode Features Geometry based programming Incremental and absolute dimensions Automatic diameter cutter comp Circular interpolation Linear interpolation Look graphics with a single button push List step graphics with programmed events displayed Alphanumeric program names Program data editing Canned cycles o Position 8 Southwestern Industries Inc TRAK SX Knee Mill amp Proto TRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Drill Bolt Hole Mill Arc Circle pocket Rectangular pocket Circular profile Rectangular profile Program pause Conrad automatic corner radius Math helps with graphical interface Auto load of math solutions Tool step over adjustable for pocket routines Pocket bottom finish pass three axis CNC models Selectable ramp or plunge cutter entry three axis CNC models Subroutine repeat of programmed events Nesting Rotate about Z axis for skewing data three axis CNC models Edit Mode Features Delete e
4. That way if a floppy disk or hard drive becomes unusable you will not have to re write the program To back up your files press the BACK UP softkey from the Program In Out Mode screen E 0807 2 PT4 E SWI 2615 PT4 Fi F2 F3 Fa F5 F FF Fs DATA DATA OPEN BACKUP BACKUP TAB Ewa BACK FOLDER FROM fo PetURN FIGURE 14 8 Backing up The top part of the screen shows all the items in Drive A The bottom part shows the items that have been picked for backing up The basic procedure for backing up is 1 Use the navigation procedure described in Section 14 2 above and highlight the program file or folder you wish to back up 2 Press the BACKUP FROM softkey You will see the item appear along with its directory path in the new listing area under the main listing area Repeat the above for as many items as you wish Use the navigation procedure to select a different drive or a different folder oe w Open the drive or folder using the Open folder key 6 Press BACKUP TO When the back up operation is completed you will see the items and their directories in the new location 132 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Note It is good practice to back up files to a different drive rather than to a different folder on the same drive For example if you keep your programs on the ProtoTRAK SMX C
5. 0 0000 7 0 7 0 17 MILL 3 0 1875 10 0 0 0000 inc 0 0000 26 mut 2 0 3750 10 0 0 0000 inc 0 0000 mut 2 0 3750 7 0 10 0 0 0000 inc 0 0000 2s m 2 3750 7 0 10 0 0 0000 inc 0 0000 j 2 ZFEEDRATE M Fi F4 F5 F FF FS PAGE CHANGE ALL FIGURE 11 2 5 Type the new Z Feed and then SET to change all the highlighted values from 5 to 7 11 3 Erase Program Use the ERASE PROG soft key to erase the program from the current memory Erasing the program from current memory will not affect any programs that are stored If you have made changes to the program and wish to save this modified program you will need to store it See Section 14 4 11 4 Clipboard Advanced Features Option The Clipboard feature is a way to copy events in one program in order to put them into a different program It is a two part process that takes place in two different Modes First in the Edit Mode the desired events are copied or placed on the Clipboard from the source program Then the events are inserted into the destination program in the Program Mode When you press the Clipboard key from the Edit Mode you start the process that copies the events that you want to put into a different program than the one in current memory Before you do that you should write a program or open the program file that has the events you want to copy This is called the source program Inspect the events you
6. ADJUST VIEW gives additional options for adjusting the view of the drawing See below FIT DRAW automatically resizes the drawing to fit the entire part program on the screen 55 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual LIST STEP displays the list of events on the left side of the screen and with a purple highlight on the first event As LIST STEP is pushed the highlight shifts to the next event As this happens that event is also highlighted in the graphics by having its color change to purple START EVENT NUMBER will prompt you to enter an event number for highlighting This is useful for moving quickly to a particular event in a large program XY displays a view in the XY plane YZ displays a view in the YZ plane XZ displays a view in the XZ plane 3D displays an isometric view Softkeys in Adjust view FIT DRAW automatically resizes the drawing to fit the entire part program on the screen v shifts drawing down shifts drawing up 4 shifts drawing to the left gt shifts drawing to the right ZOOM IN makes the drawing larger ZOOM OUT makes the drawing smaller RETURN returns you to the first LOOK screen The adjustments you made will stay on the screen until you press another selection that overrides those adjustments The LIST STEP function may be used with the adjustment unaltered Note The LOOK rou
7. Enter Program Mode Program Header Screen 7 3 1 Program Name 7 3 2 General Program Options 7 3 3 Program Header Softkeys Auxiliary AUX Functions Multiple Fixtures 7 5 1 The Default Fixture 7 5 2 Fixtures amp Running the Program 7 5 3 Editing Fixtures Assumed Inputs Z Rapid Positioning Softkeys within Events Programming Events Editing Data While Programming LOOK Finish Cuts Two vs Three Axis Programming for Three Axis CNC Models Two Axis Program Events 58 POSN Drill BOLT HOLE Events MILL Events ARC Events POCKET Event 8 5 1 Circular Pocket 8 5 2 Rectangular Pocket 8 5 3 Irregular Pocket 8 5 4 Tool Path in Pocket Events 8 5 5 Conrad in Pocket Events 8 5 6 Face Mill Islands 8 6 1 Circular Island 8 6 2 Rectangular Island 8 6 3 Irregular Island Profile Events 8 7 1 Circle Profile 8 7 2 Rectangular Profile 8 7 3 Irregular Profile Engrave Event Subroutine Events 8 9 1 Repeat 8 9 2 Mirror 8 9 3 Rotate COPY Events Finishing Teach Events Three Axis Program Events 71 POSN Position Events DRILL Events BOLT HOLE Events MILL Events ARC Events POCKET Event 9 6 1 Circular Pocket 9 6 2 Rectangular Pocket 9 7 9 8 9 11 9 12 9 13 9 14 10 1 10 2 10 3 10 4 10 5 10 6 10 7 10 8 10 9 10 10 10 11 11 0 11 1 11 2 11 3 11 5 12 0 12 1 9 6 3 Irregular Pocket 9 6 4 Tool Path in Pocket Events 9 6 5 Zigzag Z Depth Cuts 9 6 6 Conrad in Pocket Events 9 6 7 Bo
8. For this reason Z and X Y motion will not occur simultaneously First the Z head will move to the higher of the Z rapid position of the current and next event then the X table and Y saddle will move at to the programmed position To program a Position event press the POSN soft key Prompts for the Position event X END is the X dimension to the position Y END is the Y dimension to the position Z Rapid is the Z dimension to the position RPM is the spindle RPM for the event INC SET will use the RPM of the previous event RPM programming is available only if the Programmable Electronic Head Option is active Tool is the tool number you assign SET will use the tool number of the previous event DRILL Events This event positions the table to the specified X and Y position moves the HEAD at rapid to the Z RAPID location feeds the quill to the Z END location and rapids back to Z RAPID for drill and feeds back for bore Press the DRILL soft key Prompts for the drill event Drill 1 Bore 2 selects whether the hole is to be drilled or bored X is the X dimension to the hole Y is the Y dimension to the hole Z Rapid is the Z dimension to transition from rapid to feed Z End is the bottom of the hole PECKS is the number of tool withdrawal cycles Each cycle drills and then retracts to the Z rapid position The factory setting is for each peck to be successively smaller taking the largest cuts at the beginning
9. If you turn on the limits and leave them at the default of 0 Absolute the program will not run 12 4 Fixture Offsets Advanced Features Option Fixture offsets are entered in the Set Up Mode From the screen in Figure 12 0 press the Fix Offset key The following screen will result SET UP 3 AXIS INCH FIXTURE XOFFSET YOFFSET ZOFFSET 1 BASE BASE BASE 2 8 1230 0 1160 0 0000 3 0 0000 0 0000 4 0 0000 0 0000 0 0000 5 0 0000 0 0000 0 0000 6 0 0000 0 0000 0 0000 X 0 0000 ABS Y 0 0000 ABS Z 0 0000 ABS X OFFSET FROM FIXTURE 1 TO 3 NN F2 F3 F4 F5 F F7 Fa Fi DATA DATA DATA DATA ERASE DOWN UP LEFT RIGHT TABLE JOG RETURN Figure 12 4 The Fixture Offset screen 115 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Setting up fixtures is easy First establish your base by setting your X Y and Z absolute zero You can do this in the DRO Mode but the X Y and Z Absolute position dimensions are also on this screen for your reference Fixture 1 is always the base Once you set your absolute zero on the base it is simple a matter of entering the distance from the base to up to five other fixture locations You can do this one of two ways By entering the numbers with the keypad or by positioning to the next fixture putting the cursor on the correct offset value and then pressing ABS SET 12 5 Verify Part Adva
10. Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual SIMULATION OFF SPEED 1 The status line shows whether simulation is on or off the speed of the verification the status of STOP or GO and the tool number for the tool that is being simulated The first 5 softkeys are used to adjust the part view and can be pressed before the simulation or during the simulation when the tool is cutting the part If you are using a mouse you may left click and hold to rotate the stock as it is being cut or once the part is finished The right button on the mouse can be used to pan the part on the screen and pressing the middle button or scroll wheel can be used to zoom in and out on the part Press VERIFY PART to launch the solid graphic part verification routine as shown below Before or during the verification press the feed up and down button use the U or D button when on offline software to speed up or slow down the machining representation There are 24 different speeds to choose from The default speed will work fine for most parts If the tool moves too fast press the down feedrate override button one or more times and then press VERIFY PART again You can adjust the speed on the fly as well If you press the feed down button 4 times it will go into single step mode where you can move the tool one move at a time through the verification Press the GO button each time to move through e
11. KEYBOARD FAN FLOPPY DRIVE USB PORTS BEEPER m ESTOP RSG 1 AMP FUSE 8 AMP FUSE AC ON OFF Ser 17 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Pendant Right Side with USB Ports Keyboard P S2 port This port is for the keyboard only If this port is used the connection must be made before the ProtoTRAK is turned on If the ProtoTRAK is already on it will not recognize the keyboard until it is rebooted with the keyboard plugged in You may also plug the keyboard into one of the USB ports USB Ports The USB ports are the only ports available for plugging in a mouse They may also be used for a keyboard or for plugging in the USB Thumb Drive flash memory Items used by USB ports will be recognized even if they are plugged in after the ProtoTRAK is turned on If you need more than two USB ports we recommend that you install a USB hub If you use the USB Thumb Drive to store a G code gcd program file you must leave the Thumb Drive plugged into the USB port the entire time the program is in current memory If you unplug the thumb drive with the program still in current memory the ProtoTRAK will display an error message Drivers for most major brands of mouse and keyboard are already in the ProtoTRAK SMX Ifa mouse or keyboard is not recognized by the ProtoTRAK it means that the driver is not availa
12. Operating amp Care Manual The prompts for the rectangular pocket X1 is the X dimension to any corner Y1 is the Y dimension to the same corner as X1 X3 is the X dimension to the corner opposite X1 incremental is from X1 Y3 is the Y dimension to the same corner as X3 incremental is from Y1 Z Rapid is the Z dimension to transition from rapid to feed Z End is the Z dimension at the bottom of the pocket incremental is from the previous event Conrad is the value of the tangential radius in each corner Direction is the clockwise input 1 or counterclockwise input 2 direction for milling Passes is the number of cycles to machine to the final depth spaced equally from Z Rapid to Z End hint keep Z Rapid small Entry mode choose between a zigzag ramp and a plunge The plunge will machine straight down Z to the appropriate Z depth The zigzag ramp will move in a zigzag pattern to depth See Section 9 6 5 for more information about the zigzag ramp Fin Cut is the width of the finish cut If 0 is input there will be no finish cut See Section 9 6 7 for a bottom finish cut RPM is the spindle RPM for the event INC SET will use the RPM of the previous event RPM programming is available only if the Programmable Electronic Head Option is active FIN RPM is the spindle RPM for the finish cut FIN RPM programming is available only if the Programmable Electronic Head Option is active Z Feedrate is the Z feedrate f
13. Programming Operating amp Care Manual 11 2 2 Sorting Data Data may be sorted by any of the data types displayed in the column head Red letters show which column is used for sorting the data To change the sort press the SORT softkey then select the type of data you want to use for sorting from the softkeys The table will be changed to sort the data in ascending order the smallest value first the largest last 11 2 3 Making Global Changes to Data Sometimes it is useful to be able to change data in a program without having to go through each event one at a time For example if you were to want to change the tool number for every milling event it may be a chore to go through each event in a long program to make the changes on that event type In order to make global changes 1 Sort the data in a way that groups together the things you want to change 2 Highlight the data value that is highest on the table nearest to the top that you want changed 3 Press the CHANGE ALL softkey All the inputs that are the same as the one you highlighted and are listed together below the data you highlighted will then be highlighted 4 Enter the new value then press set All the highlighted data will be changed to the value you just input Example The following example uses Z axis data for a three axis CNC model From the screen shown in Figure 11 2 1 we will change the Z Feed for each of the mill events in the program
14. Take off gloves before you start the machine Gloves are easily caught in moving parts Remove all tools wrenches check keys etc from the machine before you start Loose items can become dangerous flying projectiles Never operate a milling machine after consuming alcoholic beverages or taking strong medication or while using non prescription drugs Protect your hands Stop the machine spindle and ensure that the CNC control is in the stop mode e Before changing tools e Before changing parts e Before you clear away the chips oil or coolant Always use a chip scraper or brush e Before you make an adjustment to the part fixture coolant nozzle or take measurements e Before you open safeguards protective shields etc Never reach for the part tool or fixture around a safeguard Protect your eyes and the machine as well Don t use a compressed air hose to remove the chips or clean the machine oil coolant etc Stop and disconnect the machine before you change belts pulley gears Keep work area well lighted Ask for additional light if needed Do not lean on the machine while it is running Prevent slippage Keep the work area dry and clean Remove the chips oil coolant and obstacles of any kind around the machine 6 Southwestern Industries Inc TRAK SX Knee Mill amp Proto TRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 16 17 18 19 20 21 22 23 2
15. The idea of retaining tool information in memory in order to reduce the amount of set up needed requires that care be taken to avoid mistakes Milling work usually requires a lot of tools many of which are not preset into fixed tool holders That means tool information that is not very recent is probably no good Think of the information in the tool table this way if you clearly remember setting the tools and entering the diameters very recently then use the tool table in DRO and CNC run If you can t remember setting the tools clearly erase the table and start over it only takes a moment This may cause some confusion because the normal sequence for running a two axis program is to load in a tool touch it off and set zero then press GO The ProtoTRAK SMX CNC will apply the tool offset after the GO press making the Z dimension meaningless You have two choices 1 Use the tool table setting the reference and absolute dimension for one of them per the instructions above This will save you from having to touch off tools every time they are changed in program Run 2 Don t use the tool table Erase the entire tool data so that the ProtoTRAK SMX CNC will not try to apply offsets 12 1 3 Initial Tool Set Up This procedure is used for setting up tools when the tool table is clear 1 When you enter this screen for the first time the words NOT SET appear directly under the Z OFFSET column in the REF row The Data Input Line reads TO
16. is the spindle RPM for the finish cut FIN RPM programming is available only if the Programmable Electronic Head Option is active FIN CUT PCKT finish cut along the perimeter of the pocket If 0 is input there will be no finish cut See the previous section for a bottom finish cut Z FEEDRATE is the Z feedrate from Z rapid to Z end XYZ FEEDRATE the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 FIN FEEDRATE the finish milling feedrate for both the island and pocket finish cuts TOOL is the tool number you assign 9 7 3 Irregular Island Advanced Features Option Press the IRREG ISLAND key if you wish to mill an island other than a rectangle or circle The Irregular Island gives you the powerful Auto Geometry Engine to define a shape made up of straight lines and arcs The first screen in an Irregular Island event will define the beginning point and some of its general parameters The last event of the irregular pocket must end at the same point as defined in the first event Prompts for the Irregular Island event X BEGIN X dimension to the beginning of the island Y BEGIN Y dimension to the beginning of the island Z RAPID is the Z dimension of the transition from rapid to feed Z END is the Z dimension at the bottom of the pocket incremental is from the previous event PASSES the number of roughing passes to the depth ENTRY MODE choose between zigzag ramp and plunge The plunge will machine stra
17. keys and pressing INC SET or ABS SET If you enter an incorrect number before you press INC SET or ABS SET you may clear the number by pressing RSTR Restore Then input the correct number and press SET If incorrect data has been entered and SET you may correct it as long as you are still programming that same event Press the DATA BACK or DATAFWD Forward soft key until the incorrect prompt and data are highlighted and shown in the conversation line Enter the correct number and SET The ProtoTRAK SMX CNC will not allow you to skip past prompts by pressing DATA FWD which need to be entered to complete an event except when using the A G E in the Irregular Pocket or Irregular Profile event Previous events may be edited by pressing the BACK hard key to the left of the soft keys The previous event will be shifted from the left side of the screen to the right and may be edited The BACK key may be pressed all the way to the Program Header Screen the PAGE BACK softkey will work as well 7 11 LOOK As you program each event it is helpful to see your part drawn For quick graphics while in the Program Mode press the LOOK hard key This function is active at the end of each event or whenever the conversation line is prompting Select Event Press the LOOK key and the ProtoTRAK SMX CNC will draw the part Press LOOK again or BACK to bring back the Select Event screen You may also select a new view or adjust the view Softkeys in LOOK
18. or simply press SET to input no modifier 10 The highlight moves to Tool Type and a green window appears with your choices Input 1 to 9 corresponding to your choice and then SET This moves you to the Diameter input for your next tool 110 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 11 Repeat steps 5 to 8 for each of the tools you want to set up Remember to touch the same surface you used to set the reference tool Once the reference position is set you will not be able to move the highlight back to the word SET Note You must set an absolute zero reference in the DRO Mode before machining the part You may use any tool that you have set up with the above procedure to set your reference and the ProtoTRAK will automatically compensate for the difference in length for the rest of the tools 12 1 4 Starting Over Erasing Tool Information There will be times when you don t completely trust the information that is in the tool table For example perhaps you have loaded in a program that you wrote a month ago and you recall that one of the tools you used was held in a chuck In that case you probably want to erase the table and start over In order to do this simply press the ERASE TABLE softkey and answer yes to the prompt All the data in the tool table will be erased including the reference The numbers of the tools used in any program i
19. will be available for setting a Go To dimension 6 7 Teach Teach gives you the ability to enter X and Y dimensions into a program It can bea useful way of entering a few manual moves for operations like clearing out excess material or remembering a few hole locations The process of using Teach is in two parts The first part takes place in the DRO Mode This is where you start the Teach program establish the program events and enter the X and Y dimensions The second part is in the Program Mode This is where you complete the Teach events that you began in the DRO Mode by entering the rest of the data Once the data is entered the Teach events become just like the other events that make up a program 6 7 1 Entering Teach Data From the DRO screen press Teach On the top of the screen you will see the message Teach and an event counter When you enter Teach you are actually programming events If there is already a program in current memory Teaching will add events to the end of the program If there is not already a program in current memory Teaching will start a new program For example if you already had a program in current memory that had 10 events when you press Teach the event counter will say EVENT 11 If there was no program the event counter will say EVENT 1 The event counter shows the event for which data is being entered You may teach in position drill and mill events only 45 Southwestern Ind
20. 1 Sort by event type to get all the Mill events together 2 Highlight the Z Feed in the first Mill event Event 8 See Figure 11 2 3 3 Press the CHANGE ALL softkey All the Z Feeds in the Mill events are highlighted See Figure 11 2 4 4 Type in the new Z Feed value and press INC SET or ABS SET See Figure 11 2 5 103 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual In this example the Z feed is changed from 5 0 to 7 0 for all the Mill Events EDIT PIN RO424 11 3 AXIS INCH Z XYZ FIN EVT TYPE TOOL FEED FEED FEED Z RAPID CONRAD 14 BOLT HOLE 3 0 1875 5 0 0 1000 abs 25 BOLT HOLE 1 0 2500 5 0 0 1000 abs 36 BOLT HOLE 3 0 1875 5 0 0 1000 abs 4 m 2 0 3750 10 0 0 0000 inc 0 0000 s5 mut 20 3750 50 10 0 0 0000 ine 0 0000 e mut 20 3750 5 0 10 0 0 0000 ine 0 0000 as mut 3 1975 5 0 10 0 0 0000 inc 0 0000 as mut 3 1875 5 0 10 0 0 0000 inc 0 0000 az mut 3 1875 5 0 10 0 0 0000 ine 0 0000 2 mut 2 3750 5 0 10 0 0 0000 ine 0 0000 mut 2 03750 5 0 10 0 0 0000 inc 0 0000 2s m 20 3750 5 0 10 0 0 0000 inc 0 0000 j 2 ZFEEDRATE 80 FA F2 F3 F4 F5 F FF FS PAGE PAGE CHANGE y a 4 p SORT FWD BACK ALL FIGURE 11 2 3 After sorting by Event Type the highlighter is placed on the Z feed of the f
21. 1 if the first event DRILL OR BORE Drill PECKS FOR DRILL 1 peck CONRAD 0 You may change these assumed inputs by simply inputting the desired data when the event is programmed 52 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 7 7 7 8 Z Rapid Positioning Three Axis CNC Models Between any two events the head will always move to the higher of the Z rapid of the event just completed or the Z Rapid of the next event unless the two events are connective see Section 5 9 Remember when using part geometry programming two milling events are not connective unless they lie in the same plane Softkeys within Events Once a geometry Event such as Mill or Bolt Hole is selected the softkeys will change See Figure 7 8 Fi F2 F3 Fa F5 F FE F PAGE PAGE DATA DATA DATA INSERT DELETE FWD BACK FWD BACK BOTTOM EVENT EVENT FIGURE 7 8 Soft keys used while programming an event PAGE FWD moves forward through the programmed events PAGE BACK moves backwards through the programmed events DATA FWD moves forward through the event inputs Note use the DATA FWD key and not a SET key when you do not want to input a value DATA BACK moves backwards through the event inputs DATA BOTTOM puts the Highlight on the last input INSERT EVENT use this to insert a new event into the program This new event will take the p
22. 14 5 Copying Programs To copy a program file from one storage location to another press the COPY softkey from the Program In Out Mode screen Only one file may be copied at a time using this operation To copy multiple files or folders see Section 14 8 129 Southwestern Industries Inc TRAK SX Knee Mill amp Proto TRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual PROG O 3AXIS INCH COPY Lookin f CAptASwI TEST PROGRAMS ES ZREPEAT PT4 E BALLBAR PT4 E DPMV3 EXERCISE PT4 E DPMV5 EXERCISE PT4 E EUCLID PT4 E TAP ALUMINUM PT4 TAP STEEL PT4 E X REPEAT PT4 E Y REPEAT PT4 File Name Fi F2 F3 H DATA DATA OPEN COPY PASTE i FWD BACK EA FILE FILE Peru FIGURE 14 5 The Copy screen The copy operation is in two parts First use the navigation procedure described in Section 14 2 above and highlight the program you wish to copy Press the COPY FILE softkey to copy the file Then go to the new file or drive open it using the Open Folder softkey and press PASTE FILE Once the file has been copied it can be pasted to as many other locations as you want Additional softkeys in COPY COPY FILE Makes a copy of the highlighted file PASTE FILE Writes a copy of the file to the location shown in the Look In box RETURN Returns to the Program In Out Mode screen When the pasting operation is finished you will see the file name added to the listing area 14 6 Deleting
23. Administrators or experienced users To access these utilities press the SYS hardkey on the ProtoTRAK SX then press the Config Net softkey See Figure 14 12 5 above Change IP Address gives you access to the Internet Protocol Properties screen The default of the ProtoTRAK SX is to obtain addresses automatically from the DHCP server See Figure 14 12 7 147 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Internet Protocol TCP IP Properties MIP Address J Automatically obtain IP Address from a DHCP Server IP address Subnet mask Default gateway r DNS Server J Automatically obtain IP Address of DNS Server from DHCP Preferred DNS Server i Alternate DNS Server WINS Server IV Automatically obtain IP Address of WINS Server from DHCP Preferred WINS server i y Alternate WINS Server 5 7 i01135 Figure 14 12 7 TCP IP Properties Add User Password allows you to establish different users or passwords for the ProtoTRAK SX This is not recommended because it means that the ProtoTRAK SX will need to have a keyboard plugged in each time it is turned on This may not be desirable in a shop environment Share Drive Folder we used to allow sharing of the optional USB flash thumbdrive however as explained above this is no longer possible M
24. CNC and other TRAK CNC s Optional converters are purchased separately Standard converters and optional converters that are ordered and shipped with the machine are activated at the factory You can tell which converters are activated by looking in the Open As see Figure 14 9 3 or Save As windows see Figure 14 4 If you purchase a converter after you have installed your machine you must activate it yourself using the procedure described in Section 3 1 8 133 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 14 9 2 Converting From a Different Format into a ProtoTRAK SMX CNC Conversions from a different format into a ProtoTRAK SMX CNC occur when the file is opened PROG VO F E AXIS l INCH OPEN Look In fara File Name 070501 Mx3 Open As Fi F2 F3 F4 F5 F F FS DATA DATA OPEN OPEN TAB FWD BACK FOLDER Rie FETORN FIGURE 14 9 2 Use the Open As box to tell the ProtoTRAK SMX CNC what kind of file it is Use the Open As box to tell the ProtoTRAK SMX CNC what format the file is in so that it knows how to convert it to the ProtoTRAK SMX CNC format In Figure 14 9 2 the ProtoTRAK SMX CNC could guess that the file to be converted was from a previous version of ProtoTRAK because of its file extension mx3 But since file extensions may be missing or may not really describe the file format correctly you can use the O
25. FIN CUT ISL Finish cut for the Island If 0 is input there will be no finish cut X1 POCKET X dimension for one corner of the rectangular pocket that surrounds the island Y1 POCKET Y dimension for one corner of the rectangular pocket that surrounds the island X3 POCKET X dimension for the opposite corner of the rectangular pocket that surrounds the island Y3 POCKET Y dimension for the opposite corner of the rectangular pocket that surrounds the island CONRAD PCKT the value of the tangential radius in the corners of the rectangular pocket that surrounds the island FIN CUT PCKT finish cut along the perimeter of the pocket If 0 is input there will be no finish cut FEEDRATE the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 FIN FEEDRATE the finish milling feedrate for both the island and pocket finish cuts TOOL is the tool number you assign When the initial screen is complete you will define the perimeter of the island with a series of A G E Mills and A G E Arcs Programming with the Auto Geometry Engine is explained in Section 10 0 PROFILE Events This event allows you to mill around the outside or inside of a circular or rectangular frame or an irregular profile The irregular profile may be closed or open When the irregular profile event is started the ProtoTRAK SMX CNC will automatically initiate the powerful Auto Geometry Engine See Section 10 0 for programming with A G E 8 7 1 Circ
26. K4 CAUTION Do not run ProtoTRAK SM program unless the table and saddle clamps are free 4 2 3 Raising Lowering the Knee The knee is raised and lowered using the hand crank located on the left front of the knee Clockwise rotation moves the knee up while counterclockwise rotation moves the knee down Be sure the knee is unclamped before raising or lowering 4 2 4 Spindle Brake The mechanical spindle break is activated pulling it down or pushing it up When the lever arm is in the horizontal position the brake is off CAUTION Be certain that the spindle brake is released before starting the motor Never attempt to activate the spindle brake when the motor is on 4 2 5 Draw Bar The draw bar holds the R8 or 40 NST tool holders into the spindle taper The bar has a 5 8 11 right hand thread and should be tightened with a 23mm wrench from the top of the head When tightening it is necessary to activate the spindle brake See 4 2 0 above If the tool holder does not release from the spindle lightly tap on the top of the bar to dislodge the tool 4 2 6 High Low Neutral Level For both the standard head and the Programmable Electronic Head Option the range selection is made through the High Low Neutral Lever Figure 4 2 6 32 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual CAUTION Never attempt to change the range selection t
27. Lever Two Axis CNC Models The Feed Trip Lever stops the quill feed motion when the quill stop knob reaches the quill micrometer dial Move the lever to the left to engage or to the right to disengage 4 2 14 Fine Hand Quill Feed Two Axis CNC Models 1 Disengage the Power Feed Engagement Lever 2 Set the fine feed direction shaft to the neutral position 3 Rotate the Fine Feed handwheel 4 2 15 Fine Automatic Quill Feed Two Axis CNC Models 1 Be certain the quill lock is off 2 Set the quill micrometer dial to the proper depth 3 Engage the Power Feed Engagement lever when the motor is stopped 4 Select proper quill feed see above 4 2 16 Setting Stops for Three Axis CNC Models When the Z axis ballscrew and motor assembly is installed for three axis CNC operation the quill stop mechanism is not available Instead there are convenient inputs in the DRO Mode and the Run Mode for setting quill stops 35 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 5 0 Definitions Terms amp Concepts 5 1 5 2 ProtoTRAK SMX CNC Axis Conventions X Axis positive X axis motion is defined as the table moving to the left when facing the mill Consequently measurement to the right is positive on the workpiece Y Axis positive Y axis motion is defined as the table moving toward you Measurement toward the machine away from you is
28. OFF Override 100 Feed Rate 150 0 Override 100 Fi F2 F3 F4 F5 F FT FS SHOW SHOW SHOW SHOW RAKING ABS INC PATH PROG 101145 FIGURE 13 4 Press the GO feed key to start running Where The part number being run is shown in the status line e The event number and type and the repeat number if applicable being run is shown at the top of the screen e The current X Y Z absolute positions are shown in the information area e The SHOW ABS soft key which is automatically assumed if one of the other 3 show keys are not selected will show the absolute X Y Z positions as the part is run e The SHOW INC soft key will show the incremental or distance to go within the event X Y Z positions as the part is run e The SHOW PATH soft key will show the tool path graphics as the part is run e The SHOW PROG soft key will show the programmed data for the event being run and the next event as the part is run The run procedure is very simple Follow the instructions on the conversation line and proceed by pressing the GO key Once the STOP hard key is pressed additional softkeys will be available TRAKing select this softkey to control the X Y and Z programmed motion with the table or saddle handwheel See section 13 5 below The TRAKing Electronic Handwheels Option must be active for this function CNC Run select this softkey to start the CNC run 123 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTR
29. On Off Forward Reverse The spindle switch is located on the left side of the milling head e Turn the Spindle switch to left to 1 for forward clockwise spindle rotation if the Hi Lo Neutral lever is in the low position e Turn the Spindle switch right to 2 for forward clockwise spindle rotation if the Hi Lo Neutral lever is in the high position e Turn the Spindle switch straight ahead for off 30 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual CTRAK K3 3 K3 9 SPINDLE BRAKE HI NEUTRAL LOW LEVER QUILL FEED SELECTOR POWER ENGAGMENT LEVER FINE FEED HANDWHEEL QUILL FEED HANDLE FINE FEED DIRECTION SHAFT FEED PS TRIP N LEVER MICROMETER QUILL ADJUSTMENT LOCK 100206 LOCK amp NUT Figure 4 2 0 TRAK K3 Mill head front view Shown without the standard quill glass scale 31 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 4 2 2 Table Saddle Knee Clamps The table clamps are located on the front of the saddle Rotate them clockwise until snug overtightening is not necessary The saddle clamp is located on the left side of the saddle Pull forward to clamp the table until snug overtightening is not necessary The knee clamps are located on the left side of the knee for the K2 and K3 mills and on the right side for the
30. Operating amp Care Manual Last Event is the event number of the last event to be mirrored if only one event is to be mirrored the last event is the same as the first Cutting Order input 1 to cut from the lowest mirrored event to the highest forward and 2 to machine from the highest mirrored event to the lowest backward This way you can keep all the machine motion in a consistent direction as it moves from the original shape to the mirrored shape and keep all cutting either climb or conventional Mirror Axis is the selection of the axis or axes to be mirrored input X or Y or XY SET X Offset is the distance from Y absolute 0 to the Y axis line of reflection Y Offset is the distance from X absolute 0 to the X axis line of reflection 9 10 3 Rotate Press the ROTATE soft key First Event is the event number of the first event to be rotated Last Event is the event number of the last event to be rotated if only one event is to be rotated the last event is the same as the first X Center is the X absolute position of the center of rotation Y Center is the Y absolute position of the center of rotation Angle is the angle of rotation of the repeated events positive is counterclockwise negative is clockwise Repeats is the number of times events are to be rotated up to 99 9 11 COPY Events Advanced Features Option Copy Events are programmed exactly like Subroutine Events The only difference is
31. Plunge routine We recommend that you check your Z feedrate to make sure it will be correct for a plunge Event Comments Event comments are not supported on the ProtoTRAK or TRAK CNC Event comments will be ignored Thread Mill This routine does not exist in the ProtoTRAK or TRAK CNC Thread Mill events will be ignored We recommend that you replace these events with the Helix Events and Mill Events to ramp in and ramp out of the helix Tool Table Info The part programs for ProtoTRAK or TRAK CNC do not contain tool table information This information is kept separately Tool table information will have to be set in the ProtoTRAK or TRAK CNC as usual Irregular Profile The ProtoTRAK or TRAK CNC does not contain an Irregular Profile Event The Irregular Profile Event will be converted to Mill and Arc Events and the programming of the finish cut and steps will be lost We recommend that after conversion you add repeat events for the steps and finish cut using the technique of overstating the size of the cutter you will use to cut the profile 14 11 Running G Code Files The ProtoTRAK SMX allows you to run G Code files directly without having them converted to the ProtoTRAK SMX programming format You may want to do this if you have a very large CAM file made up of small XYZ position moves or if there is complex surface contouring In 137 Southwestern Industries Inc TRAK
32. Programs Programs in current memory are removed from current memory in Edit Mode See Section 11 3 To remove a program file from a storage location press the DELETE softkey from the Program In Out Mode screen Use the navigation procedure described in Section 14 2 above and highlight the program file or folder you wish to delete Press the DELETE FILE or DELETE FOLDER softkey A warning message will appear for confirmation Additional Softkeys in DELETE DELETE FILE Press this to delete a file DELETE FOLDER Press this to delete a folder Softkeys that appear with the confirmation message 130 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual YES Press this if you want to delete NO Press this if you do not want to delete The delete operation will be aborted and the previous softkey selections will return When the delete operation is finished the file or folder name will disappear from the listing area 14 7 Renaming To rename either a file or a folder press the RENAME softkey from the Program In Out Mode screen To rename a file or folder 1 Use the navigation procedure described in Section 14 2 above and highlight the program file or folder you wish to rename 2 TAB to the New Name area and enter a new name Use the same procedure as for naming a program see Section 7 3 1 3 TAB to the New Extension and enter a new e
33. Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 9 4 MILL Events 9 5 This event allows you to mill in a straight line from any one XYZ point to another including at a diagonal in space It may be programmed with a CONRAD if it is connective with the next event this next event must lie in the same plane as the Mill event Prompts for the Mill Event X Begin is the X dimension to the beginning of the mill cut Y Begin is the Y dimension to the beginning of the mill cut Z Rapid is the Z dimension to transition from rapid to feed Z Depth is the depth of the cut in Z If the Advanced Features Option is active Z Begin and Z End prompts will appear in the place of Z Depth Z Begin is the Z dimension to the beginning of the mill cut Advanced Features Option X End is the X dimension to the end of the mill cut incremental is X Begin Y End is the Y dimension to the end of the mill cut incremental is Y Begin Z End is the Z dimension to the end of the mill cut incremental is Z Begin Advanced Features Option Conrad is the dimension of a tangential radius to the next event that must lie in the same plane for part geometry programming Tool Offset is the selection of the tool offset to right input 1 offset to left input 2 or tool center no offset input 0 relative to the programmed edge and direction of tool cutter movement a
34. Z end XYZ FEEDRATE the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 FIN FEEDRATE the finish milling feedrate for both the island and pocket finish cuts TOOL is the tool number you assign When the initial screen is complete you will define the perimeter of the island with a series of A G E Mills and A G E Arcs Programming with the Auto Geometry Engine is explained in Section 9 0 PROFILE Events This event allows you to mill around the outside or inside of a circular or rectangular frame or an irregular profile The irregular profile may be closed or open All profiles are limited to the XY plane When the irregular profile event is started the ProtoTRAK SMX CNC will automatically initiate the powerful Auto Geometry Engine See Section 10 0 for programming with A G E 9 8 1 Circle Profile Press the CIRCLE soft key if you wish to mill a circular frame Prompts in the Circle Profile event X Center is the X dimension to the center of the circle Y Center is the Y dimension to the center of the circle Z Rapid is the Z dimension to transition from rapid to feed Z End is the Z dimension to the bottom of the frame incremental is from the previous event Radius is the finish radius of the circle Direction is the clockwise input 1 or counterclockwise input 2 direction for milling Tool Offset is the selection of the tool offset to the right input 1 offset to the left input 2 or tool cen
35. a different mode and does not need to be set at the beginning of each operation The feedrate is modal once it is set it remains the same until changed Lines the line feed or carriage return line feed signals the end of the line ASCII code hex 0A or OD 0A A semicolon is optional Coordinates may be formatted in inch or metric The addresses used for specifying coordinates are X Y Z J K The valid ranges are Inch min 99 9999 to max 99 9999 Mm min 999 99 to max 99 999 Rapid moves rapid moves are generated by the ProtoTRAK automatically as part of the definition of an event For this reason GO moves are discarded unless they specify a location other than the beginning of the following event Linear moves G01 are formatted the same as rapid moves Arcs Arc centers are specified by the address J and K for the X Y and Z axes The number following the J and K are incrementally referenced from the starting point of the arc Radius values are not allowed Tool Numbers and Tool Changes the format of the tool number is from T1 to T99 During program run the ProtoTRAK will rapid to home for a tool change and pause for the tool to be loaded manually and the operator to press GO Feed rates the ProtoTRAK is programmed in inches or mm per minute using the F address Spindle speed f the Programmable E Head Option is not active the S values are ignored File name use the CAM extension so the Proto
36. and the smallest at the end Variable You may change this to equal pecks To do this press the HELP key when the highlight is on this 71 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 9 3 prompt This will take you to a screen where you may choose to have the same amount of material taken per peck Fixed You can also choose Chip Break where the tool will perform fixed pecks but only rapid out about 020 after each peck instead of going back to the Z rapid position after every peck This new setting will remain until you change it again RPM is the spindle RPM for the event INC SET will use the RPM of the previous event RPM programming is available only if the Programmable Electronic Head Option is active Z Feedrate is the drilling feedrate Tool is the tool number you assign BOLT HOLE Events This event allows you to program a bolt hole pattern without needing to compute and program the position of each hole Prompts for the Bolt Hole event Drill 1 Bore 2 selects whether the hole is to be drilled or bored If the Programmable Electronic Head Option is active you will also have the choice Tap 3 Holes is the number of holes in the bolt hole pattern X Center is the X dimension to the center of the hole pattern Y Center is the Y dimension to the center of the hole pattern Z Rapid is the Z dimension to
37. beginning of the ARC event is 2 0 inches from the end of the MILL event 38 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 5 7 Tool Diameter Compensation Tool diameter compensation allows the machined edges shown directly on the print to be programmed instead of the center of the tool The ProtoTRAK SMX CNC then automatically compensates for the programmed geometry so that the desired results are obtained Tool cutter compensation is always specified as the tool either right or left of the workpiece while looking in the direction of the tool motion SSO i00176 O FIGURE 5 7 1 Examples of tool right OS i00175 FIGURE 5 7 2 Examples of tool left Tool center means no compensation either right or left That is the centerline of the tool will be moved to the programmed points 39 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 5 8 Tool Diameter Compensation when Contouring in Z with Part Geometry Note Z contouring requires the Advanced Features Option Section 3 1 2 Left and right tool diameter offsets are always those projected into the XY plane Tool offsets in the Z direction are always up and assume the use of a ball end mill When contouring in the Z axis this up tool offset is always activated regardless of left right center
38. exactly what to do to run the program These messages will appear in a green box in the middle of the screen When a tool change is required the tool information entered in the Tool Table will appear in the green box Any Event Comments you entered during programming will appear on the Data Input Line See section 7 3 2 to use Event Comments The Event Comments feature is part of the Advanced Features Option Once the program starts a Run Time Clock will appear in the center of the status line at the top of the screen This clock displays the time remaining until the end of the program or the next tool change and will count down as the program is run The Run Time Clock is part of the Advanced Features Option Note the program must first be viewed as Tool Path in the Set Up Mode to initialize the Run Time Clock Otherwise it will show 0 00 Section 12 2 RUN PINBALLPRK1122 3 14 TOOL 1 3 AXIS INCH 101148 Figure 13 6 The Run Time Clock is in the center of the status line 13 7 Stop At any time the program may be halted by pressing the STOP key This freezes the program at that point You may choose to continue running the program by pressing the CNC RUN softkey or pressing the GO key If the Advanced Features Option is active You may also run the program by using the table or saddle handwheels by pressing the TRAKing softkey 124 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrof
39. example doc is the extension that appears after a file name for a file stored using Microsoft Word Usually but not always the file name indicates what program was used to create the file Sometimes this is not the case Some programs like those found in early models of CNC do not attach a file extension to a file name at all Also a user may attach his own extension to a file name for his own purposes ProtoTRAK and TRAK A G E CNC s always attach an extension to every file that is stored The extension mx2 is used for files or programs written and stored on a ProtoTRAK MX2 126 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual ProtoTRAK M2 or TRAK A G E 2 CNC The extension mx3 is used for the ProtoTRAK MX3 ProtoTRAK M3 and TRAK A G E 3 CNC s The ProtoTRAK SMX CNC uses the extension PT4 whether the program is two or three axis Before opening the file the ProtoTRAK SMX CNC is able to determine what kind of file it is A file extension that is unique to the ProtoTRAK SMX CNC is GCD The GCD extension tells the ProtoTRAK SMX CNC that a particular program is a standard RS274 or G Code program When you specify this extension the ProtoTRAK SMX CNC will treat that program in a special way This is explained in Section 14 11 14 1 Softkey Selections in the Program In Out Mode YES to display only supported programs NO to disp
40. from other applications such as CAD CAM The operation of the ProtoTRAK SMX CNC has been painstakingly refined to bring you the best in technology while retaining the ease of use that has made ProtoTRAK the top brand in controls for low volume production The ProtoTRAK SMX CNC allows you to choose the CNC configuration that is right for you The base system is a powerful CNC for toolroom work You may add options for additional features and capabilities This manual will describe the operation of all basic and optional features in the appropriate context Where optional features are discussed a note will explain in which option the particular feature is found 1 1 Models The ProtoTRAK SMX CNC is featured as a two or three axis CNC in the following products Retrofits Model Description PTSMX2 Two axis CNC retrofit to your knee mill PTSMX3 Three axis CNC retrofit to your knee mill Knee Mills TRAK K2SX Two axis CNC 33 x 12 3HP TRAK K3SX Two axis CNC 32 x 16 3 HP TRAK K4SX Two axis CNC 32 x 16 2 5 HP TRAK K2SX 2 Three axis CNC 33 x 12 3 HP TRAK K3SX 3 Three axis CNC 32 x 16 3 HP TRAK K4SX 3 Three axis CNC 32 x 16 1 2 5 HP Please note that the TRAK K2 and K4 machines have been discontinued as of 1 1 11 1 2 Manual Organization Notes This manual covers the operation of all retrofit and TRAK K Mill products that use the ProtoTRAK SMX CNC Some Sections do not apply to all users For exam
41. functions during event programming Auxiliary Functions are optional for three axis CNC models only Event Comments If you select Yes for event comments you will have the opportunity to insert a comment in each event For Irregular Pocket and Irregular Profile events you will be able to enter a comment at the header event but not for each A G E Turn and A G E Arc event This function is part of the Advanced Features Option Comments appear in the RUN mode on the Data Input Line as the event begins to run Comments may be composed of letters numbers and some symbols and may be up to 20 characters While programming the event with the Event Comments set to Yes when the highlight is on the Event Comments prompt you may enter a comment using the same methods used to enter a program name as described above Multiple Fixtures Asks you if you wish to turn on the multiple fixtures offset Answering Yes will cause a prompt to appear at each event asking which fixture the event was referenced from If you select Yes the Data Input Line will ask you to enter a fixture default number from one to six The fixture default number is the fixture that will be applied to all the events in current memory when Multiple Fixtures is turned on or when a new event is programmed without another event being specified Enter the default fixture or leave the number unchanged and press SET Multiple Fixtures are 49 Southwestern Industries Inc TRAK
42. helix milling canned cycles of the ProtoTRAK are obvious examples of three axis simultaneous interpolation Three axis program run of non cam files is part of the Advanced Features Option In order to run a CAM program the program must be posted through a post processor that makes some adjustments to the output of the CAM software so that it is understood by the ProtoTRAK The ProtoTRAK uses a post processor that is very similar to the Fanuc 6M 150 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual If you are not familiar with writing a post processor we recommend that you contact your CAD CAM supplier We will be happy to work with him to get you the post processor you need 14 13 1 Writing a Post Processor The following are modifications to a Fanuc 6 post processor that are necessary for writing the ProtoTRAK post processor Beginning file format The ProtoTRAK has no special requirements it does not need any special characters End of file format the ProtoTRAK requires the to show the end of the file Characters after the will be ignored Beginning of an operation the ProtoTRAK requires that the tool number feedrate and tool offset appear before or on the same line as a move command In addition the ProtoTRAK requires the spindle speed be set if the Programmable E Head Option is active The absolute zero of the ProtoTRAK is set in
43. if the Part Geometry option is selected There is no Z axis up tool offset applied when the Tool Path option is selected Special attention must always be paid to tool offsets when machining with a ball end mill The reason for this is that the tool diameter changes in the bottom part that portion equal to the tool radius of the tool The tool is always positioned at the beginning of a milling operation so that the correct point on the ball end of the tool is tangent to the beginning point and offset perpen dicular to the machined edge by the radius of the tool Consider the example below of milling a ramp in the XZ plane from point B to point C Z s XZ VERTICAL PLANE B X FIGURE 5 8 1 Ball end mill position with respect to program points Tool starts so end mill is tangent to BC R from center of tool is perpendicular to BC Note how the tool at the beginning point point B starts below in the Z direction point B so that it can actually touch this point If this were not true a cusp would remain to the left of point B Now consider a similar example milling from A to B to C in the XZ plane XZ VERTICAL PLANE Ha X 100178 FIGURE 5 8 2 In order to respect the lines defined by the programmed points the ball end mill never touches point B Tool starts centered over A offset up by the tool radius R It moves right until it is tangent to both AB and BC Then moves to point C as in the first example Note the Tool at B
44. in 10 percent increments The changes in speed may be seen in the Feed rate box and on the green feed rate indicator The amount of override is displayed in the Override box h To jog at a certain rate simply enter that number as inches or mm per minute and then press the X Y or Z key You may also use the override key to adjust this number Press RSTR to return to 150 ipm or 3800mm min i Press RETURN soft key to return to manual DRO operation Power Feed The servomotors can be used as a power feed for the table saddle or quill or all three simultaneously a Press the POWER FEED soft key b A message box will appear that shows the power feed dimensions All power feed moves are entered as incremental moves from the current position to the next position c Enter a position by pressing the axis key the distance to go and the key if needed Input the entry by pressing INC SET For example if you wanted to make a power feed move of 2 00 of the table in the negative direction you would enter X 2 INC SET d Initiate the power feed move by pressing GO e The feedrate is automatically set to 10 ipm or 254 mm per min Press FEED or FEED to adjust the feedrate from 1 ipm to 100 ipm or 254 to 2540 f Press STOP to halt power feed Press GO to resume Repeat the process beginning at c above as often as you wish Press RETURN soft key to return to manual DRO operation 44 Southwestern Industrie
45. lit when the servos motors are not moving the machine 13 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Override Keys F S selects the function for the override operation F is for feedrate When the LED above the F is lit arrow presses will increase or decrease axis feedrate S is for spindle RPM When the LED above the S is lit arrow presses will increase or decrease the spindle RPM Note the spindle override is active only when the Programmable Electronic Head Option is installed M Feedrate Override to increase feedrate or spindle rom up to 150 W Feedrate Override to decrease feedrate or spindle rom down to 10 Each button push Modifies the feedrate in 10 increments and the spindle speed in 5 increments ACCESSORY When the switch is in the On position the flood coolant pump or spray coolant will come on and stay on during machining operations In the Auto mode the coolant pump or spray coolant will be controlled as programmed by the Auxiliary functions To get to the Auto operation press and hold the Accessory key If neither light is on the coolant pump or spray coolant will not operate F C Selects between fine and course resolution for the X and Y handwheels when the TRAKing Electronic Handwheels Option is installed The LED above the letter indicates which feed is active Fine feed moves the axis 200 inches per revolut
46. machine and hot flying chips When working in manual mode not CNC make sure the computer control is switched to DRO or OFF An optional interlocked guard is available from Southwestern Industries Inc for TRAK Knee Mills if the use of the table guard is deemed necessary by the user for his application 7 Southwestern Industries Inc TRAK SX Knee Mill amp Proto TRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 3 0 Description ProtoTRAK SMX CNC Specifications In its base form the ProtoTRAK SMX CNC is powerful and easy to use For knee mill applications the two axis CNC is usually preferred because of its simplicity and ease of use When three axis CNC is required a ballscrew and motor is mounted to the head to drive the quill The list below summarizes the features and specifications Each feature is described in more detail in the appropriate section of the manual 3 1 3 1 1 Basic System Specifications Control Hardware 2 or 3 axis CNC 3 axis DRO Real handwheels for manual operation 10 4 color active matrix screen Industrial grade Intel processor 128 Mb Ram P S 2 Keyboard connector 2 USB connectors Override of program feedrate LED status lights built into display TEAC floppy drive Software Features General Operation Clear uncluttered screen display Prompted data inputs English language no codes Soft keys change within context Windows operating system
47. pocket that surrounds the island CONRAD PCKT the value of the tangential radius in the corners of the rectangular pocket that surrounds the island FIN CUT PCKT finish cut along the perimeter of the pocket If 0 is input there will be no finish cut 62 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual FEEDRATE the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 FIN FEEDRATE the finish milling feedrate for both the island and pocket finish cuts TOOL is the tool number you assign 8 6 2 Rectangular Island Advanced Features Option When the Advanced Features Option is active press the RECT ISLAND softkey if you wish to machine a rectangular island Prompts for the RECT ISLAND X1 ISLAND X dimension for one corner of the rectangular island Y1 ISLAND Y dimension for one corner of the rectangular island X3 ISLAND X dimension for the opposite corner of the island Y3 ISLAND Y dimension for the opposite corner of the island CONRAD ISL the value of the tangential radius in the corners of the island DIRECTION is the milling direction clockwise or counterclockwise FIN CUT ISL Finish cut for the Island If 0 is input there will be no finish cut X1 POCKET X dimension for one corner of the rectangular pocket that surrounds the island Y1 POCKET Y dimension for one corner of the rectangular pocket that surrou
48. self diagnostic routine and scold you for not following the instructions More importantly it can corrupt files Note When you turn the PROTOTRAK SMX CNC off always wait a few seconds before turning it back on 4 1 3 Emergency Stop Press the button to shut off power to the spindle motor and axis motors Rotate the switch to release 4 1 4 Switching Between Two and Three Axis Operation For three axis retrofit and TRAK Knee Mill models The ProtoTRAK SMX CNC may be operated as a two or three axis CNC Press the SYS hard key Softkey F2 will read GO TO 2 AXIS when the ProtoTRAK SMX CNC is currently operating in three axis and it will say GO TO 3 AXIS when the ProtoTRAK SMX CNC is currently operating in two axis See Figure 4 1 4 ICED FEATUR ORY Copyright 1998 2004 Southwestem Industries Inc FA F2 F3 F FS F FT FB CONFIG GOTO SHUT UPDATE UPDATE UPDATE OPTIONS NET 2AXIS DOWN MASTER SLAVE OPTIONS ON OFF 101150 FIGURE 4 1 4 You will see this screen when the SYS hard key is pressed The choice GO TO 2 AXIS shows that the CNC is currently in 3 Axis operation 4 1 5 Coolant Pump Spray Coolant An optional coolant system may be connected to your mill If you do not have the Auxiliary Functions option manual controls for the system are provided If you do have the optional Auxiliary Functions the operation of the coolant system may be programmed within the program events The Auxiliary Functions ar
49. the Z feedrate from Z rapid to Z end XYZ Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Fin Cut is the width of the finish cut If 0 is input there will be no finish cut See Section 9 6 7 for a bottom finish cut RPM is the spindle RPM for the event INC SET will use the RPM of the previous event RPM programming is available only if the Programmable Electronic Head Option is active FIN RPM is the spindle RPM for the finish cut FIN RPM programming is available only if the Programmable Electronic Head Option is active Fin Feedrate is the finish cut milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Tool is the tool number you assign When the initial screen is complete you will define the perimeter of the pocket with a series of A G E Mills and A G E Arcs Programming with the Auto Geometry Engine is explained in Section 9 0 No islands may exist in an irregular pocket 9 6 4 Tool Path in Pocket Events In Program Run the pocket path will be either the plunge or zigzag cuts to Z depth along either the X or Y followed by the required number of cuts to clear out the interior material and then the rough cut along the inside of the perimeter This will be repeated for each pass and then followed by a finish pass if FIN CUT was not zero along the inside of the perimeter at the Finish Feedrate and final depth If a bottom finish cut was programmed it will be machined
50. the bolt hole circle Angle 9 abs Angle of first hole from zero 0 degrees of Pecks for Drill 6 abs Sets drill function for 6 pecks Z Feedrate 10 abs Sets Z plunge rate to 10 ipm Tool 3 abs Selects Tool 3 0 5 drill This is the end of the program 158 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 15 2 Sample Program No 2 2 Axis Profile with Limited Print Data The Program This program is designed to provide practice with the ProtoTRAK SMX A G E programming system that is part of the Advanced Features Option A basic rule of thumb for A G E programming e When you have unknown tangent elements you may skip data e When you have unknown non tangent elements you use the Guess feature All programs start by first selecting Program from the front panel softkeys You may enter in an alphanumeric program description or simply press Go to Begin to get started Be certain to start your program by selecting Profile Sample Drawing 2 eV 100851 159 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual EVENT 1 IRREGULAR PROFILE NOTES X Begin 1 abs Leads into part no witness mark Y Begin 6 66 abs Leads into part no w
51. the events and prompts you encounter when programming your ProtoTRAK SMX two axis CNC If you have a three axis TRAK Knee Mill or retrofit SMX CNC you may want to skip this section Events are fully defined pieces of geometry By programming events you tell the ProtoTRAK SMX CNC what geometry you want to end up with it figures the tool path for you from your answers to the prompts and the tool information you give it in the Set Up Mode 8 1 8 2 8 3 POSN DRILL This event type positions the table and quill at a specified position The positioning is always at rapid speed modified by feedrate override and in the most direct path possible from the previous location You would use this event type to program a hole for drilling In program run the CNC will move to the dimension you program and will wait for you to press GO before moving to the next event You may also use this event type to position the table for some other purpose such as to avoid a clamp or to move off the workpiece for a tool change To program a Position event press the POSN DRILL soft key Prompts for the Position event X END is the X dimension to the position Y END is the Y dimension to the position Tool is the tool number you assign SET will use the tool number of the previous event BOLT HOLE Events This event allows you to program a bolt hole pattern without needing to compute and program the position of each hole Prompts for the Bolt Hole eve
52. the table see below Programming vertical planes requires the Advanced Features Option Section 3 1 2 Unlike most CNC controls the ProtoTRAK SMX CNC can 2 machine arcs in any vertical plane rather than just XZ or YZ FIGURE 5 3 Vertical Planes 5 4 Absolute amp Incremental Reference The ProtoTRAK SMX CNC may be programmed and operated in either or in a combination of absolute or incremental dimensions An absolute reference from which all absolute dimensions are measured in DRO and program operation can be set at any point on or even off the workpiece To help understand the difference between absolute and incremental position consider the following example ABSOLUTE DIMENSIONS ABSOLUTE REFERENCE i00169 INCREMENTAL DIMENSIONS FIGURE 5 4 Each point has both an absolute and an incremental reference in the X axis The ProtoTRAK SMX CNC allows you to program using either 37 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 5 5 5 6 Referenced amp Non Referenced Data Data is always loaded into the ProtoTRAK SMX CNC by using gt SET or ABS SET key X Y Z positions are referenced data In entering any X Y or Z position data you must note whether it is an incremental or absolute dimension and enter it accordingly All other information non referenced data such as tool diameter feedrate etc is not a positio
53. to 9999 9999 D signed coordinate word denoted lt scoord gt 1 format negative number lt coord gt positive number lt coord gt or lt coord gt 2 range metric 99999 999 to 99999 999 inch 9999 9999 to 9999 9999 E tool function denoted lt tool gt 1 format dd use 2 digit only 2 leading 0 suppression 3 range 1 to 99 F miscellaneous or M codes function number denoted lt prep func gt 1 format dd 2 leading 0 suppression 3 range 1 to 99 G feedrate values denoted lt frate gt 1 format metric ddddd inch ddd dd leading 0 suppression decimal point not required fractional portion is optional range metric 1 to 6350 inch 0 1 to 250 H RPM command VM 1 format dddd 1000 1000 RPM OTEO 14 13 5 G Codes That Generate Errors G Code Function G27 Reference point return check G28 Return to reference point G29 Return from reference point G30 Return to 2 reference point G31 Skip function G33 Thread cutting G37 Tool length automatic measurement G38 Cutter radius compensation vector change 154 Southwestern Industries Inc TRAK SX Knee Mill amp Proto TRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual G39 Cutter radius compensation corner rounding G45 Tool offset increase G46 Tool offset decrease G47 Tool offset double increase G48 Tool offset double decrease G62 Auto
54. want to copy Make sure that the dimensioned data uses Absolute references in the first event to be copied and in all events where it will be important Incremental references may be used but keep in mind where the Incremental reference will be made from See the section on Incremental Reference Position in this manual In addition you may want to modify this program in order to get all the events you want together For example if you want to copy events 2 5 and 7 12 you may want to 105 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual modify the program to delete events 1 and 6 first That way you can copy the all the events as they are now numbered from 1 to 10 Remember that you can modify this program just for this purpose and it will not affect the original program unless you save it with the modifications in the Program In Out Mode When the source program is ready press the CLIPBOARD softkey A message will appear that says Copy Events Onto Clipboard and the Data Input Line will read From Event Enter the number of the first event that you want copied and press SET The Data Input Line will read To Event Enter the number of the last event you want copied and press SET The group of events that you have specified is now on the clipboard and will remain there until you replace it with something else by going through the same procedure Whe
55. within the program The effect of this event is to move the head to the Z retract location with the X and Y position corresponding to the end of the previous event and stopping the program run Pause events are useful if you want to stop the program to make a measurement change a fixture etc NOTE In general you should avoid programming a PAUSE event between two connective events The Pause event will cause the events to NOT be connective To program a Pause Event press the PAUSE soft key Because there is no input required simply press SET to load and the event counter will advance by one and the Select Event screen will reappear In run press the GO key after a pause to continue 89 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 9 14 Tap Events Programmable Electronic Head Options Tap events allow you to tap holes using a floating tapping head The feedrate of the thread will be calculated from the pitch and RPM entered The RPM range that the ProtoTRAK SMX can tap for low gear is 40 to 200 RPM and for high gear is 300 to 1000 RPM An error message will occur if you try to tap outside of these ranges To program a tap event press the TAP soft key Prompts in the Tap event X the X dimension to the center of the hole Y the Y dimension to the center of the hole Z Rapid is the Z dimension to transition from rapid to feed Make sur
56. 000 Y0 750000 Z 1 000000 10 000000 J0 250000 K0 000000 G64 x Event 2 Rees t x Find what Fi 0 Find Next Replace with Replace a Replace All Match whole word only Cancel Figure 11 5 2 The find and replace routine Click in the Find What box and enter the item you want to find Click on the Find Next box and the G Code Editor will locate the next occurrence of that item Successive clicks on Find Next will continue to search through the program Use Match Whole Word to limit the search to the entire word For example if you want to find G2 but not G20 or G22 select Match Whole Word Only Instead of typing the item into the Find What box you may simply highlight an item on the G Code Editor screen That item will be entered into the Find What box for you To make changes to Find What items type what you want to have into the Replace With box You can replace items one at a time by clicking first the Find Next box then the Replace With box for as many changes as you want to make You can replace every item in the program with a single click of the Replace All box Return closes the G Code Editor and returns the screen to the Edit Mode Note If you use the USB Thumb Drive to store a G code gcd program file you must leave the Thumb Drive plugged into the USB port the entire time the program is in current memory If you unplug the thumb drive with the program still in current memory the ProtoTRAK will d
57. 000 abs SCALE ANON Ne nro N NAN 0 abs AUXILIARY Fl EVENT COMA MULTIPLE FD DIMENSION Text Length 0 000000 F F5 F F FS F F2 FB BACK CLEAR SPACE A lt gt ENTER END i01057 FIGURE 8 8 The above figure shows the text and special characters available for the Engrave event Notice the field that is labeled Text Length This field will display the total length of your programmed text and will update as you enter each character 66 Southwestern Industries Inc TRAK SX Knee Mill amp Proto TRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 8 9 Subroutine Events The Subroutine Events are used for manipulating previously programmed geometry within the XY plane The Subroutine Event is divided into three options Repeat Mirror and Rotate Repeat and Rotate may be connective As long as the rules of connectivity are satisfied see Section 5 9 the ProtoTRAK SMX CNC will continue milling between preceding and subsequent events REPEAT allows you to repeat an event or a group of events up to 99 times with an offset in X and or Y This can be useful for drilling a series of evenly spaced holes duplicating some machined shapes or even repeating an entire program with an offset for a second fixture Repeat events may be nested That is you can repeat a repeat event of a repeat event of some programmed event s One new tool number may be assigned for each Repeat Ev
58. 135 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 14 10 ProtoTRAK and TRAK CNC Compatibility File exchange between the ProtoTRAK SMX CNC and other ProtoTRAK and TRAK CNC s is possible because the ProtoTRAK SMX CNC is backward compatible In other words the ProtoTRAK SMX CNC can store and retrieve other ProtoTRAK and TRAK CNC files The actual transfer of the files can be accomplished by using a floppy disk USB flash memory and or Ethernet cable In order to transfer files between the ProtoTRAK SMX CNC and previous generations of ProtoTRAK and TRAK CNC you must have the MX2 and MX3 converters activated See Section 14 9 above Note Previous ProtoTRAK and TRAK CNC s allow numeric filenames of eight 8 characters or less while the ProtoTRAK SMX CNC allow alphanumeric filenames letters and numbers of up to twenty five 25 characters Be sure to use only numeric filenames when storing a file on a ProtoTRAK SMX CNC that will be retrieved by previous ProtoTRAK and TRAK CNC s Before conversion you can easily rename the file in the ProtoTRAK SMX CNC current memory 14 10 1 File Formats The ProtoTRAK SMX CNC can store and retrieve the following ProtoTRAK and TRAK CNC file formats Previous ProtoTRAK and TRAK CNC file formats ProtoTRAK M2 mx2 ProtoTRAK MX2 mx2 ProtoTRAK MX2E mx2 TRAK AGE2 mx2 ProtoTRAK EDGE mx2 ProtoTRAK M3 mx3 ProtoT
59. 17 5A E head no longer available as of 1 1 11 Maximum Weight on 750 Ibs 850 Ibs 850 Ibs Table Machine Weight 2200 Ibs 2816 Ibs 3630 Ibs Machine dims w h 70 x 57 x 83 71 x 59 x 84 71 x 59 x 9 Max rapid feed X Y 100 IPM 100 IPM 100 IPM Max rapid feed Z CNC 50 ipm down 100 ipm 50 ipm down 100 ipm up 50 ipm down 100 ipm up Way surface type up Dovetail X Y Z Dovetail X Z Square Y Dovetail X Square Y Z Coolant Capacity 9 gallons 9 gallons 9 gallons Precision 7207 CP4 spindle bearings Chrome hardened and ground quill Meehanite castings Slide ways are Turcite coated Wide way surfaces are hardened and ground 21 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 3 3 1 Manual Lubrication System Ways and Ballscrew Lubrication The TRAK Knee Mill X Y Z way surfaces and ball screws are lubricated manually with the lubrication pump located on the left side of the knee Pull the handle fully and release 4 to 6 times at the beginning of each shift and once every four hours of operation thereafter 1 At the beginning of each day check the oil level in the pump If low fill with SAE 30 or 30W oil 2 Every six months of operation apply a liberal coating of Mobile Grease MP or equivalent to the Z Axis ACME screw CAUTION Failure to manually act
60. 4 25 26 27 Avoid getting pinched in places where the table saddle or spindle head create pinch points while in motion Securely clamp and properly locate the workpiece in the vise on the table or in the fixture Use stop blocks to prevent objects from flying loose Use proper holding clamping attachments and position them clear of the tool path Use correct cutting parameters speed feed depth and width of cut in order to prevent tool breakage Use proper cutting tools for the job Pay attention to the rotation of the spindle Left hand tool for counterclockwise rotation of spindle and right hand tool for clockwise rotation of spindle Prevent damage to the workpiece or the cutting tool Never start the machine including the rotation of the spindle if the tool is in contact with the part Check the direction or of movement of the table when using the jog or power feed Don t use dull or damaged cutting tools They break easily and become airborne Inspect the sharpness of the edges and the integrity of cutting tools and their holders Use proper length for the tool Large overhang on cutting tools when not required result in accidents and damaged parts Prevent fires When machining certain materials magnesium etc the chips and dust are highly flammable Obtain special instruction from your supervisor before machining these materials Prevent fires Keep flammable materials and fluids away from the
61. 4 1 If you order this option do not activate the software for the TRAKing Electronic Handwheels Option until the electronic handwheels are installed on the machine Contact your local Southwestern Industries Inc Sales Representative or the Southwestern 11 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Industries Inc Service Department to make arrangements for an authorized technician to install the electronic handwheels For three axis CNC models the Go To dimensions for the Z axis are a part of the base product even if this option is not ordered You do not need this option for Z axis Go To dimensions 3 1 8 How To Buy Software Options If you did not buy the software options described above with your machine you may purchase them later In order to use these options a Software Activation Password is required These passwords are unique to your ProtoTRAK SMX CNC Software Options are not free You may call your local Southwestern Industries Sales Representative or Southwestern Industries Inside Sales at 310 608 4422 for a price quotation 1 We recommend that you install the latest version of the ProtoTRAK SMX master software before installing the newest option See our web site at www southwesternindustries com for software downloads 2 Go to the ProtoTRAK SMX CNC on which the option is to be installed use Service Code 318 to go to t
62. 68 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Mirror Axis is the selection of the axis or axes to be mirrored input X or Y or XY SET X Offset is the distance from Y absolute 0 to the Y axis line of reflection Y Offset is the distance from X absolute 0 to the X axis line of reflection 8 9 3 Rotate Press the ROTATE soft key First Event is the event number of the first event to be rotated Last Event is the event number of the last event to be rotated if only one event is to be rotated the last event is the same as the first X Center is the X absolute position of the center of rotation Y Center is the Y absolute position of the center of rotation Angle is the angle of rotation of the repeated events positive is counterclockwise negative is clockwise Repeats is the number of times events are to be rotated up to 99 8 10 COPY Events Advanced Features Option Copy Events are programmed exactly like Subroutine Events The only difference is that in Copy the events are rewritten into subsequent events If for example in Event 11 you Copy Repeated Events 6 7 8 9 10 with 2 repeats Events 6 10 would be copied with the input offsets into Events 11 15 and recopied into 16 20 Copy Events may be Repeat Mirror or Rotate Copy is very useful With copy you can Edit the events that are being repeated mirrored o
63. 7 3165 Fax 310 886 8029 Table of Contents 2 3 3 0 3 1 3 2 3 3 3 4 Introduction 1 Models Manual Organization Notes Safety 3 Safety Publications Danger Warning Caution and Note Labels and Notices Used in this Manual Safety Precautions Description 8 ProtoTRAK SMX CNC Specifications 3 1 1 Basic System Specifications 3 1 2 Advanced Features Option 3 1 3 Networking Option 3 1 4 Installing and using the USB Thumb Drive Flash Memory 3 1 5 The DXF File Converter Option 3 1 6 Converter Options 3 1 7 TRAKing Electronic Handwheels Option 3 1 8 How to Buy Software Options Display Pendant 3 2 1 Front 3 2 2 Pendant Left Side 3 2 3 Pendant Right Side TRAK Knee Mill Specifications 3 3 1 Manual Lubrication System Optional Equipment 3 4 1 Electronic Handwheels 3 4 2 Electronic Head 3 4 3 Position Encoders 3 4 4 Auxiliary Functions 3 4 5 Power Draw Bar 3 4 6 Remote Stop Go Switch 3 4 7 Work Light 3 4 8 Coolant Pump 3 4 9 Spray Coolant 3 4 10 Limit Switches 3 4 11 Chip Pan 3 4 12 Table Guard 3 4 13 Auto Lubrication System Servo Motors Ballscrews Quill Glass Scale Z Axis Ball Screw and Motor Assembly Electrical Cabinet Basic Operation 26 ProtoTRAK SMX Basic Operation 4 1 1 Switching on the ProtoTRAK SMX CNC 4 1 2 Shutting Down the ProtoTRAK SMX CNC 4 1 3 Emergency Stop 4 2 5 9 5 10 5 11 6 0 6 1 6 2 6 4 6 5 6 6 6 7 6 8 6 9 6 10 4 1 4 Switching Betwee
64. AK SMX CNC Retrofit Safety Programming Operating amp Care Manual 13 5 TRAKing TRAKing Electronic Handwheel Option TRAKing is a special kind of CNC run When you press the TRAKing softkey the programmed head table and saddle motion is controlled by turning the table or saddle electronic handwheel Moving the X or Y handwheel in the clockwise direction moves forward through the program moving counterclockwise moves backward through the program To TRAK slowly use the Y handwheel To TRAK quickly use the X handwheel TRAKing comes in handy whenever you are a little unsure about any aspect of your program or set up For example on the first run of a part instead of pressing GO and holding your hand on the stop button use TRAKing to bring the tool to the part while you watch the DRO Once assured that everything is all right press STOP and get into CNC run Note When TRAKing a three axis program if the Programmable Spindle Control option is installed the spindle must be on in order to TRAK once the head reaches the programmed Z Rapid position 13 5 1 TRAKing in Two Axis CNC When running the ProtoTRAK SMX as a two axis CNC TRAKing works with the manual operation of the Z The tool may be put in position when the messages Set Z or Check Z appear When TRAKing through an XY move the Z axis handwheel is not active 13 6 Program Run Messages While in the Run Mode clear instructions and prompts from the SMX CNC will tell you
65. Axis DRO TRAK K2SX 3 TRAK K3SX 3 TRAK K4SX 3 ProtoTRAK SMX CNC ProtoTRAK SMX CNC ProtoTRAK SMX CNC 3 Axis CNC 3 Axis DRO 3 Axis CNC 3 Axis DRO 3 Axis CNC 3 Axis DRO Table Size 49 X9 50 X 10 50 X 10 T Slots 5 8 x3 x2 V2 5 8 x3 x 2 V2 5 8 x3 x2 V2 Table Travel 33 32 32 Saddle Travel 12 16 16 V2 Knee Travel 16 16 16 V2 Ram Travel 12 15 19 Maximum Quill Travel 2 5 5 5 axis CNC Maximum Quill Travel 3 4 1 4 1 4 1 axis CNC Quill Diameter 3 3 8 3 3 8 3 15 16 Spindle Taper R8 R8 NMTB 40 Spindle Speed Vari 60 500 600 4200 RPM 60 500 600 4200 RPM 70 500 600 3950 RPM speed head Spindle Speed Optional E head no longer available as of 1 1 11 40 600 and 300 5000 RPM 40 600 and 300 5000 RPM 40 600 and 300 5000 RPM Head Tilt 45 deg forward 45 deg back 90 deg left 90 45 deg forward 45 deg back 90 deg left 90 deg 90 deg left 90 deg right deg right right Spindle Motor Power 3HP 3HP 5HP Vari speed head Spindle Motor Power 3HP 3HP 5HP Optional E head no longer available as of 1 1 11 Power Requirement 110V 1P 10A 110V 1P 10A 110V 1P 10A Control Power requirements machine with vari speed head 220 440V 3P 8 5 4 25A 220 440V 3P 8 5 4 25A 220 440V 3P 14 7A Power req with Optional 220V 3P 11A 220V 3P 11A 220V 3P
66. CNC may be operated as either a two or three axis CNC Many jobs in tool rooms are simply easier to do with a two axis CNC Other jobs are more complex or require a lot of metal removal so the extra programming and set up of the three axis is worth the effort The ProtoTRAK SMX CNC lets you choose how much CNC you want to use on the job at hand See Section 4 1 4 for switching between two and three axis operation Programming is very similar between the two EVENT 1 BOLT HOLE EVENT 1 BOLT HOLE DRILL OR BORE HOLES HOLES X CENTER X CENTER Y CENTER Y CENTER RADIUS Z RAPID ANGLE Z END TOOL RADIUS ANGLE PECKS FOR DRILL Z REEDRATE TOOL FIGURE 7 13 Programming a Bolt Hole On the left the prompts required in programming in three axis CNC On the right the prompts required for two axis In Figure 7 13 the prompts for programming a Bolt Hole in two axis and in three axis are shown side by side Note that the difference is that the three axis requires a few additional prompts For the convenience of users who have two axis CNC models the programming will be explained in two different sections If you have a three axis CNC model we suggest you skip the two axis programming section since the programming is very similar 57 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 8 0 Two Axis Program Events This section describes
67. DRAW will re draw automatically sizing to fit the screen necessary only if an adjustment changed the drawing from its initial sizing 113 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual STEP each press of the STEP button shows the next tool move You may hold the STEP button down to draw the graphic without repeated button presses To complete the drawing automatically press FIT DRAW XY YZ XZ 3D shows the same drawing on the screen with adjustments in the view you select Soft keys in ADJ UST VIEW FIT same as the FIT DRAW va 4 gt moves the drawing in that direction ZOOM IN ZOOM OUT resizes the drawing RETURN returns to the previous soft keys retaining the adjustments that were made to the drawing 12 3 Reference Positions REF POSN The Reference Positions screen for three axis CNC models shows the retract status the home locations and software limits for all axes For two axis models only the X and Y limits are shown SET UP PIN R0424 11 POSITION STATUS Z RETRACT X HOME 0 0000 abs Y HOME 0 0000 abs Z LOWER LIMIT OFF X LIMIT OFF X LIMIT OFF Y LIMIT OFF Y LIMIT OFF Fi LIMITS ON OFF FS RETURN FIGURE 12 3 Reference positions for three axis CNC models The Z Retract is not set Position the head and press a SET key 114 Southwestern Industries Inc TRAK SX Kne
68. EP EVT a se i FIGURE 10 8 2 When the events are calculated based on Guessed data they are represented by a dotted line 10 9 Calculated Data Prompts that are skipped or for which guesses are entered may be replaced by data calculated by the ProtoTRAK SMX CNC Calculated data is shown in red in order to distinguish it from the data that you entered You cannot edit calculated data but you may edit your original input By putting the event with the calculated data on the right side of the screen you may position the cursor to the prompt and re input the data 10 10 Arcs and Conrads If the print is missing a lot of data it may be desirable to program arcs as separate events where possible This gives the system more information to work with 10 11 Tangency Tangency can occur between a mill and arc or an arc and arc Specifically it means necessary but not sufficient that the two geometries share one and only one You would answer yes to the TANGENCY prompt if the event you are programming is tangent to the 99 Southwestern Industries Inc TRAK SX Knee Mill amp Proto TRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual previous event The information that events are tangent helps the Auto Geometry Engine calculate other dimensions You can often tell by looking at the print if events are tangent tangent intersections tend to blend smoothly without a sharp corner Ze a smooth probably
69. End Y CENTER is the Y dimension to the center of the arc incremental is from Y End CONRAD is the dimension of a tangential radius to the next event RADIUS is the radius of the arc CHORD LENGTH is the straight line distance from the begin point to the end point CHORD ANGLE is the angle spanned by the arc In addition to the normal Softkeys this additional one will appear in A G E Arc programming GUESS this softkey will appear when the prompt is on X or Y dimensioned data Press the Guess key before you press INC SET or ABS SET to enter the data as a guess See Section 10 7 10 4 Skipping Over Prompts In the A G E events don t have to be fully defined before you can go to the next one You can skip the data you don t know by using the DATA FWD softkey After you press the DATA FWD key at the last prompt the event will move to the left side of the screen and the Select Event screen will appear When skipping over prompts or editing always use the DATA FWD or DATA BACK key Using INC SET or ABS SET will change the data If you want the event back on the right side use the BACK hard key 10 5 The OK NOT OK Flag Each A G E event has a flag that tells you if it has been fully defined Sometimes data from later events is needed to define previous events To the immediate right of the event type the words OK or NOT OK appear depending on whether that particular event is defined Once the OK flag appears for the event y
70. Feedrate 5 abs Sets the ramp feedrate to 5 ipm XYZ Feedrate 20 abs Sets the pocket cutting feedrate to 20 ipm Fin Feedrate 15 abs Sets the finish pocket feedrate to 15 ipm Tool abs set Sets tool to default 1 EVENT 2 Bolt Hole NOTES drill for 0 1 bolt pattern Drill or Bore 1 Selects Drill Function of Holes 5 abs Known print value X Center abs Defaults to X zero Y Center abs Defaults to Y zero Z Rapid 1 abs Sets the rapid plane to 0 1 Z End 6 abs Sets the drill depth to 0 6 Radius 1 625 abs The radius of the bolt hole circle Angle 45 abs Angle of first hole from zero 0 degrees of Pecks for Drill 6 abs Sets drill function for 6 pecks Z Feedrate 10 abs Sets Z plunge rate to 10 ipm Tool 2 abs Selects Tool 2 0 1 drill EVENT 3 DRILL NOTES center drill for 0 1 hole patterns Drill or Bore 1 abs Selects Drill Function X 2 75 abs Known print value Y 1 5 abs Known print value Z Rapid 1 abs Sets the rapid plane to 0 1 Z End 6 abs Sets the drill depth to 0 1 of Pecks for Drill 6 abs Sets drill function for 6 pecks Z Feedrate 5 abs Sets Z plunge rate to 5 ipm Tool inc set Keeps Tool 2 0 1 drill Select More then Copy then Repeat to do the drilling using the previous event info EVENT 4 COPY REPEAT NOTES for the drill 0 1 operation First Event 3 abs Selects the first event to copy from Last Event 3 abs Selects the last event to copy to X Offset inc set Does not offset
71. Islands programming is available as part of the Advanced Features Option See Section 3 1 2 Within the Pocket event choices you may also select a circular rectangular or irregular island An island is a shape that is left standing when the surrounding material is removed The ProtoTRAK gives you the ability to machine almost any shape as an island within a rectangular pocket Both the shape of the island and the dimension of the surrounding pocket are defined within the island event The tool path for machining the island event is that the tool will first plunge or ramp into the material next to the island offset by the programmed finish cut to the depth of the first pass The tool will machine the perimeter of the island offset by the island finish cut Then the tool will machine the material in the pocket in a spiral path moving away from the island in the programmed clockwise or counterclockwise direction It will continue this outward spiral motion until it encounters the programmed rectangular perimeter or pocket It will then follow the perimeter offset by the pocket finish cut It will proceed in this manner through the number of programmed passes On the final pass it will machine the island finish cut then the pocket finish cut If a Z finish cut is programmed it will do this in the same spiral pattern as the roughing passes between machining the island and pocket finish cuts The tool will ramp away from the finish cut by the amo
72. K SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual CONRAD PCKT the value of the tangential radius in the corners of the rectangular pocket that surrounds the island FIN CUT PCKT finish cut along the perimeter of the pocket If 0 is input there will be no finish cut See the previous section for a bottom finish cut RPM is the spindle RPM for the event INC SET will use the RPM of the previous event RPM programming is available only if the Programmable Electronic Head Option is active FIN RPM is the spindle RPM for the finish cut FIN RPM programming is available only if the Programmable Electronic Head Option is active Z FEEDRATE is the Z feedrate from Z rapid to Z end XYZ FEEDRATE the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 FIN FEEDRATE the finish milling feedrate for both the island and pocket finish cuts TOOL is the tool number you assign 9 7 2 Rectangular Island Advanced Features Option Press the RECT ISLAND softkey if you wish to machine a rectangular island Prompts for the RECT ISLAND X1 ISLAND X dimension for one corner of the rectangular island Y1 ISLAND Y dimension for one corner of the rectangular island X3 ISLAND X dimension for the opposite corner of the island Y3 ISLAND Y dimension for the opposite corner of the island Z RAPID is the Z dimension of the transition from rapid to feed Z END is the Z dimension at the
73. LOCKWISE i00166 Figure 4 2 10 33 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual The power feed is engaged or disengaged with this selector Pull out the knob and rotate it clockwise to disengage power feed Rotate it counterclockwise to engage power feed CAUTION It is recommended that the selector be disengaged when the spindle is not running Never have the feed engaged when the spindle RPM is over 3000 Always leave the selector in the disengaged position unless the feed function is being used 4 2 11 Fine Feed Direction Shaft Two Axis CNC Models NEUTRAL NER NNA i00166 Figure 4 2 11 The direction of the fine feed is set by the position of the fine feed direction shaft IN sets the direction down OUT sets the direction up and NEUTRAL in the middle 4 2 12 Quill Feed Selector Two Axis CNC Models Figure 4 2 12 1 Quill Feed Selector for the K2 amp K3 Figure 4 2 12 2 Quill Feed Selector for the K4 This selector is used to set the quill feed speed To change speeds pull the knob out and rotate the selector to the proper position It is generally easier to change speeds with the spindle running or rotated by hand Do not force the lever 34 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 4 2 13 Feed Trip
74. Manual EVENT 14 AGE MILL NOTES Tangent 1 Selects tan mill X End 0 inc X value is unchanged Y End Guess 6 6 abs Unknown value Guess Conrad 0 15 Known print value Angle End Press Page Forward now as no further Length data is required Line Angle EVENT 15 AGE ARC NOTES Tangent 2 Not tangent Direction 1 CW X End 0 abs Known print dimension Y End 6 66 abs Known print dimension X Center 0 abs Known print dimension Y Center 0 abs Known print dimension Conrad Press Page Forward now as no further Radius data is required Chord Length Chord Angle EVENT 16 AGE MILL NOTES Tangent 1 Selects tan mill off the part X End 1 abs Known value Y End 0 inc Value unchanged Conrad Press Page Forward now as no further Angle End data is required Length Line Angle Press the Look Key Now If all is OK press Look key again to return to program and End the AGE 163 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Southwestern Industries Inc TRAK Warranty Policy Warranty TRAK products are warranted to the original purchaser to be free from defects in work manship and materials for the following periods Product Warranty Period Materials _ Factory Labor ees Sd New 1 Year 1 Year TRAK ProtoTRAK Any EXCHANGE Unit 90 Days 90 Days The warranty period starts on the date of the invoice to t
75. NC 14 11 3 Valid Characters for Word Address Sequences Networking 14 12 1 A Basic Peer To Peer Network 14 12 2 Assigning a Name amp Selecting a Workgroup 14 12 3 Mapping Network Drive 14 12 4 General Information for Advanced Networks 14 12 5 Network Description of the ProtoTRAK SMX CAD CAM amp Post Processors 14 13 1 Writing a Post Processor 14 13 2 Convertible G Codes 14 13 3 Supported Addresses 14 13 4 Format Terms amp Definitions 14 13 5 G Codes that Generate Errors 14 13 6 Accepted M Codes Sample Programs 156 Sample Program 1 Sample Program 2 TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 1 0 Introduction Congratulations Whether you bought the ProtoTRAK SMX CNC as a retrofit or as the CNC integrated into the TRAK Knee Mill you have an excellent toolroom machine The ProtoTRAK SMX has an easy to use interface and dozens of features that maximize your productivity for any toolroom job Manual Machining is always available and made easier with features like power feed 100 inch per minute rapids tool offsets and all the best features of sophisticated DRO s Two Axis Machining is available at the touch of a button for the prototyping and moderately complex low volume work that is typically done on knee mills Three Axis CNC Machining is also available for retrofit and with the TRAK Knee Mills Programs may be entered at the control or imported
76. NC flash drive it is a good idea to back them up on a floppy disk or to another computer that is networked into the ProtoTRAK SMX CNC That way if the ProtoTRAK SMX CNC flash drive becomes unusable you will have the part programs somewhere else so that you can reload them when the problem with the ProtoTRAK SMX CNC flash drive is resolved 14 9 Converters Converters are programs within the ProtoTRAK SMX CNC that translate CNC program files of another format into a ProtoTRAK SMX CNC file or a ProtoTRAK SMX CNC file into a different format With converters you can run programs written on the ProtoTRAK SMX CNC on a machine that does not have a ProtoTRAK SMX CNC and vice versa Each ProtoTRAK SMX CNC comes with converters for other ProtoTRAK and TRAK CNC s Converters for other brands of CNC s are sold separately Program conversions take place by first translating the file into a neutral run engine then from neutral to the desired file format For this reason you should think of conversions as being only one way The conversion process changes the file in ways that are harmless and so the results are correct However when converted back it will not be the same as it was originally written it will create the same part but some of the lines of code will be different 14 9 1 Activating Converters Converters must be activated before you can use them Standard converters include those that handle the translation between the ProtoTRAK SMX
77. OFFSET RIGHT PASSES 2 FIN CUT 0 0100 Z FEEDRATE 4 0 XYZ FEEDRATE 15 0 FIN FEEDRATE 10 0 TOOL 1 Fi F2 F3 F4 F5 F F7 FB AGE A G E END ABORT MILL ARC AGE AGE FIGURE 10 1 Once the profile header screen is finished you choose between an A G E Mill and an A G E Arc to define the shape Two axis CNC programming will not require Z data Where A G E Mill A straight line from one X Y point to another 94 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual A G E Arc Any part of a circle End A G E Ends the A G E programming for the Irregular Pocket or Irregular Profile Abort A G E Aborts all A G E events The data for all the events is lost 10 2 A G E Mill Prompts Press the A G E Mill key PROG PIN PIN 0812 2 TOOL 1 3 AXIS INCH EVENT 1 IRR PROFILE EVENT2 AGE MILL Ke X BEGIN 0 0000 abs TANGENT Y BEGIN 0 0000 abs XEND 0 0000 abs Z RAPID 0 0500 abs Y END Z END 0 2500 abs CONRAD TOOL OFFSET RIGHT ANGLE END PASSES 2 LENGTH FIN CUT 0 0100 LINE ANGLE Z FEEDRATE 4 0 XYZ FEEDRATE 15 0 FIN FEEDRATE 10 0 TOOL FIGURE 10 2 A G E Mill prompts Enter what you know skip or guess the ones you don t Prompts in A G E Mill programming Tangent this refers to the tangency of the mill to the previous event See Section 10 11 for a discussion of tangency X END is the X dimensi
78. OTATE these 4 events are rotated through a 45 degree angle about a point offset from absolute zero by X Center and Y Center dimensions A is rotated 3 times to produce shape B C and D Press the SUBROUTINE SUB soft key to call up the Repeat Mirror and Rotate options 9 10 1 Repeat Press the REPEAT soft key Where First Event is the event number of the first event to be repeated Last Event is the event number of the last event to be repeated if only one event is to be repeated the Last Event is the same as the First Event X Offset is the incremental X offset from event to be repeated Y Offset is the incremental Y offset from event to be repeated Z Offset is the incremental Z offset from event to be repeated Z Rapid Offset is the incremental Z rapid offset from event to be repeated Repeats is the number of times events are to be repeated up to 99 RPM is the percentage of RPM in the programmed events SET will load in the assumed of 100 RPM programming is available only if the Programmable Electronic Head Option is active Feed the percentage of the feeds programmed in the repeated events 100 is assumed Tool is the tool number you assign 9 10 2 Mirror Advanced Features Option Press the MIRROR soft key First Event is the event number of the first event to be mirrored 86 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming
79. Option is active use the Profile event to accomplish the same thing 74 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 9 6 POCKET Event This event selection gives you a choice between circle pocket rectangular pocket and irregular pocket within the XY plane Pockets include machining the circumference as well as all the material inside the circumference of the programmed shape If a finished cut is programmed it will be made at the completion of the final pass The cutter will arc in and arc out of the finish cut and position itself the finish cut dimension away from the part before moving the tool out of the part The factory setting for tool stepover while machining a pocket is 70 This may be changed When you first enter the pocket event the blue will appear next to the help key Pressing Help will give you the choice of entering a new tool stepover percentage The value you enter here will remain the same until you change it again 9 6 1 Circular Pocket Press the CIRCLE PCKT soft key if you wish to mill a circular pocket Prompts for the circle pocket X Center is the X dimension to the center of the circle Y Center is the Y dimension to the center of the circle Z Rapid is the Z dimension to transition from rapid to feed Z End is the Z dimension at the bottom of the pocket incremental is from the previous event Radius is
80. RAK MX3 mx3 ProtoTRAK MX3E mx3 TRAK AGE3 mx3 TRAK QMV mx3 14 10 2 Opening MX2 and MX3 files on a ProtoTRAK SMX CNC Programs written on previous generation ProtoTRAK and TRAK CNC s may be opened and run on the ProtoTRAK SMX CNC You will need to have the MX2 or MX3 converters activated see Section 14 9 above The ProtoTRAK SMX CNC will automatically convert the file MX2 or MX3 to a PT4 file The original file will remain on the storage device unchanged and the converted file will be in current memory You will have to save the converted file using the procedure in Section 14 4 above in order to place it into storage Note that previous generation ProtoTRAK and TRAK CNCs had a 3 and 4 sided pocket canned cycle This event type will be recognized and run by the SMX CNC but converted into an Irregular Profile event 14 10 3 Running ProtoTRAK SMX Files on ProtoTRAK and TRAK CNC Controls In order to have a program written on a ProtoTRAK SMX run on a previous version ProtoTRAK or TRAK CNC you will need the MX2 and MX3 converters activated see section 14 9 above Save the program as either a MX2 or MX3 file depending on the control or program you want to run 136 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Since there are some feature differences between the CNC s the process will generally yield a useable mx2 or mx3 program b
81. RATION SAFEGUARDING IT S THE RES PONSET OF THE EMPLOYER TO PROVIDE CNC CONTRI S IN THE STOP M FORE CHANGIN s Aar ais a Signi HONG AND ENSU Aral OF OPERATION etal OR ADJUSTING THE TOOL OR WORKPIECE Oar 910 212 MILLING MACHIN 7 SOUTH WESTERN INDUSTRIES or 2615 HOMESTEAD PLACE RANCHO DOMINGUEZ CA 90220 MODEL ____ TRAKK ________ ESen ELECTRICAL RATINGS VOLTS _8 5_JAMPS _3 _ PHASE 60 _ H FLA OF LARGEST MOTOR AMPS SHORT CIRCUIT INTERRUPT AMPS ELECTRICAL DRAWING 20598 1 CNC CONTROL ELECTRICAL RATINGS IF APPLICABLE VOLTS _8 JAMPS 1T PHASE O MACHINE ONLY MADE IN XXXXXX O i00902 Safety amp Information Labels Used On The TRAK Knee Mills It is forbidden by OSHA regulations and by law to deface destroy or remove any of these labels Retrofit customers please see the manual that came with your machine for information about safety and information labels 4 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual HIGH VOLTAGE 220 440 VOLTS WARNING IMPROPER INSTALLATION OR OPERATION OF THIS MOTOR MAY CAUSE INJURY TO PERSONNEL OR MOTOR FAILURE READ OPERATING INSTRUCTIONS MOTOR MUST BE INSTALLED AND GROUNDED PER LOCAL AND NATIONAL ELECTRICAL CODES TO REDUCE POTENTIAL OF ELECTRICAL SHOCK DISCONNECT ALL POWER SOURCES BEFORE INITIATING ANY MAINTENANCE OR REPAIRS KEEP FINGERS AND FO
82. REIGN OBJECTS AWAY FROM VENTILATION AND OTHER OPENINGS KEEP AIR PASSAGES CLEAR EYEBOLTS OR LIFTING HOOKS WHEN SUPPLIED ARE INTENDED FOR LIFTING THE PRODUCT ONLY AND MUST NOT BE USED TO LIFT ADDITIONAL WEIGHT USE ONLY GRADE 5 SHOULDER EYEBOLTS WITH MINIMUM THREAD LENGTH OF 1 1 2 TIMES DIAMETER Safety amp Information Labels Used On The ProtoTRAK SMX CNC It is forbidden by OSHA regulations and by law to deface destroy or remove any of these labels 5 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 2 3 Safety Precautions 1 10 11 12 13 14 15 Do not operate this machine before the ProtoTRAK SMX CNC Safety Installation Maintenance Service and Parts List Manual and the Safety Programming Operating amp Care Manual have been studied and understood Do not run this machine without knowing the function of every control key button knob or handle Ask your supervisor or a qualified instructor for help when needed Protect your eyes Wear approved safety glasses with side shields at all times Don t get caught in moving parts Before operating this machine remove all jewelry including watches and rings neckties and any loose fitting clothing Keep your hair away from moving parts Wear adequate safety headgear Protect your feet Wear safety shoes with oil resistant anti skid soles and steel toes
83. RREG PCKT soft key if you wish to mill a pocket other than a rectangle or circle The Irregular Pocket event gives you the powerful Auto Geometry Engine to define a shape made up of straight lines Mills and arcs The first screen in an irregular pocket event will define the beginning point and some of its general parameters The last event of the irregular pocket must end at the same point as defined in the first event X Begin is the X dimension of the beginning of the pocket 60 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Y Begin is the Y dimension of the beginning of the pocket Fin Cut is the width of the finish cut If 0 is input there will be no finish cut Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Fin Feedrate is the finish cut milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Tool is the tool number you assign When the initial screen is complete you will define the perimeter of the pocket with a series of A G E Mills and A G E Arcs Programming with the Auto Geometry Engine is explained in Section 10 0 No islands may exist in an irregular pocket 8 5 4 Tool Path in Pocket Events In Program Run the ProtoTRAK SMX will first direct the cutter along a path to rough out all the material inside of the perimeter and then will do a rough cut along the inside of the peri
84. Retrofit Safety Programming Operating amp Care Manual EVENT 10 AGE MILL NOTES Tangent 1 Selects tan mill X End Press Page Forward now as no further Y End data is required Conrad Angle End Length 1 1648 Line Angle EVENT 11 AGE ARC NOTES Tangent 1 Selects tan arc Direction 1 CW X End data forward Unknown value not required Y End data forward Unknown value not required X Center 2 43 abs Known print dimension Y Center 4 55 abs Known print dimension Conrad data forward Radius 0 175 abs Known print dimension Chord Length Press Page Forward now as no further Chord Angle data is required EVENT 12 AGE ARC NOTES Tangent 1 Selects tan arc Direction 1 CW arc X End Data Forward Unknown data Y End Data Forward Unknown Data X Center Data Forward Unknown Data Y Center Data Forward Unknown data Conrad Data Forward Radius 9 abs Radius of Arc Chord Length Press Page Forward now as no further Chord Angle data is required EVENT 13 AGE ARC NOTES Tangent 1 Selects tan arc Direction 2 CCW X End 1 02 abs Known print dimension Y End 5 505 abs Known print dimension X Center 1 17 abs Known print dimension Y Center 5 505 abs Known print dimension Conrad Press Page Forward now as no further Radius data is required Chord Length Chord Angle Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care
85. SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual these cases the ProtoTRAK SMX can handle the files more efficiently by running the G Code directly While running the G Code file directly does not give you the benefit of the easy programming format of the ProtoTRAK SMX you are not likely to be able to use this benefit with a very large or complex file anyway To run the G Code file directly open the file using OPEN AS G Code GCD The entire program will be brought into current memory You will be able to view the tool path when you run the program in the Run Mode but you will not be able to edit the program or view it in the Program Mode In order to edit the program use the G Code Editor in the Edit Mode Section 10 5 14 11 1 G Codes Recognized by the ProtoTRAK SMX CNC G ae Position at maximum feedrate G00 X0 0 Y0 0 Z0 0 c01 Linear Interpolation G01 X0 0 Y0 0 Z 1 F15 F Feedrate in Inches per minute Circular Interpolation Clockwise G02 X1 Y2 ZO 10 J2 KO lyd e aine Ne Ay Y a Z centerpoints respectively incremental from the starting point G01 G02 G03 G06 07 j j 3 of the arc Circular Interpolation Counter G03 X2 YO ZO 12 JO KO clockwise Helix Clockwise GOPAN ees MAJIN K defines the incremental center point in Z of the first revolution Helix Counter clockwise GOL AO oe ea D defines the of revolutions Select XY Plane Select XZ Plan
86. SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual explained more fully in Section 7 5 This function is part of the Advanced Features Option Dimension Definition The ProtoTRAK SMX CNC gives you a choice in programming either tool path or geometry Part Geometry programming allows you to define the geometry you want your part to have and then the CNC does the difficult job of calculating tool path for you automatically This is a great benefit for most parts most of the time because it means that the CNC is doing the hard work of determining tool position One restriction to part geometry programming is that for events to be connective they must lay on the same plane see Section 5 3 for a definition of planes For this reason the ProtoTRAK SMX CNC gives you the option of entering your own tool path If you wish to program the part by defining tool path yourself you may choose the TOOL PATH softkey Otherwise Part Geometry programming is assumed Tool Path operates under the same rules as standard RS274 A program must be entirely written in Part Geometry or Tool Path programming you cannot combine the two methods in one program Tool Path programming is part of the Advanced Features Option 7 3 3 Program Header Softkeys The following softkeys are encountered in the Program Header Screen The first five listed below are always there The last four appear when relevant to the general programm
87. TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Document 24493 Covers Models Version 032015 Retrofit PTSMX2 PTSMX3 TRAK Knee Mill with 2 Axis CNC TRAK K2SX TRAK K3SX TRAK K4SX TRAK Knee Mill with 3 Axis CNC TRAK K2SX 3 TRAK K3SX 3 TRAK K4SX 3 Southwestern Industries Inc 2615 Homestead Place Rancho Dominguez CA 90220 5610 USA T 310 608 4422 F 310 764 2668 Service Department 800 367 3165 e mail sales southwesternindustries com service southwesternindustries com web southwesternindustries com Copyright 2015 Southwestern Industries Inc All rights are reserved No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means mechanical photocopying recording or otherwise without the prior written permission of Southwestern Industries Inc While every effort has been made to include all the information required for the purposes of this guide Southwestern Industries Inc assumes no responsibility for inaccuracies or omission and accepts no liability for damages resulting from the use of the information contained in this guide All brand names and products are trademarks or registered trademarks of their respective holders Southwestern Industries Inc 2615 Homestead Place Rancho Dominguez CA 90220 5610 Phn 310 608 4422 Fax 310 764 2668 Service Department Phn 800 36
88. TRAK will recognize the file as a CAM file and convert it into ProtoTRAK events when it is opened File names may include up to 20 alpha numeric characters 14 13 2 Convertible G Codes The following G codes may be used in a CAM file that you want to have converted to a ProtoTRAK program G Codes that are not on the list below have no correspondent Operation in the ProtoTRAK events and will be ignored when the program is converted 151 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual If a G Code is essential to your program and you do not see it here you can do one of two things Convert the file from CAM to ProtoTRAK and add an event to the resulting ProtoTRAK program Run the program as a GCD file See Section 14 11 G Codes Recognized by the ProtoTRAK SMX CAM G Position at maximum feedrate GOO X0 0 Y0 0 Z0 0 NS ogee el Linear Interpolation G01 X0 0 YO 0 Z 1 F15 F Feedrate in Inches per minute Circular Interpolation G02 X1 Y2 ZO 10 J2 Ko l J amp K define the X Y amp Z Clockwise centerpoints respectively Circular Interpolation incremental from the starting point Counter clockwise G03 X2 YO Z0 I2 JO KO of the arc Input in Inch 2 Input in Metric Cutter compensation cancel Cuttter compensation left Cutter compensation right fixture offset 1 Base offset fixture offset 3 fixture is being used Fix
89. The Auxiliary functions consist of the following e Spindle off command e An air solenoid to control spray coolant or other pneumatically activated peripheral equipment Shop air should not exceed 125 psia e Switched and fused 120 VAC 8 Amp outlet for coolant pumps automatic oilers etc e INPUT OUTPUT to interface with programmable indexers dividing heads etc o Output from ProtoTRAK SMX CNC is an actuation of a solid state relay between pin 3 plus and pin 4 minus o Input to the ProtoTRAK SMX CNC is an actuation of a solid state relay between pin 1 plus and pin 2 minus o Note Pin 1 is on top 2 on right 3 on left 4 on bottom 3 4 5 Power Draw Bar A manual draw bar comes standard with the machine A power draw bar option may be ordered For the TRAK K4 or other NMTB 40 machines the draw bar included in the option may be CAT or NMTB NST An NMTB NST type of draw bar is the appropriate length to fit tool holders that have a threaded tang on the top The CAT type is longer to thread into CNC tool holders that have the tool changer grip or retention knob removed 3 4 6 Remote Stop Go Switch For the convenience of operation while running the program a Remote Stop Go switch may be purchased This switch is on a ten foot cable and operates like the FEED Stop and Go keys on the display 3 4 7 Work Light An optional halogen work light is available It mounts to the left side facing of the column and plugs into a 110
90. UCHOFF REFERENCE POINT This is prompting you to establish a reference for the rest of your tools 2 To establish a reference put a cutting tool or some other reference setting tool into the spindle and touch the tool to a surface We recommend that you use something besides a tool that you intend to use machining the job Ideally you will have a reference tool that you keep handy for setting up your tools every time That way a reference point can be easily re established later 3 We also recommend that you use the top of the vice or table as your reference surface because it is constant and never changes 4 With the highlight on the screen on the words NOT SET and the tool touching some reference point press SET NOTE If you do use a tool as your reference tool and it breaks you must retouch off all tools 5 The words will change from NOT SET to SET and the highlight will shift to the DIAMETER column of Tool 1 Note that you may not be interested in setting up Tool 1 if it is not one of the active tools of the program If this is the case use the DATA softkeys to move to a tool you are interested in 6 Input the diameter for the tool and press SET 7 The highlight will move to the Z OFFSET column Put this tool in the spindle and touch it to the same surface as you used to touch the reference tool in Step 2 above Press set The highlight moves to the Z Modifier column Input and set a Z modifier if you wish see below
91. UPPORTED PROGRAMS ONLY With a highlighted YES or NO PROGWO Posy BAXS INCH List Supported Programs Only YES ee Fi F2 F3 Fa F5 F F FB BACK UP YES NO OPEN SAVE COPY eere renane FIGURE 14 0 Supported programs are part programs that can run on the ProtoTRAK SMX CNC You do not have to answer this question every time you are at this screen Simply press the softkey for the operation you want Supported programs are the programs that will run on your ProtoTRAK SMX CNC Itis possible to view other types of files through the Program In Out Mode for example Microsoft Word files This type of file is not supported on the ProtoTRAK SMX CNC in the sense that you cannot open it and work on it We recommend a Yes response to this prompt Filenames and File Extensions Most places in the ProtoTRAK SMX CNC we refer to the program or part In Program In Out Mode this program or part is called a file Filenames are program names or part names They are the name you give to the programs you write on the ProtoTRAK SMX CNC plus a file extension Although the ProtoTRAK SMX CNC can have program names up to 25 characters that use letters and special symbols most other CNC s must have file names that are eight or fewer characters using numbers only File extensions are part of filenames that help describe the file They appear after the filename and are composed of three letters following a period For
92. Z Modifiers 12 1 8 Resetting the Reference Point 12 1 9 Saving Tool Information 12 1 10 Opening a Program 12 1 11 Making Tool Set Ups Easy 12 1 12 The Tool Table amp Two Axis CNC Operation Tool Path 12 2 1 Soft Keys in Tool Path Reference Positions REF POSN 12 3 1 ZRetract 12 3 2 Home Positions 12 3 3 Limit Positions Fixture Offsets Verify Part Service Codes RUN MODE 121 Run Mode Screen Two vs Three Axis Running Starting to Run Program Run TRAKing Program Run Messages Stop Feedrate amp Speed Overrides Trial Run Data Errors Fault Messages Program In Out Mode 126 Softkey Selections in the Program In Out Mode Basic Navigation of Program In Out Mode Screens 14 2 1 Basic Parts of the Program In Out Mode Screens 14 2 2 Softkeys in the Program In Out Mode Screens Opening a File Saving Programs Copying Programs Deleting Programs Renaming Backing Up Converters 14 9 1 Activating Converters 14 9 2 Converting from a Different Format into a ProtoTRAK SMX CNC Converting from a ProtoTRAK SMX CNC to a Different Format ProtoTRAK amp TRAK CNC Compatibility 14 10 1 File Formats 14 10 2 Opening MX2 amp MX3 Files on a ProtoTRAK SMX CNC 14 10 3 Running ProtoTRAK SMX Files on ProtoTRAK amp TRAK CNC Controls Running G Code Files 14 9 3 14 12 14 13 15 0 15 1 15 2 14 11 1 G Codes Recognized by the ProtoTRAK SMX CNC 14 11 2 M Codes Supported by the ProtoTRAK SMX C
93. above in the section on basic navigation Three additional parts of the screen appear once the SAVE softkey is pressed 128 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual PROG VO l PIN 0807 l E AXIS l INCH SAVE Look In Jaa B E 0807 2 PT4 E SWI 2615 PT4 File Name 0807 Save As FS RETURN F4 OPEN FOLDER F CREATE FOLDER TAB FIGURE 14 4 The Save screen File Name displays the name of the file that is in current memory Save As lists the formats for which the file may be saved The default is PT4 Three additional softkeys appear CREATE FOLDER Use this to create a new folder for the program file This new folder will be added to the list shown in the listing area at the same level of organization as the files and folders shown Once the CREATE FOLDER softkey is pressed a Data Input Line will appear for entering the name of the folder The name Folder1 will be written in the box To accept this name press SET You may input a name you select by writing over this name Use the same procedure for naming a program see Section 7 3 1 SAVE FILE Saves the program file to the location shown in the Look In area RETURN Returns to the Program In Out Mode screen Once the save operation is finished you will see the file name added to the files in the listing area
94. ach step You may stop verification by pressing the STOP key and continue again using the GO key use S and G on offline 117 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual SIMULATION ON SPEED 1 STATUS STOP TOOLNO 4 Press SHOW PART to simply show the final result Press EXIT or MODE to exit the verification and go back to the DEFINE STOCK page 2 Axis Verify Software When using VERIFY software on 2 axis products or 2 axis mode on a 3 axis products you can enter the depth you wish to have the tool feed down to during simulation by adding event comments to certain events in your program The Z value only needs to be entered on the first event if multiple events are at the same depth In other words if your program has 10 events with events 1 through 5 being machined at a depth and events 6 through 10 at a 3 4 depth you only need to enter event comments on events 1 and 6 The format by which you should enter the Z value is as follows in the event shown The event below calls out for the tool to go to a 1 2 depth You must call out all depths as negative numbers You can also add additional event comments before or after the Z 5 information below EVENT 4 MILL Y BEGIN 3 0160 abs X END 3 2990 abs Y END 1 6660 abs CONRAD 0 0000 TOOL OFFSET LEFT RPM 2000 00 FEEDRATE 10 0 TOOL 1 EVENT COMMENTS Z 5 CONTINUE NO 118
95. akes the drawing larger ZOOM OUT makes the drawing smaller ENTER END when the cursor is at the point you want to use as a guess use this to enter the end point of a line or an arc ENTER CENTER use this to register a guess for the center of an arc You can enter a combination of guessed and non guessed data For example if you were to enter the dimension for X End without guessing you would still be able to enter the dimension of Y End using guess 98 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Your guess entries are loaded into the program when you exit the LOOK screen by pressing BACK or by pressing LOOK again The ProtoTRAK will use the last ENTER key press and load that into the program When you use the graphics to guess dimensions on arcs you may load in guesses for both the X Y End and the X Y Center before leaving the LOOK screen When you have not first pressed the Guess key pressing LOOK gives you the same screen as in regular programming Whether you enter the guesses as key presses or by using the graphics the drawing of the LOOK screen distinguishes between events that are fully defined and those that rely on guessed data OK events are represented by solid lines NOT OK events are represented by dashed lines PROG PIN 080701 SAXIS INCH Fi F2 F3 F4 F5 F F7 FS ADJUST FIT LIST START VIEW DRAW ST
96. alculate Math Helps are powerful routines that enable you to use the data you have available to calculate missing print data For example Math Help type 28 enables you to solve an entire right triangle by giving two known pieces of data To exit from the Math Help press the Mode key 28 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual MAH _PINBRKTOOS f BAXS INCH Triangle A 1 6000 B C G 27 5000 H Solution 4 of 1 A 1 6000 B 3 0736 c 3 4651 G 27 5000 H 62 5000 Fi F2 F3 F4 F5 F F FS EDIT RETURN FIGURE 4 1 6 2 Math Help 28 In this example by entering the length of line A and the value of angle G the other values are calculated You may have the Math Help solutions load directly into your program This saves you from having to write down the solution and then key it in While you are programming the event that needs the data from Math Help simply press the HELP key to start the Math Help Once a solution is obtained you will have the following soft key selections Load Begin will load the displayed solution into the event as the X and Z beginning Load End will load the displayed solution into the event as the X and Z end Load Center will load the displayed solution into the event as the X and Z center Next Solution when there is more than one solution to the problem this will display the alternat
97. am is being written it is in current memory Storage of programs can be done on a USB device or on a disk in the floppy drive We strongly recommend you habitually back up programs When the Network Option is purchased program storage can also be saved to an offline computer that is networked to your SMX CNC 42 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 6 0 DRO MODE The ProtoTRAK SMX CNC operates in DRO Mode as a sophisticated 3 axis digital readout with jog and power feed capability 6 1 Enter DRO Mode Press MODE select DRO soft key The screen will show DRO ie eoo INCH X 0 0000 ves Y 0 0000 ss Z 0 0000 ves Gee Spindle RPM 1000 10 100 450 Override 100 Feed Rate 250 0 10 100 150 Override 100 Fi F2 F3 F4 F5 F F7 FS POWER DO GO RETURN SPIN TOOL oe FEED ONE TO Bees ABSO SPEED FIGURE 6 1 The DRO screen Note the RETURN soft key is lit when in Jog or Power Feed operation 6 2 DRO Functions Clear Entry Press RESTORE then re enter all keys Inch to MM or MM to Inch Press IN MM and note LCD screen status line Reset One Axis Press X or Y or Z INC SET This zeros the incremental position in the selected axis Preset Press X or Y or Z numeric data INC SET to preset selected axis Reset Absolute Reference Press X or Y or Z ABS SET to set selected axis absolute to ze
98. ammed event s One new tool number may be assigned for each Repeat Event MIRROR Advanced Features Option is used for parts that have symmetrical patterns or mirror image patterns In addition to specifying the events to be repeated you must also indicate the axis or axes X or Y or XY are allowed that the reflection is mirrored across In addition you must specify the offset from absolute zero to the line of reflection You may not mirror another mirror event or mirror a rotate event Consider the figure below LINE OF ee S X OFF SET 1 100839 FIGURE 9 10 1 Holes 1 4 are mirrored across the Y axis to 5 8 respectively about a line X OFFSET from X absolute 0 ROTATE is used for polar rotation of parts that have a rotational symmetry around some point in the XY plane In addition to specifying the events to be repeated you must also indicate the absolute X and Y position of the center of rotation the angle of rotation measured counterclockwise as positive and clockwise as negative and the number of times the specified events are to be rotated and repeated You may not rotate another rotate event however you can rotate a mirror event Consider the figure below 85 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Y CENTER L NZ 0 0 ABSOLUTE X CENTER i00840 FIGURE 9 10 2 Shape A programmed with 4 MILL events and Conrads Using R
99. angular pocket Both the shape of the island and the dimension of the surrounding pocket are defined within the island event The tool path for machining the island event is that the tool will machine the perimeter of the island offset by the island finish cut Then the tool will machine the material in the pocket in a spiral path moving away from the island in the programmed clockwise or counterclockwise direction It will continue this outward spiral motion until it encounters the programmed rectangular perimeter or pocket It will then follow the perimeter offset by the pocket finish cut 8 6 1 Circular Island Advanced Features Option When the Advanced Features Option is active press the Circle Island soft key if you wish to mill a circular island Prompts for the Circular Islands X CENTER is the X dimension of the center of the Island Y CENTER is the Y dimension of the center of the Island RADIUS is the finish radius of the Island DIRECTION is the milling direction clockwise or counterclockwise FIN CUT ISL Finish cut for the Island If 0 is input there will be no finish cut X1 POCKET X dimension for one corner of the rectangular pocket that surrounds the island Y1 POCKET Y dimension for one corner of the rectangular pocket that surrounds the island X3 POCKET X dimension for the opposite corner of the rectangular pocket that surrounds the island Y3 POCKET Y dimension for the opposite corner of the rectangular
100. ap Network Drive is covered above in Section 14 12 3 under On the ProtoTRAK SX for the basic peer to peer network 14 12 5 Network Description Of The ProtoTRAK SX The following data may be useful to Network Administrators or advanced users in setting up a more advanced network Operating System Windows XP Embedded w SP2 Processor Celeron 400 Memory RAM 256MB Disk Optional 256MB or higher USB Thumb Drive flash Floppy drive yes Network 10 100 base T Ethernet Ports available LPT1 USB1 and 2 PS2 for keyboard System software not accessible to the user 148 Southwestern Industries Inc TRAK SX Knee Mill amp Proto TRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Default password Default user name ADMINISTRATOR Network settings TCP IP Default protocols TCP IP Network log in Auto TCP IP set up obtain IP address automatically DNS Auto Gateway Not used Wins configuration Use DHCP for wins resolution There are several command line utilities available from the CMD prompt that are useful in setting up a network The following are three utilities and an example of the information that is returned IPCONFIG all Windows IP Configuration Host Name a 4 Primary Dns Suffix Node Type Enes IP Routing Enabled WINS Proxy Enabled Ethernet adapter INTEL LAN Connection specifi Description z Physical Address Dhcp Enabled Ts c DNS Suffix E
101. backwards through the table va 4 gt highlights data for editing Only data that is highlighted and appears in the Data Input Line may be edited Note the EVT event number and event TYPE may not be edited in Search Edit so the highlighter will not go there SORT enables you to change the sort to any of the data displayed See Section 11 2 2 CHANGE ALL enables you to make global changes of data See 11 2 3 11 2 1 Selecting Data to be Displayed on the Search Edit Table In order to change the data selected in the table press the HELP hard key There will be a listing of all the data types that may be edited in Search Edit Press the RETURN soft key and the table will be reloaded with the data that you selected EDT PIN R0424 11 B AXIS INCH RPM X BEGIN Z CENTER FIN RPM Y BEGIN X1 Z FEED Z BEGIN Y1 XYZ FEED X END X3 FIN FEED Y END Y3 Z RAPID Z END PASSES CONRAD X CENTER FIN CUT Fi F2 F3 F4 F5 F F FS v a 4 b RETURN FIGURE 11 2 2 Pressing Help while viewing the spreadsheet lets you change the program parameters After you press the HELP hard key the screen will display all the different parameters that can be displayed on the spreadsheet To either select or deselect any parameter simply highlight that parameter and press SET When you are finished press the Return softkey and return to the spreadsheet 102 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety
102. before the perimeter finish cut Whether the cuts to clear the interior material of the irregular pocket are along the X or Y axis depends on if there are hidden areas of the pocket The ProtoTRAK SMX CNC always looks to cut along the X axis first If there are areas that are hidden to the X axis it will machine along the Y axis If there are hidden areas that cannot be machined continuously in the X or Y axis the tool will return to Z retract and then reposition to machine the hidden area 9 6 5 Zigzag Z Depth Cuts In programming pocket events you have a choice to program the cuts to Z depth either as a plunge or a zigzag ramp For rectangular and circular pockets the tool will start in the center of the pocket For irregular pockets since there is no center defined the tool will start in the lower left corner of the pocket The direction of the ramp will be the same as the initial direction in either X or Y depending on how the pocket is to be cut The tool will zigzag back and forth along the X or Y over a length of one tool radius while at the same time moving in the Z direction When it travels one tool radius along this direction it will have traveled a distance of ten percent of the tool diameter along the Z This works out to roughly ramping into the part at an angle of 11 degrees In order to use a zigzag ramp the X or Y move must be larger than the diameter of the tool plus the radius of the tool minus the finish cut of the poc
103. ble Loading a new driver is not difficult for a qualified computer administrator who can access the start menu on the ProtoTRAK with a keyboard plugged in see the Catch 22 However most users would be happier to simply go get a keyboard and mouse that are already supported We recommend Microsoft Logitech and Belkin brand products AC on off The ProtoTRAK should be shut down properly before turning off Section 4 1 2 18 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 3 3 TRAK Knee Mill Specifications see Figures 3 3 1 and 3 3 2 This section describes the TRAK Knee Milling machines it does not apply to ProtoTRAK SMX retrofits SPINDLE MOTOR SPINDLE BRAKE XAXIS MOTOR ASSEMBLY Y AXIS HANDWHEEL ASSEMBLY aun FIGURE 3 3 1 The TRAK Knee Mill Machine Overview Note Machine shown above is in the two axis CNC configuration 19 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual ELECTRICAL i00888 FIGURE 3 3 2 The TRAK Knee Mill back view 20 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual TRAK K2SX TRAK K3SX TRAK K4SX ProtoTRAK SMX CNC ProtoTRAK SMX CNC ProtoTRAK SMX CNC 2 Axis CNC 3 Axis DRO 2 Axis CNC 3 Axis DRO 2 Axis CNC 3
104. bottom of the pocket incremental is from the previous event CONRAD ISL the value of the tangential radius in the corners of the island DIRECTION is the milling direction clockwise or counterclockwise PASSES the number of roughing passes to the depth ENTRY MODE choose between zigzag ramp and plunge The plunge will machine straight down Z to the appropriate Z depth The zigzag ramp will move in a zigzag pattern to depth See the previous section for more information about the zigzag ramp FIN CUT ISL Finish cut for the Island If 0 is input there will be no finish cut See the previous section for a bottom finish cut X1 POCKET X dimension for one corner of the rectangular pocket that surrounds the island Y1 POCKET Y dimension for one corner of the rectangular pocket that surrounds the island X3 POCKET X dimension for the opposite corner of the rectangular pocket that surrounds the island Y3 POCKET Y dimension for the opposite corner of the rectangular pocket that surrounds the island CONRAD PCKT the value of the tangential radius in the corners of the rectangular pocket that surrounds the island RPM is the spindle RPM for the event INC SET will use the RPM of the previous event RPM programming is available only if the Programmable Electronic Head Option is active 80 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual FIN RPM
105. brication System The way and ballscrew lubrication is wired to operate while the spindle is running Factory Default Values Interval Time 60 min Discharge Time 15 sec Discharge Pressure Approximately 100 150psi To adjust the amount of Discharge Pressure displayed on the lube pump gauge loosen the jam nut and turn the adjustment screw located on the top right side of the lube pump while the lube pump is activated To activate the lube pump turn spindle on and press the Feed for continuous pumping and RST for a single programmed pump CAUTION Failure to lubricate the mill will result in the premature failure of bearings and sliding surfaces CAUTION Failure to manually activate the pump at the beginning of each day or allowing the Auto Lube to run dry may cause severe damage to the mill s way surfaces and ballscrews The settings for the lube pump can be viewed by doing the following press Service Codes press A software press Code 313 This screen lists the values programmed for the cycle time and discharge time 3 5 Servo Motors The servo motors on table saddle and ram are 280 in oz torque Integrated into each motor is an encoder with 0 0000364 underlying resolution 24 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 3 6 3 7 3 8 3 9 Ballscrews For both retrofit and TRAK Knee Mills precisio
106. d direction of tool cutter movement Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Fin Cut is the width of the finish cut If 0 is input there will be no finish cut Fin Feedrate is the finish cut milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Tool is the tool number you assign When the initial Irregular Profile screen is complete the rest of the profile is programmed using A G E Mill and A G E Arc events Programming with the Auto Geometry Engine is explained in Section 10 0 Irregular Profile and Auto Geometry Engine programming is part of the Advanced Features Option 65 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 8 8 Engrave Event Advanced Features Option The Engrave Event allows you to machine numbers letters and special characters as part of a part program See figure 8 8 below for the letters and special characters that are available in the Engrave Event When programming with the Engrave Event the ProtoTRAK will construct a box to contain the text you define This box is oriented along the X axis like the text in this sentence and you may program up to 40 characters per event although you will only be able to see 20 characters on the prompts screen To machine text in a direction other than the X axis simply use multiple Engrave Events and place the lower le
107. de the ProtoTRAK from programs such as Windows Server Update Service where the software will automatically try to download updates to the control 155 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 15 0 Sample Programs 15 1 Sample Program No 1 Basic 21 2 Axis This program is designed to give you practice on programming 2 axis Program events for 3 axis CNC programming To practice on 2 axis CNC simply ignore the Z prompts The Program All programs start by first selecting Program from the front panel softkeys You may enter in an alphanumeric program description or simply press Go to Begin to get started Start your program by selecting Pocket and then Circle Pocket Sample Drawing 2 156 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual EVENT 1 CIRC PCKT NOTES X Center abs set Sets the pocket center to X zero Y Center abs set Sets the pocket center to Y zero Z Rapid 1 abs Sets the Rapid plane to 0 1 Z End 6 abs Sets the pocket depth to 0 6 Radius 1 25 abs Sets radius of pocket to 1 25 Direction 2 abs Makes the cut direction CCW of Passes 2 abs Cuts the pocket using two 2 depths Entry Mode 1 abs Makes the tool ramp into the material Fin Cut 01 abs Takes a 0 01 cut to finish the pocket Z
108. does not drop below the AB line and therefore never touches point B As a result a fillet is formed at point B equal to the tool radius This second example of continuous machining from one cut AB to another BC with full cutter compensation between requires the two cuts to be made with events which are connective see Section 5 9 or 5 10 for a more complete discussion of this requirement 40 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 5 9 Connective Events Connective events occur between two milling events either Mill or Arc when the X Y and Z ending points of the first event are in the same location as the X Y and Z starting points of the next event In addition the tool offset and tool number of both events must be the same And both events must lie in the XY plane or the same vertical plane see Section 5 2 5 10 Conrad Conrad is a unique feature of the PROTOTRAK SMX CNC that allows you to program a tangentially connecting radius between connective events or tangentially connecting radii for the corners of pockets and frames without the necessity of complex calculations For the figure below you program an Arc event from X1 Y1 to X2 Y2 with tool offset left and another Arc event from X2 Y2 to X3 Y3 also with tool offset left During the programming of the first Arc event the system will prompt for Conrad at which time yo
109. e G3 Select YZ Plane c20 _sinputininch oe o ooo S O Ger _InputinMetic SOC iS CDSSSCUUUUCUC dYUUOOOO O OCOCSY G40 Cutter compensation cancel co O D o o G41 Cutter compensationlet lt on O o o o G42 Cutter compensation right oa D o O The offset difference from each AEE a ey on our control Will feed into exact position at G61 Exact Ston movement intersection points before p proceeding to next event May hesitate briefly G 6 G61 64 Blending movement G64 Will blend intersection points together for smoother motion G80 8 Cannedcyclecancel c SSS y O Z final depth G81 Drilling cycle G81 X0 YO Z 1 R 1 F15 R rapid position 138 Southwestern Industries Inc TRAK SX Knee Mill amp Proto TRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual G82 Drilling cycle dwell at bottom GORAN or Poitou P dwell time in milliseconds G83 Peck drilling cycle ae wore S R Q depth of peck For machines with programmable G84 Tapping cycle BOs A NO L ATE B209 spindle only S defines RPM F15 Pitcth F S Boring cycle G85 X0 YO Z 1 R1 F15 o Boring cycle dwell at bottom G89 X0 YO Z 1 R 1 P800 F15 P dwell time in milliseconds Absolute programming G90 Incremental programming G91 G98 Return to initial point in canned G98 cycle Return to R point in canned cycle G99 14 11 2 M Codes Supported by t
110. e Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 12 3 1 Z Retract Three Axis CNC Models The Z Retract is where the head will go for a tool change or at the end of running a program Programs may not be run in three axis CNC until the Z Retract is set Since the Z axis head is operated manually in two axis CNC it is not necessary to set the Z retract to run a two axis CNC part As a general rule always set your Z retract so that your longest tool is above the set up When you first enter the Reference Positions screen the Z Retract will show NOT SET and the message window will instruct you to move the quill to the desired retract position and then press SET You may have to go into the DRO Mode to move the quill to where you want it and then return to the Reference Positions screen to set this position 12 3 2 Home Positions Three Axis CNC Models X and Y home positions are where the table and saddle go when there is a tool change or at the end of the program These dimensions must always be from absolute zero Note Z home is the same as Z Retract 12 3 3 Limit Positions X and Y limit positions one for plus direction one for minus will stop the program if they are exceeded during run Note that pressing the LIMIT ON OFF soft key will turn the prompted limit off or back on to its input value If the limits are turned on your program and home positions must fit within the limits you define
111. e optional for three axis models 27 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual only With the Auxiliary Functions set up manual control of the coolant system is through the Accessory key on the front panel of the SMX CNC To operate the mister or coolant pump manually use the ACCESSORY hard key e ON will turn on the mister or coolant pump until you turn it off e AUTO will turn on the mister or coolant pump on as programmed into events e Off no light the coolant pump or mister stays off 4 1 6 Help Functions When a blue question mark appears next to the HELP hard key that means special functions or configuration settings are available for the current operation For example at the program header with the highlight on the program name the blue question mark appears Pressing the HELP key at that time will call up a table with alpha and special characters you can use to name your program Math Helps When the blue question mark does not appear pressing HELP will initiate the Math Helps MATH PINBRKTOOS BAXS INCH Line Line Intersection Line Arc Intersection Arc Arc Intersection Line Arc Tangency Centers Points Radius Angles Polar Cartesian Transformation Calculator A B Cc D E F G FIGURE 4 1 6 1 The first Math Helps screen Choose among the alternatives based on the information you need to c
112. e rotated through a 45 degree angle about a point offset from absolute zero by X Center and Y Center dimensions A is rotated 3 times to produce shape B C and D Press the SUBROUTINE SUB soft key to call up the Repeat Mirror and Rotate options 8 9 1 Repeat Press the REPEAT soft key Where First Event is the event number of the first event to be repeated Last Event is the event number of the last event to be repeated if only one event is to be repeated the Last Event is the same as the First Event X Offset is the incremental X offset from event to be repeated Y Offset is the incremental Y offset from event to be repeated Repeats is the number of times events are to be repeated up to 99 Feed the percentage of the feeds programmed in the repeated events 100 is assumed Tool is the tool number you assign 8 9 2 Mirror Press the MIRROR soft key First Event is the event number of the first event to be mirrored Last Event is the event number of the last event to be mirrored if only one event is to be mirrored the last event is the same as the first Cutting Order input 1 to cut from the lowest mirrored event to the highest forward and 2 to machine from the highest mirrored event to the lowest backward This way you can keep all the machine motion in a consistent direction as it moves from the original shape to the mirrored shape and keep all cutting either climb or conventional
113. e that Z rapid is set high enough to compensate for the amount of float in the floating tapping head Z End the depth of the thread PITCH the distance from one thread to the next in inches or mm It is equal to one divided by the number of threads per inch For example the pitch for a 1 4 20 screw is 1 20 05 inches RPM spindle RPM Tool is the tool number you assign 9 14 1 SX Knee Mill Tapping Speed Recommendations A aluminum only AS aluminum and steel 3 HP machines K2 amp K3 Tap Size 40 100 200 300 500 750 1000 vs RPM 4 40 AS AS AS AS A 8 32 AS AS AS AS AS A Y 20 AS AS AS AS AS AS A 3 8 16 AS AS AS AS AS AS Y 13 AS AS AS AS A 5 8 11 AS AS A 5 HP machine K4 Tap Size 40 100 200 300 500 750 1000 vs RPM 4 40 AS AS AS AS A 8 32 AS AS AS AS AS A Y4 20 AS AS AS AS AS AS A 3 8 16 AS AS AS AS AS AS 2 13 AS AS AS AS AS 5 8 11 AS AS A A 4 10 AS AS A nterpolate speeds for tap sizes in between the ones noted in the table 90 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 9 14 2 Tapping Notes and Recommendations e RPM and pitch programmed may not exceed 50 ipm Feedrates above this limit will create an error e Harder materials will require slower speeds and tap size may also be li
114. ed usually by a cable so they may share information Networks within a single building are called LANs for Local Area Network The benefit of networking is that you can move information easily between computers This ease of use enables some handy functionality for example 1 An effective file Back up routine File back ups are essential if you want to retain programs for future use Any hard drive or floppy drive could fail Having program files backed up to a different location saves you from rewriting the programs from scratch if a failure occurs 2 An easy way to import CAD CAM or DXF files from other computers 3 An effective revision control Having a single shared folder on the network enables you to have a single location with all the latest versions of the programs Of course the above functions are possible without a network by shuttling floppy disks around The reason to have a network is that it saves time Once it is set up you can do repetitive functions without much work For example if a particular job requires you to run a CAM file that you don t have on the ProtoTRAK SX already going to the pre arranged networked location using the Program In Out of the SX gets you going right away Without networking someone has to make you a disk or USB drive with the file on it Another example is program file back ups With networking you can back up with a simple routine in the Program In Out Mode Without networking you must
115. en will cause your original guessed data to reappear 10 8 LOOK and Guess Guessed data may be entered by pressing the number keys and then SET However you may find it more convenient to use the LOOK graphics to enter guesses When the highlight is on the prompt for which you wish to enter a guess press the Guess key The Data Input Line will say Enter Guess for X END for example At this point press the LOOK key PROG PIN SWI617KL 3 AXIS INCH EVENT 1 IRR PROFILE EVENT2 A G E MILL X BEGIN 0 0000 abs TANGENT Y BEGIN 0 0000 abs XEND SS Z RAPID 0 0250 abs YEND Z END 0 8560 abs CONRAD TOOL OFFSET RIGHT ANGLE END PASSES 4 LENGTH FIN CUT 0 0100 LINE ANGLE Z FEEDRATE 3 0 XYZ FEEDRATE 17 5 FIN FEEDRATE 20 0 TOOL 1 Guess for X END E Fi F2 F3 F4 F5 F6 Fr FS PAGE PAGE DATA DATA DATA INSERT DELETE GUESS FWD BACK FWD BACK BOTTOM EVENT EVENT Figure 10 8 1 When the Data Input Line says Enter Guess pressing LOOK gives you the ability to use graphics to make your guesses On the screen shown in the figure above the Data Input Line says Enter Guess for X BEG Pressing LOOK at this point will take you to a special version of the LOOK graphics Using a mouse or the cursor keys you may move a point around the screen When you come to the place where your point is use the Enter key The softkeys for this special version of the LOOK graphics gt M Y move the cursor around the screen ZOOM IN m
116. ent MIRROR Advanced Features Option is Y ERE N used for parts that have symmetrical patterns or mirror image patterns In addition to 10 Os specifying the events to be repeated you must also indicate the axis or axes X or Y or XY are 9 allowed that the reflection is mirrored across 30 O7 In addition you must specify the offset from absolute zero to the line of reflection You may 40 O8 not mirror another mirror event or mirror a rotate event Consider the figure ABSOLUTE FIGURE 8 9 1 Holes 1 4 are mirrored across the Y X OFF SET axis to 5 8 respectively about a line X OFFSET from i X absolute 0 i00839 ROTATE is used for polar rotation of parts that have a rotational symmetry around some point in the XY plane In addition to specifying the events to be repeated you must also indicate the absolute X and Y position of the center of rotation the angle of rotation measured counterclockwise as positive and clockwise as negative and the number of times the specified events are to be rotated and repeated You may not rotate another rotate event however you can rotate a mirror event Consider the figure below 67 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Y CENTER L NZ 0 0 ABSOLUTE X CENTER i00840 FIGURE 8 9 2 Shape A programmed with 4 MILL events and Conrads Using ROTATE these 4 events ar
117. etup to a have unique computer names b have the same workgroup name c d e obtain IP address automatically share a folder on your desktop pc and an S daane Se o map a network drive on your ProtoTRAK control to location of the shared folder Initial Setup The following instructions will help you set up the most basic peer to peer network between a ProtoTRAK SX CNC and a computer A peer to peer network simply connects two computers of equal status together 141 Southwestern Industries Inc TRAK SX Knee Mill amp Proto TRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Hardware 1 Obtain a DSL Cable router with DHCP services Acceptable routers are made by Linksys and Netgear and are available at computer stores This type of router will automatically assign IP addresses to your ProtoTRAK and computer saving you a confusing step 2 Obtain a sufficient quantity of twisted pair category 5 rated Network Cable This looks like a telephone cable except slightly larger and is available at computer stores 3 Make sure your computer has a Network Interface Card installed This is also known as an Ethernet Card 4 Plug both the computer and the ProtoTRAK SX into the router in the hub side of the router The hub side is the side with multiple cable ports Avoid the port that is by itself unless you really know what you are doing The ProtoTRAK SX is configured to get IP addresses automa
118. event Resolving the difference in tool position where the first event ends and the next event begins means either the CNC calculates and makes an unprogrammed move or it retracts the tool out and then back into the part 36 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual These cases are not encountered often but when they are you have the option of using Tool Path programming In Tool Path programming you define the events the same way but all inputs are treated as tool center It is your job to calculate and program the tool path Note Tool Path programming is part of the Advanced Features Option Programs generated by CAD CAM systems are always generated as Tool Path programs and are run as such even if the Advanced Features Option has is not active on the ProtoTRAK SMX CNC 5 3 Planes and Vertical Planes A plane is any flat surface If that surface lies flat on the table it is the XY plane That is if you move your finger along that surface or plane you are moving in the X and or Y direction but not in Z or at least not until you pick your finger up If you tilted that surface think of it as a piece of paper straight up so that it faces the front of the machine it would be in the XZ plane If you tilted it up so that it faced left or right it would be in the YZ plane A vertical plane is any plane or surface tipped up on its edge on
119. ey If at any time there is no description above a key that key will not operate Sometimes the description or function of the key is visible but grayed out This indicates that the particular function is not available because of some other condition For example if there is no program in the current memory the EDIT Mode softkey will be grayed out because there is no program to edit Emergency Stop Switch The emergency stop E stop switch kills all power to the spindle and ProtoTRAK s servomotors The computer and pendant remain powered The Liquid Crystal Display LCD The display of the ProtoTRAK SMX CNC is a 10 4 active matrix color LCD The very top is the Status Line that shows the overall status of the ProtoTRAK SMX CNC This includes the current Mode the current program part number the current tool number 2 or 3 axis mode and whether the X Y and Z dimensions are in inch or millimeter mm Just above the soft keys is a data input line that appears when an input is required 15 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 3 2 2 Pendant Left Side See Figure 3 2 2 MACHINE ID 101115 FIGURE 3 2 2 The ProtoTRAK SMX CNC left side with connectors labeled 16 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 3 2 3 Pendant Right Side
120. fiers Z modifiers make it easy to adjust the depth of cut of particular tools without having to change programmed Z end dimensions or change the tool offsets 111 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual For example say an end mill was under cutting the depth of a part by 003 An easy way to correct this is to enter a Z modifier 1 Highlight the number in the Z MODIFIER column in the row for the correct tool 2 Enter the amount of the adjustment you wish to make To cut deeper enter a negative number To cut shallower enter a positive number In the example above to correct this undercut we would enter 003 3 Press SET The ProtoTRAK SMX CNC will apply this modifier each time this tool is used 12 1 8 Resetting the Reference Point Once the reference reads SET you are not allowed to highlight and reset it If you need to reset the reference there are two ways to change the reference to NOT SET You can erase the table and lose all the tool information or load in a program 12 1 9 Saving Tool Information Tool information is saved with the program If you have made changes to the program or to the tool table that you wish to keep you must save or store the program in the Program In Out Mode 12 1 10 Opening a Program When you open a program the tool information that is saved with the program will be loaded into the
121. fit Safety Programming Operating amp Care Manual EVENT 6 AGE ARC NOTES Tangent 1 Selects tan arc Direction 1 CW arc X End Data Forward Unknown data Y End Data Forward Unknown Data X Center Data Forward Unknown Data Y Center Data Forward Unknown data Conrad Data Forward Radius 9 abs Known print dimension Chord Length Press Page Forward now as no further Chord Angle data is required EVENT 7 AGE ARC NOTES Tangent 1 Selects tan arc Direction 1 CW X End data forward Unknown value not required Y End data forward Unknown value not required X Center 2 43 abs Known print dimension Y Center 4 55 abs Known print dimension Conrad data forward Radius 175 abs Known print dimension Chord Length Press Page Forward now as no further Chord Angle data is required EVENT 8 AGE MILL NOTES Tangent 1 Selects tan mill X End Press Page Forward now as no further Y End data is required Conrad Angle End Length 1 1648 Line Angle Event 9 AGE ARC NOTES Tangent 1 Selects tan arc Direction 2 CCW X End data forward Unknown value not required Y End data forward Unknown value not required X Center 0 abs Known print dimension Y Center 0 abs Known print dimension Conrad data forward Radius 4 85 abs Known print dimension Chord Length Press Page Forward now as no further Chord Angle data is required Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC
122. ft corner of the box wherever you would like The numbers and letters you program will always have a standard orientation like the letters on this page you cannot program tilted or inverted letters with the Engrave Event The letters are of the font shown in the figure and all capitals Prompts for the Engrave Event First define the lower left corner of the box that will contain your text X BEGIN The X coordinate of where you want your text to begin Y BEGIN The Y coordinate of where you want your text to begin HEIGHT The height of your text Each character varies in width the set height of the character will change the width in order to keep the overall size of the character proportional TEXT The text to be milled When you get to this prompt the Alpha keys will automatically pop up to allow you to enter the text Once you have finished entering text you must press End F8 and then any of the SET keys to successfully enter your text into the event The alpha keys will appear automatically if the text field is blank If you have already entered text but wish to make a change you will see a blue question mark appear on the lower left corner of the screen when you Scroll to this field press the Help button and the alpha keys will appear FEEDRATE The feedrate of XYZ along the path of the text Tool is the tool number you assign PROG l PINO l TOOL 1 ul 2 AXIS INCH EVENT 0 EVENT 1 ENGRAVE PROGRAM NAME 0 X BEGIN 0 0
123. hat the ProtoTRAK control may retain your settings If for any reason Windows prompts you to restart the computer you MUST select NO If you select yes the computer will NOT retain the changes you just made We have our own method for permanently saving changes See section 14 12 3 14 12 3 Mapping Network drive On The ProtoTRAK SMX SLX 1 Press the SYS Hardkey then the Config Net softkey The PT4SX Network Tools box appears See Figure 14 12 5 2 Pick Map Network Drive and click OK 145 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual i PT45X Network Tools 5j Change IP Address x Exit Ee p Pean C Add User Password C Share Drive Folder Save Map Network Drive i01130 Figure 14 12 5 The PT4SX Network Tools box 3 In the Drive box type in E You must type in both the E and the See Figure 14 12 6 below Drive letters A through D are used by other drives 4 Inthe Folder box Browse for the folder on your computer that you shared following the instructions above When you click browse you may have to go through a few layers of file hierarchy before you find the folder you shared Map Network Drive x windows can help you connect to a shared network folder and assign a drive letter to the connection so that you can access the folder using My Computer Specify the drive lette
124. have a good system for managing floppy disks or USB drives including labeling storage and retrieving program files You are more likely to do regular back ups if the process is easier Networking can be tricky If you do not have experience setting up a network be warned Computer companies haven t done for networks what we have done for CNCs 140 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Getting everything to work properly can require hours of troubleshooting even for experts There are instructions below to guide you through the most basic case of establishing a peer to peer network Beyond that you should consult a qualified Network Administrator 14 12 1 A Basic Peer To Peer Network Recommended Setup NOTE This control runs the Embedded version of Windows XP The Domain Access components of XP Professional are NOT included in the specific XP Embedded build we use for our SX controls It may be possible to force the control to attach to the domain by using the net command from a command window but such a connection will eventually fail and disconnect This is because of several factors This control loads XP Embedded from a very small Compact Flash disk emulator In order to keep the Compact Flash from corrupting the file structure during unexpected power down sequences switching off without logging off the entire Flash Disk is write pro
125. he N address is defined as meaning LINE NUMBER therefore NO1 means Line 1 and so on 2 lt x lt Z Dimensions along the specified axis K Distance to arc center X J Y K Z Tool Diameter Miscellaneous Functions Preparatory Function Tool Length Offset Selector silently ignored Line Number silently ignored Tool Number Feedrate Dwell time for drill bore canned cycles Repetition count for drill bore canned cycles Depth of cut for drill bore canned cycles Reference point for drill bore canned cycles Spindle Speed k vlom dim zZ Ilol z o 14 13 4 Format Terms and Definitions Number formats A preparatory function number denoted lt prep func gt 1 format dd 2 leading 0 suppression 3 range 0 to 99 B sequence or line number denoted lt seq number gt 1 format independent of units dddd 2 leading 0 suppression 3 range 1 to 9999 C Unsigned coordinate word denoted lt coord gt 1 format 153 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual metric ddddd ddd inch dddd dddd 2 the sign is implied and therefore may be omitted 3 leading 0 suppression 4 if no decimal point is given the supplied number will be interpreted as an integer i e a whole number 5 Fractional portion is optional 6 Range metric 0 to 99999 999 inch 0
126. he ProtoTRAK SMX CNC Moo Program Stop prompts for Press Go Moo M02 End of Program M02 M05 Spindle Off M05 M06 Tool Change T1 M06 M08 Coolant On M08 M09 Coolant Off M09 M21 Indexer pulse on M21 M30 Program End M30 139 Southwestern Industries Inc TRAK SX Knee Mill amp Proto TRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 14 11 3 Valid Characters for Word Address Sequences G Prepare to execute a G COMMAND ParseGcode M Prepare to execute a M COMMAND ParseMcode N Introduces a block number ParseEventNum T Specifies the tool number to use ParseToolINum F Specifies a feedrate ParseFcode S Specifies a spindle rpm ParseScode D Specifies the diameter for the current tool ParseDval E Optional parameter ParseEval X Specifies the X dimension ParseXval Y Specifies the Y dimension ParseY val Z Specifies the Z dimension ParseZval Specifies the incremental X dimension Parsel val J Specifies the incremental Y dimension Parse val K Specifies the incremental Z dimension ParseKval L An Optional Parameter ParseLval P An Optional Parameter ParsePval Introduces a comment ParseComment 14 12 Networking The subject of networking is extensive This portion of the manual will give you basic instructions for setting up a simple peer to peer network and some system information useful to network administrators A network is simply two or more computers connect
127. he Software Options Screen 3 Highlight the option you wish to install for example A Advanced Features and press the softkey labeled INSTALL 4 A screen will appear that advises you how to purchase the option Near the bottom of the screen there will be a Hardware Key Serial Number and an Option Serial Number Write down both of these numbers 5 Call your Southwestern Industries Sales Representative or the Southwestern Industries Order Desk with your purchase order number and the numbers you wrote down in step 4 above 6 When you receive your Password Activation Number input it into the ProtoTRAK where indicated on the screen obtained in step 2 above Some options require you to reboot the ProtoTRAK to activate 7 Refer to the appropriate section of this manual for instructions on using your new features 12 Southwestern Industries Inc TRAK SX Knee Mill amp Proto TRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 3 2 Display Pendant 3 2 1 Front FEAD OROTOTRAH SMX AAS k x aaa D UF Di Aa 4S 4 4 4S i24003 Figure 3 2 1 The ProtoTRAK SMX CNC front panel Keyboard Hard Keys Feed Keys GO initiates motion in Run The green LED on the GO key will be lit when the servomotors are moving the machine either in jog or when the program run has been initiated by the GO key STOP halts motion during Run The red LED on the STOP key will be
128. he original purchaser from Southwestern Industries Inc SWI or their authorized distributor If a product subsystem or component under warranty fails it will be repaired or exchanged at our option for a properly functioning unit in similar or better condition Such repairs or exchanges will be made FOB Factory Los Angeles or the location of our nearest factory representative or authorized distributor Disclaimers of Warranties e This warranty is expressly in lieu of any other warranties express or implied including any implied warranty of merchantability or fitness for a particular purpose and of any other obligations or liability on the part of SWI or any producing entity if different e Warranty repairs exchanges do not cover incidental costs such as installation labor freight etc e SWIis not responsible for consequential damages from use or misuse of any of its products e TRAK products are precision mechanical electromechanical electronic systems and must be given the reasonable care that these types of products require e Accidental damage beyond the control of SWI is not covered by the warranty Thus the warranty does not apply if a product has been abused dropped hit or disassembled e Improper installation by or at the direction of the customer in such a way that the product consequently fails is considered to be beyond the control of the manufacturer and outside the scope of the warranty Rev 020713
129. hen you do the message window will read Ready to Begin Press Go when Ready Make sure your tool is clear and press the GO key The servos will turn on move the quill to Z retract for three axis CNC models then move the table at rapid speed to your X and Y absolute zero position and then turn off You will be at zero and in manual DRO operation Spindle Operation If the machine is equipped with the Programmable Electronic Head Option spindle speeds are set and adjusted through the SMX CNC This feature was discontinued as of 1 1 11 To set spindle speed press the SPIN SPEED softkey The Data Input Line will prompt Spindle RPM Enter the RPM value 40 600 in low 300 5000 in high and press SET If the spindle was already on when you began to enter the new speed it will stay at the current speed until you press the SET key You may override the spindle speeds with the OVERRIDE display hard key Press the F S key until the LED on the S for Spindle side is lit Use the up and down arrow keys to change the spindle speed in 5 increments per button press 6 10 Tool The ProtoTRAK SMX CNC allows you to use the data for tools in your Tool Table see Section 12 1 in the DRO Mode To change tools press the TOOL soft key and enter the tool number when prompted by the Data Input Line Even when you set up a tool in the Set Up Mode if you do not wish to use the tools in the Tool Table simply ignore the Tool feature 46
130. his operation will may restart computer 317 Update Slave Software Runs the routine that copies new slave software from a disk to the ProtoTRAK system 318 Activate Converter To activate converters and other software options See Section 3 1 8 How to Buy Software Options Machine Set up 11 Backlash Hysterisis Test Runs a routine that helps the system compute lost motion 12 Feed Forward Test Caution Machine parameters may change Run this test only if indicated by service personnel 100 Open Loop Test Caution Machine will move Check for crash conditions before running Run under the direction of service personnel 123 Calibration Mode 127 Auto Backlash Configuration 128 Backlash Calibration Constant 119 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Diagnostic Codes 54 Continuous Run Mode Cycles through the program in current memory without Z motion 81 Keyboard Test Gives a tone feedback to a button push 131 Manual DRO 132 Electronic Handwheel Test 314 Toggle Test Lights in Status Line 319 Error Logging 326 Error Message Display 327 Display Memory Check Operator Defaults Options 66 Metric Boot Up Default To have the ProtoTRAK open up in mm measurement 67 English Boot Up Default To have the ProtoTRAK open up in
131. his option may be ordered with your machine or at any time after it is installed in your shop A RJ 45 port is found on each pendant to hook up your networking cable See figure 3 2 2 below for the location of this port 10 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 3 1 4 Installing and using the USB Thumb Drive Flash Memory The first time you install the USB Thumb Drive we recommend that you install it after the ProtoTRAK SMX has booted up Once it is installed the memory will be accessible on Drive D If you want to buy additional thumb drives these are readily available in computer stores We recommend SanDisk brand 128MB or higher Other brands may require the installation of separate drivers 3 1 5 The DXF File Converter Option The DXF File Converter Option gives you powerful capability for quickly and easily translating DXF and DWG files into ProtoTRAK SMX programs If you work with CAD drawings we highly recommend that you get a demo of the DXF file converter Import and convert CAD data into ProtoTRAK programs DXF or DWG files Chaining Automatic Gap Closing Layer control Easy prompted process you can do right at the machine To tell if the DXF File Converter is active on your ProtoTRAK SMX CNC go to the options screen using Service Code 318 If the AutoCAD DXF option is in black letters it is activated If it is in gray let
132. hrough the High Low Neutral lever when the spindle is rotating Be certain the spindle ON OFF switch is in the Off position Rotate the spindle by hand to help engage the lever into the high or low position Note Shifting from the high to low range or low to high range changes the direction of rotation for the On Off switch See Section 4 2 1 4 2 7 Speed Changes For the standard vari speed head spindle speed may be varied by rotating the variable speed crank When the Programmable Electronic Head Option is installed the spindle speed is controlled by the ProtoTRAK SMX CNC See the instructions in the Program Mode DRO Mode and Run Mode CAUTION Do not rotate the variable speed crank when the spindle is stationary 4 2 8 Operating the Quill For two axis CNC models the quill may be moved up and down through its range with the quill feed handle The quill may be locked into position by rotating the quill lock clockwise Pull the handle out slightly to rotate it freely to a new position For three axis CNC models the quill is operated by the electronic handwheel mounted on the side of the Z Ballscrew and Motor Encoder Note sections 4 2 9 through 4 2 15 refer to two axis CNC models 4 2 9 Adjusting the Quill Stop Two Axis CNC Models The quill stop may be adjusted by rotating the micrometer dial nut It is locked in place with the knurled nut 4 2 10 Power Feed Engagement Lever Two Axis CNC Models COUNTER one C
133. ications for assistance in enhancing the safe use of this machine Safety Requirements For The Construction Care And Use of Drilling Milling and Boring Machines ANSI B11 8 2001 Available from The American National Standards Institute 1430 Broadway New York New York 10018 Concepts And Techniques Of Machine Safeguarding OSHA Publication Number 3067 Available from The Publication Office O S H A U S Department of Labor 200 Constitution Avenue NW Washington DC 20210 Danger Warning Caution and Note Labels and Notices As Used In This Manual DANGER Immediate hazards that will result in severe personal injury or death Danger labels on the machine are red in color WARNING Hazards or unsafe practices that cou d result in severe personal injury and or damage to the equipment Warning labels on the machine are orange in color CAUTION Hazards or unsafe practices that cou d result in minor personal injury or equipment product damage Caution labels on the machine are yellow in color NOTE Call attention to specific issues requiring special attention or understanding 3 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual NEVER WEAR GLOVES RINGS WATCHES LONG SLEEVES NECKTIES JEWELRY OR OTHER LOOSE ITEMS ALWAYS WEAR SAFETY GLASSES AND SAFETY SHOES ALWAYS STOP THE SPINDLE AND CHECK TO ENSURE THE USE ADEQUATE POINT OF OPE
134. ific operations will be discussed below 14 2 2 Softkeys in the Program In Out Mode Screens Use the softkeys to move around any of the screens in the Program In Out Mode TAB Moves the highlight between the parts of the screen Where applicable tabbing to an area will cause a drop down box to appear showing all the selections possible 127 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual DATA FWD DATA BACK Moves the highlight up and down through the list Press and hold for automatic advancement OPEN FOLDER Use this key to open a highlighted folder that contains program files When the highlight is on the root directory this will collapse the list displayed and show the next level up The root directory is represented by a folder with an up arrow followed by two periods The root directory will disappear when the most basic organization for the drive in the Look In box is reached 14 3 Opening a File To open a program file from a storage location press the OPEN softkey from the Program In Out Mode screen The ProtoTRAK SMX CNC will always default to the last folder you had open Find the file using the softkeys as described above in the section on basic navigation When a program file name is highlighted press the LOOK hard key to see a graphical representation of the part program The graphics are not a precise representation of the too
135. ight down Z to the appropriate Z depth The zigzag ramp will move in a zigzag pattern to depth See the previous section for more information about the zigzag ramp FIN CUT ISL Finish cut for the Island If 0 is input there will be no finish cut See the previous section for a bottom finish cut X1 POCKET X dimension for one corner of the rectangular pocket that surrounds the island Y1 POCKET Y dimension for one corner of the rectangular pocket that surrounds the island X3 POCKET X dimension for the opposite corner of the rectangular pocket that surrounds the island Y3 POCKET Y dimension for the opposite corner of the rectangular pocket that surrounds the island CONRAD PCKT the value of the tangential radius in the corners of the rectangular pocket that surrounds the island FIN CUT PCKT finish cut along the perimeter of the pocket If 0 is input there will be no finish cut See the previous section for a bottom finish cut RPM is the spindle RPM for the event INC SET will use the RPM of the previous event RPM programming is available only if the Programmable Electronic Head Option is active FIN RPM is the spindle RPM for the finish cut FIN RPM programming is available only if the Programmable Electronic Head Option is active 81 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 9 8 Z FEEDRATE is the Z feedrate from Z rapid to
136. illed When you get to this prompt the Alpha keys will automatically pop up to allow you to enter the text Once you have finished entering text you must press End F8 and then any of the SET keys to successfully enter your text into the event The alpha keys will appear automatically if the text field is blank If you have already entered text but wish to make a change you will see a blue question mark appear on the lower left corner of the screen when you scroll to this field press the Help button and the alpha keys will appear RPM is the spindle RPM for the event INC SET will use the RPM of the previous event RPM programming is available only if the Programmable Electronic Head Option is active Z FEEDRATE Is the feedrate from Z rapid to Z end XYZ FEEDRATE The feedrate of XYZ along the path of the text Tool is the tool number you assign PROG PIN ENGRAVE 3 AXIS INCH EVENT 0 EVENT 1 ENGRAVE PROGRAM NAME ENGRAVE X BEGIN 0 0000 abs SCALE ANNO 4 ar evine aan 0 abs abs nee ee abe even com A 2 0 FF Fee FF soc fc w i ole e m 6 Reese ey felcplelelsi f Text Length 1 324162 F5 FS i01058 Figure 9 14 The above figure shows the text and special characters available for the Engrave event Notice the field that is labeled Text Length This field will display the total length of your programmed text and will update as you enter each character 92 Southwes
137. inch measurement 79 Turn On Beeper 80 Turn Off Beeper 129 Arc Accuracy To enter the preference Default is 001 334 Set Control Options Turn on or off the control option Advanced Features Turn the ProtoTRAK off then on to activate the change 120 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 13 0 RUN MODE 13 1 Run Mode Screen Press MODE and select the RUN soft key The display will show RUN PIN BALLPRK1122 TOOL 1 3 AXIS INCH Event 1 RUN Repeat 0 X 0 0000 nes Y 0 0000 ves Z 0 0000 ves SPINDLE RPM OFF NT aiK Override 100 Feed Rate 150 0 ee A 150 Override 100 Fi F2 F3 F4 F5 F F7 FS START TRIAL CAs eee RUN i01144 FIGURE 13 1 The Run Mode The ProtoTRAK SMX CNC awaits your instructions for how to begin machining Part Number BALLPRK 1 122 Items on the Run Screen Event counter this will be the current event number and event type Repeat if a repeat event is in the event counter this will show which repeat number for example if you program a drill with 5 repeats this will show which repeat of the event that is being machined Spindle RPM the programmed RPM as adjusted by the Spindle Override The Programmable Electronic Head Option must be active for this function Red bar graphical representation of Spindle override described above Feed Rate programmed feedrate
138. ined When programs or files are named using the ProtoTRAK SMX CNC the name can be up to 20 characters long Programs imported into the ProtoTRAK SMX CNC may be longer While 20 characters are allowed the entire program name may not be shown in the status line or the program header screen PRG O Toom Program Name Scale Dwell Rewiac Auxiliary SS Event Co 3 AXIS INCH Dimensio i01051 FIGURE 7 3 Pressing the Help hard key when the Program Name is highlighted calls up alpha keys Program names can include numbers letters spaces and other characters When the Program name prompt is highlighted the Data Input Line will show Program Name At this point you may e Press number keys e Press Help to access alpha keys and special characters in the ProtoTRAK SMX CNC e Use a keyboard plugged into the ProtoTRAK SMX CNC to name the program 48 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual To use the alpha keys and special characters on the ProtoTRAK SMX CNC Use the Clear softkey to erase the entire line the Backspace softkey to erase the last character or number e Use the arrow softkeys to move around the table e Once the character you want is highlighted use the Enter softkey to load the character into the program name e Use the blank space on the lower right of the table to insert a space into the progra
139. ing at the corner programmed as X3 Y3 The prompts for the face mill X1 is the X dimension to any corner Y1 is the Y dimension to the same corner as X1 X3 is the X dimension to the corner opposite X1 incremental is from X1 Y3 is the Y dimension to the same corner as X3 incremental is from Y1 Z Rapid is the Z dimension to transition from rapid to feed Z End is the Z dimension at the bottom of the pocket incremental is from the previous event Passes is the number of cycles to machine to the final depth spaced equally from Z Rapid to Z End Z Fin Cut is the depth of the finish cut If 0 is input there will be no finish cut RPM is the spindle RPM for the event INC SET will use the RPM of the previous event FIN RPM is the spindle RPM for the finish cut Z Feedrate is the Z feedrate from Z rapid to Z end in in min from 1 to 700 or mm min from 5 to 17780 XYZ Feedrate is the milling feedrate in in min from 1 to 800 or mm min from 5 to 20320 Fin Feedrate is the milling feedrate for the finish cut Tool is the tool number you assign Note if you press the HELP key when you are on the X1 prompt you can adjust the step over distance of the face mill The default is 95 of the cutter width You can adjust it from 1 to 99 78 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 9 7 Islands Advanced Features Option
140. ing option DATA FWD moves the highlight forward through the programming options without setting an input into the program DATA BACK moves the highlight backward through the programming options without setting an input into the program GO TO BEGIN puts the Program Header on the left side of the screen and the first event on the right side GO TO END puts the last programmed event on the left side of the screen and the next event to be programmed on the right side GO TO enter the event number you wish to go to and then press SET Puts the requested event number on the right side of the screen and the previous event number on the left Note for a new program that has no Events all the GO TO selections will take you to the beginning with the program header information summarized on the left as Event 0 and the Select an Event options for Event 1 on the right YES and NO Yes and no appear when the Dwell Request Auxiliary Function Request and the Event Comments are highlighted Choosing Yes will give you prompts for using these options while you are programming You may return to the Program Header Screen at any time to choose or cancel these prompts PART GEO sets up the programming as Part Geometry TOOL PATH sets up the programming as Tool Path This function is part of the Advanced Features Option 50 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Opera
141. ion Course feed moves 800 inches per revolution INC SET loads incremental dimensions and general data ABS SET loads absolute dimensions and general data INC ABS switches all or one axis from incremental to absolute or absolute to incremental IN MM causes Inch to Metric or Metric to Inch conversion of displayed data LOOK part graphics in Program mode X Y Z selects axis for subsequent commands RESTORE clears an entry aborts a keying procedure 0 9 inputs numeric data with floating point format Data is automatically unless key is pressed All input data is automatically rounded to the system s resolution MODE to change from one mode of operation to another SYS To shut down the ProtoTRAK SMX CNC change from 2 axis to 3 axis or 3 axis to 2 axis operation and other functions A reinstates a window eliminates a window HELP displays help information math help or additional functions Active for additional functions when the help symbol a blue question mark is displayed on the screen next to the HELP key 14 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Soft Keys Beneath the display are 8 keys that are labeled with arrows These keys are called software programmable or soft keys A description of the function or use of each of these keys will be shown at the bottom of the display directly above each k
142. ion from rapid to feed Z End is the Z dimension at the bottom of the frame incremental is from the previous event Conrad is the value of the tangential radius in each corner Direction is the clockwise input 1 or counterclockwise input 2 direction for milling Tool Offset is the selection of the tool offset to the right input 1 offset to the left input 2 or tool center no offset input 0 relative to the programmed edge and direction of the cutter movement Passes is the number of cycles to machine to the final depth spaced equally from Z Rapid to Z End hint keep Z Rapid small Fin Cut is the width of the finish cut If 0 is input there will be no finish cut RPM is the spindle RPM for the event INC SET will use the RPM of the previous event RPM programming is available only if the Programmable Electronic Head Option is active FIN RPM is the spindle RPM for the finish cut FIN RPM programming is available only if the Programmable Electronic Head Option is active Z Feedrate is the Z feedrate from Z rapid to Z end XYZ Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Fin Feedrate is the milling feedrate for the finish cut if programmed Tool is the tool number you assign 9 8 3 Irregular Profile Advanced Features Option Press the IRREG PROFILE soft key if you wish to mill a profile other than a rectangle or circle The Irregular Profile event gives you the powe
143. ircle pocket X Center is the X dimension to the center of the circle Y Center is the Y dimension to the center of the circle Radius is the finish radius of the circle Direction is the clockwise input 1 or counterclockwise input 2 direction for milling Fin Cut is the width of the finish cut If 0 is input there will be no finish cut Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Fin Feedrate is the milling feedrate for the finish cut Tool is the tool number you assign 8 5 2 Rectangular Pocket Press RECTANGLE soft key if you wish to mill a rectangular pocket all corners are 90 right angles and the sides are parallel to the X and Y axes The prompts for the rectangular pocket X1 is the X dimension to any corner Y1 is the Y dimension to the same corner as X1 X3 is the X dimension to the corner opposite X1 incremental is from X1 Y3 is the Y dimension to the same corner as X3 incremental is from Y1 Conrad is the value of the tangential radius in each corner Direction is the clockwise input 1 or counterclockwise input 2 direction for milling Fin Cut is the width of the finish cut If 0 is input there will be no finish cut XY Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Fin Feedrate is the milling feedrate for the finish cut Tool is the tool number you assign 8 5 3 Irregular Pocket Advanced Features Option Press the I
144. irst Mill Event Eo PNR 3AiS Ncon Z XYZ FIN EVT TYPE TOOL FEED FEED FEED Z RAPID CONRAD 14 BOLT HOLE 3 0 1875 5 0 0 1000 abs 25 BOLTHOLE 1 0 2500 50 0 1000 abs 6 BOLT HOLE 3 0 1875 0 1000 abs MILL 2 0 3750 10 0 0 0000 inc 0 0000 l 5 0 J MiL 2 0 3750 ER ioo 0 0000 inc 0 0000 MILL 2 0 3750 ER oo 0 0000 ine 0 0000 MILL 3 0 1875 EQ oo 0 0000 inc 0 0000 MiL 3 0 1875 ER oo 0 0000 inc 0 0000 10 0 0 0000 ine 0 0000 10 0 0 0000 inc 0 0000 10 0 0 0000 inc 0 0000 10 0 0 0000 inc 0 0000 j ZFEEDRATE 0 oo F4 MILL 3 0 1875 MILL 2 0 3750 MILL 2 0 3750 28 MILL 2 0 3750 N pene neme pii FIGURE 11 2 4 Pressing the Change All softkey highlights the Z feed for all the Mill events 104 Southwestern Industries Inc TRAK SX Knee Mill amp Proto TRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual EDIT PIN RO424 11 3 AXIS INCH Z XYZ FIN EVT TYPE TOOL FEED FEED FEED Z RAPID CONRAD ae E 14 BOLT HOLE 3 0 1875 5 0 0 1000 abs 25 BOLT HOLE 1 0 2500 5 0 0 1000 abs 36 BOLT HOLE 3 0 1875 5 0 0 1000 abs a mit 20 3750 MEAM 10 0 0 0000 inc 0 0000 5 mut 20 3750 70 10 0 0 0000 inc 0 0000 e mut 2 3750 7 0 10 0 0 0000 inc 0 0000 as mit 3 1875 7 0 10 0 0 0000 inc 0 0000 i mi 3 1975 7 0 10 0 0 0000 inc
145. isplay an error message 107 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 12 0 Set Up Mode The Set Up Mode contains the tool library the tool path graphics and the machine s reference positions Enter the Set Up Mode by pressing the SET UP soft key at the Select Mode screen Tile Pan on oner Pa es FIGURE 12 0 The Set Up mode 12 1 The Tool Table From the screen above press the TOOL TABLE softkey QO Re gt m wa ZOFFSET Z MODIFIER TOOL TYPE D 7 CON OA eWNY M 0 0000 Rough End Mill 0 0000 Finish End Mill 0 0000 Drill 0 0000 Drill 0 0000 Tap 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 i0114 FIGURE 12 1 The Tool Table 108 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 12 1 1 The Tool Table Screen When you first enter the tool table by pressing the TOOL TABLE soft key you will see the screen shown in Figure 12 1 Tool the number of the tool from 1 to 99 Tool numbers shown in red are active for the program in current memory Diameter the diameter of the tool Z Offset the difference between the Z position of the tool and the Z position of the reference The Z offset is always relative to a reference point Before the reference point is
146. it Safety Programming Operating amp Care Manual 13 8 Feedrate and Speed Overrides In program Run Mode the programmed XYZ axis feeds as well as the rapid speeds may be adjusted temporarily Likewise if the Programmable Electronic Head Option is installed the programmed spindle speed may be adjusted temporarily You may override the spindle speeds or feeds with the OVERRIDE display hard key Press the F S key until the LED is lit on the side corresponding to the speed you wish to override S for Spindle F for feed Use the up and down arrow keys to change the feedrate in 10 increments per button press and the spindle speed in 5 increments 13 9 Trial Run Trial Run allows you to quickly check out your program with no Z movement for three axis CNC programs before you actually start to make parts In trial run the table will move at rapid speed regardless of what feedrates are programmed the rapid speed may be overridden with FEED and FEED keys The table will stop at each stop location for example at each drill location but immediately continue on without your input To do atrial run press the TRIAL RUN soft key from the screen shown in Section 13 1 The message box will read Ready to begin trial run Press GO to start Be certain the table is positioned so that if it moves through the part program it will not reach its travel limit Also check that the quill is fully retracted Press GO to begin 13 10 Data Error
147. itness mark Tool Offset 2 Sets tool offset LEFT Finish Cut Inc Set Means no finish cut Feedrate 10 Set Sets feedrate to 10 ipm Fin Feedrate Inc Set Means no finish feedrate Tool abs set Sets tool to default 1 EVENT 2 AGE Mill NOTES Tangent 1 Selects Tan Mill X End 0 Known print value Y End 6 66 abs Known print value Conrad Press Page Forward now as no further Angle End data is required Length Line Angle EVENT 3 AGE ARC NOTES Tangent 1 Selects Tan Arc Direction 1 abs Selects CW arc direction X End 1 02 abs Known endpoint Y End Guess 6 6 abs Unknown endpoint guess X Center Abs set Defaults to 0 known print dimension Y Center Abs set Defaults to 0 known print dimension Conrad 15 Sets Conrad of 0 15 Radius Press Page Forward now as no further Chord Length data is required Chord Angle EVENT 4 AGE MILL NOTES Tangent 2 Not tangent X End Inc set By default X will remain the same Y End 5 505 abs Known print dimension Conrad Press Page Forward now as no further Angle End data is required Length Line Angle EVENT 5 AGE ARC NOTES Tangent 1 Selects tan arc Direction 2 CCW arc direction X End data forward Unknown Endpoint Y End data forward Unknown Endpoint X Center 1 17 abs Known Center Y Center 5 505 abs Known Center Conrad data forward Radius 0 15 abs Known print dimension Chord Length Press Page Forward now Chord Angle 160 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retro
148. ivate the pump at the beginning of each day may cause severe damage to the TRAK Knee Mill way surfaces and ball screws Head Lubrication Once Each Week 1 Fill the oil cup on the front of the head with SAE 30 or 30W oil This oil lubricates the Hi Lo range shifter 2 Fill the ball oiler located in the front lower right corner of the speed hanger housing This oil lubricates the speed changer shaft 3 Extend the quill fully and apply a coating of SAE 30 or 30W oil to the outside diameter of the quill Every Four Months Apply a good grade of general purpose grease through the grease fittings on the back of the head and on the left side of the head The grease lubricates the low range gear set and the feed change gears respectively 3 4 Optional Equipment 3 4 1 Electronic Handwheels When ordered as part of the TRAKing Electronic Handwheels Option see Section 3 1 7 the electronic handwheels replace the standard mechanical handwheels for table and saddle traverse The electronic handwheels will operate when the ProtoTRAK SMX CNC is in a Mode where the machinist controls the motion of the table and saddle This includes the DRO Mode the Set Up Mode and the TRAKing operation in the Run Mode The electronic handwheels will not operate during other functions such as when the Select a Mode message appears on the screen Handwheel resolution is determined by the F C key on the display Fine feed moves 200 inches per revol
149. ive solutions Edit this allows you to go back to the data you entered in order to make changes Once you do this the Resolve key will appear Resolve press this to have the Math Help use the new data to give new solutions 4 1 7 Windows Up or Down Some of the selections in the ProtoTRAK SMX CNC will cause a window to appear with a message To eliminate the window in order to see what is behind it press the hard key To restore the window press the hard key 4 1 8 Turning Options On and Off If the Advanced Features Option has been installed you may run the ProtoTRAK SMX with it turned off This has the benefit of making the system easier to use To turn the options on or off press the SYS hard key You will get the screen shown in Figure 4 1 4 above Press the Options On Off softkey This will take you directly to the screen that will allow you to turn options on and off You can also get to this screen using Service Code 334 29 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual The Programmable E Head Option and TRAKing Electronic Handwheel Option may not be turned on or off If they are installed they must remain active 4 2 Machine Operation This section covers the operation of the TRAK Knee Mills If you purchased your ProtoTRAK SMX CNC as a retrofit please refer to the user manual that came with your machine 4 2 1 Spindle
150. ket The formula is the pocket x or y move gt tool diameter tool radius fin cut If the tool is too large for the zigzag ramp the ProtoTRAK SMX CNC will give an error message during program run and will then default to plunge This will occur for each pass of the pocket depth 77 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 9 6 6 Conrad in Pocket Events A Conrad may be added to the last event of an Irregular Pocket The Conrad will be inserted between the end of the last event and the beginning of the next event 9 6 7 Bottom Finish Cut The standard finish cut is along the walls of the part but you may have the ProtoTRAK machine a finish cut along the bottom as well When the highlight is on the Fin Cut prompt the blue appears next to the Help key Pressing help gives you the ability to choose a Finish cut in Z You can remove the bottom finish cut by placing the highlight on the Fin Cut prompt and pressing Help again When you select Yes to the bottom finish cut the following prompt will appear Z FIN CUT the finish cut at the bottom 9 6 8 Face Mill Advanced Features Option Press Face Mill soft key if you wish to face or clean up the top of a workpiece The cutter will automatically start off of the part that you define The cutter will move along the X axis to remove the material starting from where you defined X1 Y1 and finish
151. l path but should be very handy in helping to identify a file before opening In addition to the basic parts of the screen described above two additional parts of the screen appear in the open operation File Name Displays the name of the file that is highlighted from the list Open As lists the formats for which the file may be opened The default is PT4 Two additional softkeys appear OPEN FILE Opens the highlighted program file and puts it in current memory Only one file may be in current memory at a time if one is there already a warning message will appear before that file is overwritten RETURN Returns to the Program In Out Mode screen When the open operation is finished the system will return to the Select Mode screen 14 3 1 Preview Graphics As an aid to finding the file you want to open the ProtoTRAK SMX allows you to look at the part graphics before opening Simply select the file and press the LOOK hardkey The screen will show the part graphics Press LOOK again or RETURN to revert back to the Program In Out screen The graphics displayed in this process are not exact but are a handy representation of the program Note DXF and GCD files may not be previewed with the LOOK feature 14 4 Saving Programs To save a program file to a storage location press the SAVE softkey from the Program In Out Mode screen Find the drive and folder you want to save the program file in using the softkeys as described
152. lace of the one that was on the right side of the screen when you pressed the INSERT EVENT key That previous event and all the events that follow increase their event number by one For example if you started with a program of four events if you were to press the INSERT EVENT key while Event 3 was on the right side of the screen the previous Event 3 would become Event 4 and the previous Event 4 would become Event 5 If you insert a Subroutine event the event numbers will increase by one as when you insert another kind of event If you insert a copy event the event numbers will increase by the number of events that are copied DELETE EVENT this will delete the event on the right side of the screen 53 Southwestern Industries Inc TRAK SX Knee Mill amp Proto TRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 7 9 Programming Events Once you press the appropriate GO TO soft key you will begin to define your part as a series of Events For the ProtoTRAK SMX CNC an Event is a geometry or a feature of a part PROG PINO TOOL 1 3 AXIS INCH EVENT 0 EVENT 1 PROGRAM NAME 0 SCALE 1 000 DWELL REQUEST NO AUXILIARY FUNCTION NO EVENT COMMENTS NO MULTIPLE FIXTURES NO DIMENSION DEFINITION PART GEO i01052 FIGURE 7 9 1 The header screen has been completed and is on the left side Select an event type from the soft keys Three axis CNC events are shown When the MORE soft key is selected the
153. lay all files OPEN to bring a program from storage into the current memory SAVE to save the program that is in current memory to storage COPY to select and make a copy of a file in storage for pasting in another storage location DELETE to remove a file from a storage location without altering the current memory RENAME to rename a file or folder BACK UP to perform a convenient back up of program files to another storage location 14 2 Basic Navigation of Program In Out Mode Screens The screens in the Program In Out Mode do not have the normal ProtoTRAK look and feel because they are derived from the Windows operating system Most functions may be performed using a mouse or keyboard Softkeys are provided to operate the system through the control s keys 14 2 1 Basic Parts of the Program In Out Mode Screens The status line at the top of the screen will display e The Mode e The program name for the program in current memory if any e Whether the ProtoTRAK SMX CNC is in two or three axis The Look In area shows the storage areas or drives and directories that are being displayed below in the listing area In the listing area the biggest part of the screen appears all the files and folders for the location shown in the Look In box The C Drive of the ProtoTRAK SMX CNC is not accessible for program storage The File Name box shows the program file on which the operation will be performed Parts of the screen unique to spec
154. le Profile Press the CIRCLE soft key if you wish to mill a circular frame Prompts in the Circle Profile event X Center is the X dimension to the center of the circle Y Center is the Y dimension to the center of the circle Radius is the finish radius of the circle Direction is the clockwise input 1 or counterclockwise input 2 direction for milling Tool Offset is the selection of the tool offset to the right input 1 offset to the left input 2 or tool center no offset input 0 relative to the programmed edge and direction of the cutter movement Fin Cut is the width of the finish cut If 0 is input there will be no finish cut Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Finish Feedrate is the milling feedrate for the finish cut Tool is the tool number you assign 64 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 8 7 2 Rectangular Profile Press the RECTANGLE soft key if you wish to mill a rectangular frame all corners are 90 right angles Prompts for the rectangular profile X1 is the X dimension to any corner Y1 is the Y dimension to the same corner as X1 X3 is the X dimension to the corner opposite X1 incremental is from X1 Y3 is the Y dimension to the same corner as X3 incremental is from Y1 Conrad is the value of the tangential radius in each corne
155. lly start off of the part that you define The cutter will move along the X axis to remove the material starting from where you defined X1 Y1 and finishing at the corner programmed as X3 Y3 The prompts for the face mill X1 is the X dimension to any corner Y1 is the Y dimension to the same corner as X1 X3 is the X dimension to the corner opposite X1 incremental is from X1 Y3 is the Y dimension to the same corner as X3 incremental is from Y1 61 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 8 6 RPM is the spindle RPM for the event INC SET will use the RPM of the previous event FIN RPM is the spindle RPM for the finish cut Feedrate is the milling feedrate in in min from 1 to 800 or mm min from 5 to 20320 Tool is the tool number you assign Note if you press the HELP key when you are on the X1 prompt you can adjust the step over distance of the face mill The default is 95 of the cutter width You can adjust it from 1 to 99 Islands Advanced Features Option Islands programming is available as part of the Advanced Features Option See Section 3 1 2 Within the Pocket event choices you may also select a circular rectangular or irregular island An island is a shape that is left standing when the surrounding material is removed The ProtoTRAK gives you the ability to machine almost any shape as an island within a rect
156. m name e Once you finish entering the letters and special characters press the End softkey This tells the ProtoTRAK SMX CNC that you are finished with the alpha table Numbers may still be added to the program name When you are finished with the program name press SET to enter it into the current memory Note It is not necessary to enter a part number If none is entered and a GO TO soft key is pushed the system will assume a part number 0 7 3 2 General Program Options Use the DATA FWD softkey to select general programming options See Section 3 1 2 for more information about the Advanced Features Option Scale Allows a scale factor between 1 and 10 An input of 5 means the part will be 5 times as big as the programmed dimensions A value of 1 0000 is assumed if nothing is input This function is part of the Advanced Features Option Dwell Request For three axis CNC machining only Allows you to input a dwell at the bottom of a drill bolt hole or bore cycle for events you select Select the appropriate YES or NO soft key If you select YES you will be prompted to input a dwell time in seconds from 1 to 99 9 when appropriate to the event being programmed Auxiliary Function Request Asks if you wish to activate any of the optional auxiliary functions see Section 7 4 at any time during the program Select the appropriate YES or NO soft key If you select YES you will be prompted to input the type and sequencing of the auxiliary
157. matic corner override mode G63 Tapping mode G65 User macro simple call G66 User macro modal call G67 User macro modal call cancel G74 Counter tapping cycle G76 Fine boring G86 Boring cycle G87 Back boring cycle G88 Boring cycle G92 Programming of absolute zero point G95 Feed per revolution 14 13 6 Accepted M Codes Moo Pause event Moo M05 Spindle Off M05 M06 Tool Change T1 M06 M08 Coolant On M08 M09 Coolant Off Mog M12 Indexer pulse beginning of event M12 M20 Indexer pulse end of event M20 Virus Protection As a device ProtoTRAK CNCs are not generally susceptible to viral infections The part programs they run are non executable text files You can further assure protection by avoiding e mail programs and web browser programs loaded onto the ProtoTRAK and by using a router with a firewall An anti virus program is not necessary since the virus risk is low and is not recommended because the background tasks may cause damage by interfering with ProtoTRAK real time operation Microsoft Updates Please note that the ProtoTRAK control is not designed to be automatically downloading updates from Microsoft or for that matter any 3 party software There is only a limited amount of free space on the compact flash card and downloading files to it until it is full may result in the ProtoTRAK to stop working properly Also note that administrators must exclu
158. med edge and direction of tool cutter movement and as projected in the XY plane Feedrate is the milling feedrate from Begin to End in in min from 1 to 100 or mm min from 5 to 2540 Tool is the tool number you assign Continue input 1 for Yes if you want to mill continuously from this line to the next event input 2 for No if you want the ProtoTRAK SMX to stop at the end of the event ARC Events This event allows you to mill with circular contouring any arc fraction of a circle In ARC events when X Center and Y Center are programmed incrementally they are referenced from X End and Y End respectively An ARC event may be programmed with a CONRAD if it is connective with the next event Prompts for the Arc event X Begin is the X dimension to the beginning of the arc cut Y Begin is the Y dimension to the beginning of the arc cut X End is the X dimension to the end of the arc cut incremental is from X Begin Y End is the Y dimension to the end of the arc cut incremental is from Y Begin X Center is the X dimension to the center of the arc incremental is from X End Y Center is the Y dimension to the center of the arc incremental is from Y End Conrad is the dimension of a tangential radius to the next event Direction is the clockwise input 1 or counterclockwise input 2 direction of the arc Tool Offset is the selection of the tool offset to right input 1 offset to left input 2 or tool center no offset inp
159. meter which leaves the amount of material programmed in the FIN CUT prompt This will be followed by a finish pass if FIN CUT was not zero along the inside of the perimeter at the Finish Feedrate Whether the cuts to clear the interior material of the irregular pocket are along the X or Y axis depends on if there are hidden areas of the pocket The ProtoTRAK SMX CNC always looks to cut along the X axis first If there are areas that are hidden to the X axis it will machine along the Y axis If there are hidden areas that cannot be machined continuously in the X or Y axis the pocket will be machined in two or more steps When a step is completed the ProtoTRAK SMX will prompt CHECK Z at which time you should raise your quill out of the pocket Press GO and the tool will move at rapid to the beginning of the next step and then there will be a prompt for you to SET Z for you to position the tool for the depth you want In the Set Up Mode you may check your tool path for hidden areas The yellow X s show points where you will receive a prompt to move the quill The red dashed lines show the rapid moves 8 5 5 Conrad in Pocket Events A conrad may be added to the last event of an Irregular Pocket The conrad will be inserted between the end of the last event and the beginning of the next event 8 5 6 Face Mill Advanced Features Option Press Face Mill soft key if you wish to face or clean up the top of a workpiece The cutter will automatica
160. ming Operating amp Care Manual Note When an arc is a 180 arc there are several paths that all have the same beginning ending and center locations To illustrate Imagine that if you were on the earth s equator and you wanted to get to the other side of the earth you could go clockwise or counterclockwise around the equator or you could go up over the north pole or down under the south pole The ProtoTRAK SMX CNC will automatically assume that all 180 arcs that have the same beginning ending and center dimensions for Z lie in the XY plane Ifyou want a 180 arc in a vertical plane you must program two 90 arcs or some equivalent Prompts for the Arc event X Begin is the X dimension to the beginning of the arc cut Y Begin is the Y dimension to the beginning of the arc cut Z Rapid is the Z dimension to transition from rapid to feed Z Depth is the depth of the cut in Z If the Advanced Features Option is active Z Begin and Z End prompts will appear in the place of Z Depth Z Begin is the Z dimension to the beginning of the arc cut Advanced Features Option X End is the X dimension to the end of the arc cut incremental is from X Begin Y End is the Y dimension to the end of the arc cut incremental is from Y Begin Z End is the Z dimension to the end of the arc cut incremental is from Z Begin The Z End dimension is programmed only if the Advanced Features Option is active X Center is the X dimension to the cente
161. mited For example the K2 and K3 may not be capable of tapping a 12 13 thread in inconel e Softer materials than aluminum may be capable of higher speeds and you may be able to go a little bigger in terms of tap sizes than what is listed in the table e Make sure your tap is not dull Dull taps will require more torque to cut and may not cut threads to specification e Cutting oil will play a large role in determining the size of tap you can use in a given material Cutting oil was the lubrication used when creating the above table e Before tapping make sure your holder has adequate float in the tension and compression stroke The holder should float up and down with minimal force applied to the holder Also make sure your holder does not stick in tension holder pulls down or compression holder pulls up This will stop the tap from getting to the correct position programmed and may also break your tap e Always set your Z rapid higher than the tension stroke of your holder This will save your tap if the holder does get stuck in the tension stroke between holes e Make sure your tap is running true in the holder e Most tapping problems are due to a dull tap or a holder that is not floating and is stuck in a certain position 9 15 Engrave Event Advanced Features Option The Engrave Event allows you to machine numbers letters and special characters as part of a part program See Figure 9 14 below for the letters and special charac
162. n Whether as a retrofit or as part of a TRAK Knee Mill the ProtoTRAK SMX CNC combines the simplicity and flexibility of using a knee mill with the easy natural user interface that makes the ProtoTRAK the top brand in CNCs for small lot machining 4 1 ProtoTRAK SMX Basic Operation Most of the operations of the ProtoTRAK SMX CNC are organized in Modes Modes are logical groups of activities that naturally belong together This eliminates the need to memorize operations just select a mode and choose among the soft keys Most operations will be discussed within the section that treats the particular mode later in this manual The operations described in this section either don t fit in a particular mode or they are relevant to more than one mode 4 1 1 Switching on the ProtoTRAK SMX CNC To turn the ProtoTRAK SMX CNC on move the toggle switch on the display side panel to the Up position The Windows operating system and the ProtoTRAK SMX CNC software will take a few seconds to load from the system s flash memory If you have connected the ProtoTRAK SMX CNC to a network it may take as long as 90 seconds for the communications to be established When complete the ProtoTRAK SMX CNC Select Mode screen will appear Select the Mode of operation by pressing the soft key beneath the labeled box Notice that the EDIT and RUN soft keys are grayed out when the system is first turned on They will not function because there is no program in the Pr
163. n Two amp Three Axis Operation 4 1 5 Coolant Pump Spray Coolant 4 1 6 Help Functions 4 1 7 Windows Up or Down 4 1 8 Turning Options On and Off Machine Operation 4 2 1 Spindle ON Off Forward Reverse 4 2 2 Table Saddle Knee Clamps 4 2 3 Raising Lowering the Knee 4 2 4 Spindle Brake 4 2 5 Draw Bar 4 2 6 High Low Neutral Level 4 2 7 Speed Changes 4 2 8 Operating the Quill 4 2 9 Adjusting the Quill Stop Power Feed Engagement Level Fine Feed Direction Shaft Quill Feed Selector Feed Trip Lever Fine Hand Quill Feed Fine Automatic Quill Feed Setting Stops for Three Axis CNC Models 4 2 16 Definitions Terms amp Concepts 36 ProtoTRAK SMX CNC Axis Conventions Part Geometry amp Tool Path Programming Planes amp Vertical Planes Absolute amp Incremental Reference Reference amp Non Referenced Data Incremental Reference Position in Programming Tool Diameter Compensation Tool Diameter Compensation when Contouring in Z with Part Geometry Connective Events Conrad Memory amp Storage DRO Mode 43 Enter DRO Mode DRO Functions Jog Power Feed Do One Go To Teach Return to Absolute Zero Spindle Operation Tool TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 7 0 7 1 7 3 7 4 7 5 8 6 8 7 8 8 8 9 8 10 8 11 9 0 9 2 9 3 9 4 9 5 9 6 Program Mode 47 Getting Started amp Some General Info Programming Overview
164. n and may therefore be loaded with either the INC SET or ABS SET key This manual uses the term SET when either INC SET or ABS SET may be used interchangeably Incremental Reference Position in Programming When X Y Z RAPID and Z data for the beginning position of any event are input as incremental data this increment must be measured from some known point in the previous event Following are the positions for each event type from which the incremental moves are made in the subsequent event Position X Y and Z programmed Drill X Y Z RAPID and Z END programmed Bolt Hole X CENTER Y CENTER Z RAPID and Z END programmed Mill X END Y END Z RAPID and Z END programmed Arc X END Y END Z RAPID and Z END programmed Circle POCKET or FRAME X CENTER Y CENTER Z RAPID and Z END programmed Rectangle or Irregular POCKET or PROFILE X1 and Y1 corner Z RAPID and Z END programmed Helix The X END Y END Z RAPID and Z END programmed Helix programming requires the Advanced Features Option Sub The reference position as defined for the specific events above for the event prior to the first event that was repeated A G E PROFILE The appropriate reference position as defined for the specific events above for the last event that is programmed A G E Profile Programming requires the Advanced Features Option For example if an ARC event followed a MILL event a 2 0 inch incremental X BEG would mean that in the X direction the
165. n current memory will still be red 12 1 5 Adding a Tool When the reference is SET and the original touch off surface is still available you can add a tool very easily 1 First make the tool number active by using it in the program in current memory Put the new tool in the spindle Go to the Set Up Mode tool table Enter the diameter Sd eds SOS oD Touch the new tool to the same surface as the reference 6 Press SET If the surface is not available it will be necessary to establish a new reference before adding the new tool See Section 12 1 8 below Once the reference is reset use the procedure above on the new surface used to set the reference 12 1 6 Replacing a Tool If you need to replace a tool that was not used as the reference simply do the following Put the replacement tool in the spindle Put the highlight in the correct row for the tool number Reenter the diameter if different Pe I a Touch the tool to the same surface that was used to touch off the reference 5 With the highlight in the Z OFFSET column for the correct tool number press SET If you need to replace a tool that was used as a reference we recommend that you press the ERASE TABLE softkey and start all over again Not to nag but that is why it is a good idea to have a separate reference setting tool and use a constant reference surface If you work with programs that use a lot of tools this practice can really save time 12 1 7 Z Modi
166. n ground ballscrews are installed in the table and saddle to ensure smooth traverse and positive control for manual and CNC machining Quill Glass Scale For two axis CNC models a glass scale is mounted to the quill in order to provide digital readout of the quill position Z Axis Ballscrew and Motor Assembly For three axis CNC models a Z axis ballscrew and motor assembly is mounted on the head using two tramming bolts and the fine feed boss In manual and CNC operations the quill is moved by a servo motor connected by a belt to a ballscrew The ball nut of the ballscrew is attached to fork that engages the quill in the threaded hole previously used by the quill stop knob In CNC operations the motor is controlled by the CNC program In manual operations the motor is controlled by jog commands from the user and by the operation of the electronic handwheel A limit switch in the assembly prevents damage from over travel Z axis traverse is limited to 4 1 Electrical Cabinet TRAK Knee Mills Only TRAK Knee Mills use two electrical inputs Spindle 220 or 440V power is wired into the cabinet A cord is supplied from the cabinet to a 110V power source for running the ProtoTRAK SMX CNC 440V is not available for machines with the Programmable Electronic Head Option 25 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 4 0 Basic Operatio
167. n of the helix Tool Offset is the selection of the tool offset to right input 1 offset to left input 2 or tool center no offset input 0 relative to the programmed edge and direction of the cutter movement RPM is the spindle RPM for the event INC SET will use the RPM of the previous event RPM programming is available only if the Programmable Electronic Head Option is active XYZ Feedrate is the feedrate from beginning to end in in min from 1 to 100 or mm min from 5 to 2540 Tool is the tool you assign 84 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 9 10 Subroutine Events The Subroutine Events are used for manipulating previously programmed geometry within the XY plane The Subroutine Event is divided into three options Repeat Mirror and Rotate Repeat and Rotate may be connective As long as the rules of connectivity are satisfied see Section 5 9 the ProtoTRAK SMX CNC will continue milling between preceding and subsequent events REPEAT allows you to repeat an event or a group of events up to 99 times with an offset in X and or Y and or Z This can be useful for drilling a series of evenly spaced holes duplicating some machined shapes or even repeating an entire program with an offset for a second fixture Repeat events may be nested That is you can repeat a repeat event of a repeat event of some progr
168. n power is turned off to the CNC the clipboard information will also be lost The events on the clipboard are inserted into a program in the Program Mode using the copy feature See Section 8 10 11 5 G Code Editor Advanced Features Option The G Code Editor allows the edit of G Code programs that are opened as GCD files Once edited the program may be re saved as GCD files ProtoTRAK Geometry style programs may not be saved as GCD files EDIT PIN fixture 2 AXIS INCH I G Code Editor g x F10 000000 G17 G3 X1 000000 Y0 750000 Z 1 000000 10 000000 J0 250000 K0 000000 G64 Event 2 N2 MILL 100 F10 000000 G1 X1 000000 Y1 500000 2 1 000000 G61 G42 Event 3 N3 MILL G61 GO X5 000000 Y0 500000 20 100000 G64 Figure 11 5 1 Use the G Code Editor to modify G Code programs You must connect a mouse and keyboard in order to use the G Code Editor When you enter the G Code Editor the G Code program is displayed starting at the first Block Number Use the scroll bar to move up and down through the program Use the mouse and keyboard to edit like you would an MS Notepad file 106 Southwestern Industries Inc TRAK SX Knee Mill amp Proto TRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Search allows you to launch a simple find and replace routine to aid in editing large G Code files EDIT PIN fixture 1l 2 AXIS l INCH x F10 000000 G17 G3 X1 000
169. n regular data Often the information you put into the system will allow it to calculate a mathematically correct line or arc that would satisfy the conditions of the hard data you entered This line or arc may yield more than one solution to particular point you are looking for That is where the Guess comes in the A G E uses the guess to choose from the mathematically possible solutions In most cases your guesses do not have to be very precise The smaller the lines or arcs the more precise the guess should be PROG PIN PIN 0812 2 l TOOL 1 3 AXIS INCH EVENT1 IRR PROFILE EVENT 2 A G E MILL X BEGIN 0 0000 abs TANGENT Y BEGIN 0 0000 abs XEND G 1 0000 abs Z RAPID 0 0500 abs Y END Z END 0 2500 abs CONRAD TOOL OFFSET RIGHT ANGLE END PASSES 2 LENGTH FIN CUT 0 0100 LINE ANGLE Z FEEDRATE 4 0 XYZ FEEDRATE 15 0 FIN FEEDRATE 10 0 TOOL FIGURE 10 7 The X End dimension has been entered as a guess note the letter G 97 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Guesses should always be entered as absolute dimensions Once entered the guessed data is green and there is a G next to it Guessed data will be labeled this way in all the events that are flagged NOT OK Once an event is OK the guessed data will be replaced by calculated data If you wish to edit your guesses placing it on the right side of the scre
170. n the desired location is X 1 50 and Y 1 00 9 11 1 Copy Drill to Tap The copy drill to tap feature allows you to convert a series of drill events over to a tap event Prompts in this event First Event is the event number of the first drill event to be copied Last Event is the event number of the last drill event to be repeated if only one event is to be repeated the Last Event is the same as the First Event Z Rapid is the Z dimension to transition from rapid to feed Make sure that Z rapid is set high enough to compensate for the amount of float in the floating tapping head Z End the depth of the thread PITCH the distance from one thread to the next in inches or mm It is equal to one divided by the number of threads per inch For example the pitch for a 1 4 20 screw is 1 20 05 inches RPM spindle RPM Tool is the tool number you assign 9 12 Thread Mill Event Advanced Features Option To program a Thread Mill event press the Thread mill soft key This event includes an automatic move in and out by 0 050 of the thread Prompts in the Thread Mill event X CENTER the X dimension of the center of the thread Y CENTER the Y dimension of the center of the thread Z RAPID the Z dimension where the Z rapid feed slows to Z program feed Z BEGIN the Z dimension where the threading pass begins Z END the Z bottom of the thread 88 Southwestern Industries Inc TRAK SX Knee Mill amp Prot
171. nabled Autoconfiguration IP Address Subnet Mask Default Gateway DHCP Server DNS Servers Primary WINS Serve r Secondary WINS Server Lease Obtained ase Expires PING 10 1 1 1 Pinging 10 1 1 1 with 32 bytes of data Reply from 10 1 1 1 bytes 32 time lt lms Reply from 10 1 1 1 bytes 32 time lt lms Reply from 10 1 1 1 bytes 32 time lt lms Reply from 10 1 1 1 bytes 32 time lt lms 149 TT TT TT TT Cray 3 Hybrid No No Intel R PRO 100 VE 00 07 E9 BA A5 47 Yes Yes 10 1 1 220 299 29929970 10 e Osh eZ 207 69 188 186 242055 k62 10 41122 TOTIS T Network 11 21 04 12 12 04 Monday Sunday L 255 L 255 L 255 L 255 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Ping statistics for 10 1 1 1 Packets Sent 4 Received 4 Lost 0 0 loss Approximate round trip times in milli seconds Minimum Oms Maximum Oms Average Oms New connections will be remembered Status Local Remote Network Disconnected V 10 1 1 3 software eng Microsoft Windows Network The command completed successfully 14 13 CAD CAM and Post Processors In addition to running G code files the ProtoTRAK will also accept CAM files and convert them into the ProtoTRAK events This is a great advantage as it allows you to have your CAD CAM programme
172. nced Features Option Verify Part is used to see a solid graphical representation of the tools making the part It should be used as a tool along with tool path to verify the part is programmed correctly Please note that you must define the diameter of your tool along with your type of tool finish end mill ball end mill drill etc you are using when setting up your tools in tool setup This allows us to draw the correct shape for the tools you are cutting with Press VERIFY PART and the following soft keys will show DEFINE STOCK Press DEFINE STOCK if you wish to input dimensions of your rectangular stock relative to the programmed absolute zero We automatically calculate and define the stock slightly larger in the X and Y axis The Z bottom value we calculate will be based off of the largest negative value we see in the program This means if you program a drill to go through the part it will make this value the Z bottom value This can be adjusted by changing the value of the Z bottom dimension You can manually change the size of your stock by modifying any of the values If you do modify your stock size and want to get back to the values we calculated or if you modify the program after we calculated the stock the first time and want to update the values then press the AUTO button under define stock Press RETURN once you define your stock Press MAKE PART and the display shows your stock material 116 Southwestern Industries
173. nd as projected in the XY plane RPM is the spindle RPM for the event INC SET will use the RPM of the previous event RPM programming is available only if the Programmable Electronic Head Option is active Z Feedrate is the Z feedrate from Z Rapid to Z begin XYZ Feedrate is the milling feedrate from Begin to End in in min from 1 to 100 or mm min from 5 to 2540 Tool is the tool number you assign Continue Yes or no This prompt appears when the Advanced Features Option is not active in order to program a continuous tool path without stops and eliminate repetitive prompts in the next event If the Advanced Features Option is active use the Profile event to accomplish the same thing ARC Events This event allows you to mill with circular contouring any arc fraction of a circle that lies in the XY plane or a vertical plane see Section 5 3 Vertical plane arcs are also limited to those that are entirely concave or convex in other words if you think of the arc lying on the surface of the earth then it can t cross the equator In ARC events when X Center Y Center and Z Center are programmed incrementally they are referenced from X End Y End and Z End respectively An ARC event may be programmed with a CONRAD if it is connective with the next event this next event must lie in the same plane as the Arc event 73 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Program
174. nds the island X3 POCKET X dimension for the opposite corner of the rectangular pocket that surrounds the island Y3 POCKET Y dimension for the opposite corner of the rectangular pocket that surrounds the island CONRAD PCKT the value of the tangential radius in the corners of the rectangular pocket that surrounds the island FIN CUT PCKT finish cut along the perimeter of the pocket If 0 is input there will be no finish cut FEEDRATE the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 FIN FEEDRATE the finish milling feedrate for both the island and pocket finish cuts TOOL is the tool number you assign 8 6 3 Irregular Island Advanced Features Option When the Advanced Features Option is active press the IRREG ISLAND key if you wish to mill an island other than a rectangle or circle The Irregular Island gives you the powerful Auto Geometry Engine to define a shape made up of straight lines and arcs The first screen in an Irregular Island event will define the beginning point and some of its general parameters The last event of the irregular pocket must end at the same point as defined in the first event Prompts for the Irregular Island event X BEGIN X dimension to the beginning of the island Y BEGIN Y dimension to the beginning of the island 63 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 8 7
175. nt Holes is the number of holes in the bolt hole pattern X Center is the X dimension to the center of the hole pattern Y Center is the Y dimension to the center of the hole pattern Radius is the radius of the hole pattern from the center to the center of the holes Angle is the angle from the positive X axes that is 3 o clock to any hole positive angle is measured counterclockwise from 0 000 to 359 999 degrees negative angles measured clockwise Tool is the tool number you assign MILL Events This event allows you to mill in a straight line from any one XYZ point to another including at a diagonal in space It may be programmed with a CONRAD if it is connective with the next event Prompts for the Mill event X Begin is the X dimension to the beginning of the mill cut Y Begin is the Y dimension to the beginning of the mill cut X End is the X dimension to the end of the mill cut incremental is X Begin Y End is the Y dimension to the end of the mill cut incremental is Y Begin 58 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 8 4 8 5 Conrad is the dimension of a tangential radius to the next event that must lie in the same plane for part geometry programming Tool Offset is the selection of the tool offset to right input 1 offset to left input 2 or tool center no offset input 0 relative to the program
176. oTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual PITCH the distance from one thread to the next in inches or mm It is equal to one divided by the number of threads per inch For example the pitch for a 1 4 20 screw is 1 20 05 inches MAJOR DIA the largest diameter of the thread the root for an ID thread the crest for an OD thread MINOR DIA the smallest diameter of the thread the root for an OD thread the crest for an ID thread SIDE input 1 for inside 2 for outside ANGLE the angle the tool feeds into the beginning depth DIRECTION clockwise or counterclockwise PASSES the number of passes to cut the thread to its final depth Z FEEDRATE The feedrate from Z Rapid to Z Begin XYZ FEEDRATE The feedrate of XYZ along the path of the helix FIN CUT width of the finish cut If 0 is input there is no finish cut If something other than 0 is input for finish cut the following prompt appears FIN FEEDRATE the milling feedrate for the finish cut RPM is the spindle RPM for the event INC SET will use the RPM of the previous event RPM programming is available only if the Programmable Electronic Head Option is active FIN RPM is the spindle RPM for the finish cut FIN RPM programming is available only if the Programmable Electronic Head Option is active TOOL is the tool number you assign 9 13 PAUSE Events The purpose of the Pause Event is to allow you to program a stop condition
177. of the current move as adjusted by the feed override Green bar graphical representation of the feed override Override of feed override 121 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 13 2 Two Versus Three Axis Running For three axis CNC models the three axis run will control all three axes Three axis models also allow you to run two axis programs When you run two axis programs with either a two or three axis CNC model the ProtoTRAK will control the X and Y table and saddle only with you manually positioning the Z quill and or knee Most differences that occur as a consequence of either two or three axis operation are obvious Two issues are worth noting 1 The way the tool table works between two and three axis operation See Section 12 1 2 2 Positioning of the Z axis is automatic in the 3 axis CNC but in two axis the ProtoTRAK SMX CNC will prompt Check Z before a rapid move and Set Z for you to position the cutter to the machine part Here you will be able to enter a go to dimension for the Z axis 13 3 Starting to Run Before running a part you must establish the position relationship between the part and quill That is you need to identify where the part is on the table relative to the tool or quill centerline This is done by using an edge finder or dial indicator to move the table so that the part p
178. ol is loaded the Z dimension will change according to the offsets in the tool table This change will occur when the GO key is pressed after the Load Tool prompt 112 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 12 2 Tool Path When the TOOL PATH soft key is pressed the program is processed and the tool path graphics are displayed SET UP PIN R0424 11 4 35 z INCH F1 F2 F3 F4 F5 F F7 Fe ADJUST FIT VIEW DRAW STEP XY YZ XZ 3D 101143 FIGURE 12 2 The Tool Path graphics show the program and tool positions Three axis CNC graphics are shown above Two axis graphics will be simpler Most programming errors that would prevent the program from running are detected when the tool path graphics are selected For example if you were to have omitted a minus sign from a Z End dimension the system would give you an error message that the Z End should not be higher than the Z Rapid The displayed graphic is automatically sized to fit the screen and an icon that represents the X Y and Z orientation is placed at the program s absolute 0 reference point The path shown on the screen represents the center of the tool e Position and drill events are drawn in yellow e Rapid moves are in red e Programmed geometry is in blue 12 2 1 Soft Keys in Tool Path ADJUST VIEW calls up additional softkeys to adjust the view See below FIT
179. olute 0 At the same time you measured the distance between the absolute zero you just established and the lower left jaw of the other vise You entered that measurement as an offset from your base vise the first one and the other vise which is Fixture 2 Any events that you programmed using Fixture 2 would treat the lower left corner of that second vise like the absolute 0 for the X Y and Z dimensions in the events 51 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 7 6 Fixture offsets are handy for combining different programs together to run at the same time or to make multiple parts by repeating the events with different fixtures The fixture offsets are entered in the Set up mode There is a base fixture called fixture number one We recommend that Event 1 in your program uses fixture number one It doesn t have to we just believe it is clearer that way 7 5 1 The Default Fixture In the program header screen you entered a default fixture number if you didn t it assumed fixture 1 as the default fixture If there are program events already in current memory when you change the multiple fixture from NO to YES they will all receive the default fixture number automatically When you change the default fixture number in the program header screen from one fixture to another all the events that had the previous default fixture numbe
180. on Z Offset information will be applied to the Z axis DRO dimension for each tool saving you the need to touch off every time the tool is changed The tool table is organized to do the following e Make it easy to set up tools e Make it easy to replace a tool or add a tool e Retain tool information in memory to reduce set up You assign tool numbers as you write a program These tool numbers may be from 1 to 99 Before machining the diameters and Z offset of each of the tools in the program must be defined so that the ProtoTRAK SMX CNC can calculate the tool path Tools that are used in the program that is in current memory are called active tools and their numbers are in red in the tool table When you save a program all the tool information for active tools is saved with it When the program is opened the tool information is put into the tool table This information will replace any information that already is in the tool table for the same tool numbers In addition to information about the tools used in a program you may load in information for tools to be used in 2 axis CNC or in the DRO mode for machining manually When you 109 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual tell the ProtoTRAK SMX CNC which tool you are using it will adjust the Z DRO dimensions accordingly so you don t have to touch off and reset after a tool change
181. on to the end of the mill cut incremental is X Begin Y END is the Y dimension to the end of the mill cut incremental is Y Begin CONRAD is the dimension of a tangential radius to the next event ANGLE END is the angle measured counterclockwise from this mill event to the next Do not input if the next event is an arc LENGTH is the length of the mill from beginning to end LINE ANGLE is the angle of this mill line moving from begin to end measured counterclockwise from the positive X axis that is 3 o clock GUESS This softkey will appear when the prompt is on X or Y dimensioned data Press the Guess key before you press INC SET or ABS SET to enter the data as a guess See Section 10 7 for using Guess and Section 10 8 for using the Graphics to enter a Guess 95 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 10 3 A G E Arc Prompts Press the A G E ARC key Prompts in A G E Arc programming Tangent this refers to the tangency of the mill to the previous event See Section 10 11 for a discussion of tangency DIRECTION is the clockwise input 1 or counterclockwise input 2 direction of the arc X END is the X dimension to the end of the arc cut incremental is from X Begin Y END is the Y dimension to the end of the arc cut incremental is from Y Begin X CENTER is the X dimension to the center of the arc incremental is from X
182. ontains data for every event See Figure 11 2 1 EDT PIN RO424 11 TOOL 1 3 AXIS INCH Z XYZ FIN TYPE TOOL FEED FEED FEED Z RAPID CONRAD POSITION 0 1000 abs z DRILL 4 0 2500 5 0 0 0000 inc BOLT HOLE 1 0 2500 5 0 0 1000 abs MLL 2 0 3750 50 100 0 0000 inc 0 0000 MILL 2 0 3750 5 0 10 0 0 0000 inc 0 0000 MILL 2 0 3750 5 0 10 0 0 0000 inc 0 0000 m lt i cos og 7 arc 20 3750 50 100 0 0000 inc 0 0000 CIRC PCKT 2 0 3750 5 0 10 0 10 0 0 1000 abs TAP 3 0 1875 0 1000 abs HELIX 3 0 1875 5 0 10 0 0 1000 abs HREAD MILL 4 0 2400 5 0 10 0 10 0 0 1000 abs paag 12 Position 3 0 1875 0 1000 abs aj i gt TOLA Fi F2 F3 F4 F5 F FF FS PAGE PAGE CHANGE Fwo pack Y lt lt b SORT PALL FIGURE 11 2 1 The Search Edit softkey launches Spreadsheet Editing View the entire program by the variables you select The first time the screen appears the data is sorted by event number Each row represents the data for the event number shown in the first column on the left The 101 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual event number is always displayed in the first column but the other data displayed on the table can be changed Soft Keys in Search Edit PAGE FWD pages forward through the table PAGE BACK pages
183. otoTRAK SMX CNC Once a program is entered the EDIT key will function Once a program is entered and the necessary SET UP operations are complete the RUN key will function Fi F2 F3 F4 F5 F FF FS PROG DRO PROG EDIT SET UP RUN INIOUT FIGURE 4 1 1 The main select a mode screen Shown here the Edit and Run Modes are grayed out because there is no program in current memory 26 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual The ProtoTRAK SMX CNC has a Screen saver already programmed in If the system is not used either by a key stroke or by counting for 20 continuous minutes the display will turn itself off The LED s on the keypad will flash every few seconds to indicate that the system is still on Press any key or move any axis to bring the screen back to its previous display The key you press will be ignored except to turn the screen on 4 1 2 Shutting Down the ProtoTRAK SMX CNC Important the system must be turned off properly First press the SYS hard key and then press the SHUT DOWN soft key see Figure 4 1 4 After a few seconds you will see the message it is now safe to turn off your computer Turn the ProtoTRAK SMX CNC off by moving the toggle switch on the display side panel to the down position If the CNC is not shut down properly the next time you turn it on the system will make you wait while it runs a scan disk
184. ou do not need to enter more information Skip past the rest of the prompts with the DATA FWD softkey If you leave the Program Mode and then return pressing the GO TO END softkey will take you automatically to the first NOT OK event 96 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 10 6 Ending A G E Any time all the events are of an Irregular Profile are OK the A G E may be ended If you are programming an Irregular Pocket there is an additional requirement that must be satisfied before the A G E may be ended the X and Y end point of the last event must be the same as the X and Y beginning point so that the pocket is closed Otherwise the ProtoTRAK SMX CNC cannot program the tool path to clear the pocket The Irregular Profile has no such restriction since profiles may be open or closed Once the A G E is ended the Irregular Pocket or Irregular Profile event is complete and you may then choose from all the programming canned cycles from the Select an Event screen To reopen the A G E Profile or Pocket simply use the BACK hard key or the PAGE FWD or PAGE BACK softkeys to position on of the A G E events on the right side of the screen You may edit or insert other events 10 7 Guessing Data Whenever you are missing X or Y Ends or Centers you should generally enter a guess Guessed data is treated differently by the ProtoTRAK SMX CNC tha
185. pen As box to declare the file type All files or programs open on the ProtoTRAK SMX CNC as a PT4 file with one exception G Code files see below Once the file is opened as ProtoTRAK SMX CNC file you may store it as ProtoTRAK SMX CNC file with the same filename and the extension PT4 The drop down menu in the Open As box shows which converters are available Open As types that are grayed out indicate converters that are available for purchase 134 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 14 9 3 Converting From the ProtoTRAK SMX CNC to a Different Format Files or programs are converted from the ProtoTRAK SMX CNC to a different format using the Save function of Program In Out Mode PROG is l PIN BRKTOO5S l l F 3 AXIS l INCH SAVE Look In Jaa File Name 00254 Save As Fi F2 F3 F4 F5 F FF FS DATA DATA OPEN CREATE SAVE ee FWD BACK Ee Eee FILE RETURN FIGURE 14 9 3 Use the Save As box to tell the ProtoTRAK SMX CNC what kind of file you want the current program in the PT4 format to be converted into In Figure 14 9 3 the file name 00254 is being saved on drive A as a mx3 file Note that although the program or part name as shown in the status line is BRKT005 the file name given for converting the file conforms to the mx3 format fewer than eight characters long and consisting of numbers
186. ple if you own a ProtoTRAK SMX 2 axis retrofit you should skip 1 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual e Section 9 Three axis program events Sections that may not apply to all users contain a note to inform you of this fact Section 2 of this manual provides important safety information It is highly recommended that all operators of this product review this safety information carefully 2 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 2 0 Safety The safe operation of your knee mill depends on its proper use and the precautions taken by each operator 2 1 2 2 Read and study this manual Be certain every operator understands the operation and safety requirements of this machine before its use Always wear safety glasses and safety shoes Always stop the spindle and check to ensure the CNC control is in the stop mode before changing or adjusting the tool or workpiece Never wear gloves rings watches long sleeves neckties jewelry or other loose items when operating or around the machine Use adequate point of operation safeguarding It is the responsibility of the employer to provide and ensure point of operation safeguarding per OSHA 1910 212 Milling Machine Safety Publications Refer to and study the following publ
187. positive on the workpiece Z Axis positive Z axis motion is defined as moving the head up Measurement up is also positive on the workpiece Z Y X X Y Z FIGURE 5 1 ProtoTRAK SMX CNC conventions The Z RAPID dimension is the position at which Z will stop rapid traversing and switch to its programmed Z feedrate Z motion will continue until Z End depth has been reached Part Geometry amp Tool Path Programming The ProtoTRAK SMX CNC gives you ultimate flexibility in programming Programs that are entered through the ProtoTRAK SMX CNC system can be entered as either Part Geometry or Tool Path optional Part Geometry programming is the popular programming style of the ProtoTRAK family of products This is done by defining the final geometry of the part and the ProtoTRAK SMX CNC has the job of figuring out the tool path from the part dimensions and the tool set up information This is a great benefit compared to regular CNC because it doesn t force the programmer to do the difficult job of defining tool path A consequence of part geometry programming is that the following are not allowed e connection of an incline plane and another event e connection of two events that lie in different planes Using Geometry Programming it is impossible for the ProtoTRAK SMX CNC to calculate a tool path for these cases without creating a problem in cutting the geometry desired in the first event the tool ends up out of position for the next
188. prompts TEACH MILL a straight line that specifies the beginning and the end When TEACH MILL events are defined using the CONT MILL softkey the prompts for information that cannot change will be suppressed See Section 8 3 for a description of Mill event prompts When a Teach event is unfinished the words NOT OK will appear next to the event type Once the prompts are completed the words NOT OK and Teach will disappear The event will become a normal POSN DRILL or MILL event 70 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 9 0 Three Axis Program Events This section describes the program events and prompts that are available in three axis programming If your ProtoTRAK SMX CNC is configured for two axis programming only you should skip this section Events are fully defined pieces of geometry By programming events you tell the ProtoTRAK SMX CNC what geometry you want to end up with it figures the tool path for you from your answers to the prompts and the tool information you give it in the Set Up Mode 9 1 9 2 POSN Position Events This event type positions the table and quill at a specified position The positioning is always at rapid speed modified by feedrate override and in the most direct path possible from the previous location The most common use of the position event is to move the tool around an obstacle such as a clamp
189. r Direction is the clockwise input 1 or counterclockwise input 2 direction for milling Tool Offset is the selection of the tool offset to the right input 1 offset to the left input 2 or tool center no offset input 0 relative to the programmed edge and direction of the cutter movement Fin Cut is the width of the finish cut If 0 is input there will be no finish cut Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Fin Feedrate is the milling feedrate for the finish cut if programmed Tool is the tool number you assign 8 7 3 Irregular Profile Advanced Features Option When the Advanced Features Option is active press the IRREG PROFILE soft key if you wish to mill a profile other than a rectangle or circle The Irregular Profile event gives you the powerful Auto Geometry Engine to define a shape made up of straight lines Mills and arcs The Irregular Profile is a series of events that are programmed to machine continuously The first event of the series will be called an IRR PROFILE and it will define the beginning point of the profile and other information that applies to the entire profile X Begin is the X dimension of the beginning of the profile Y Begin is the Y dimension of the beginning of the profile Tool Offset is the selection of the tool offset to right input 1 offset to left input 2 or tool center no offset input 0 relative to the programmed edge an
190. r will be changed to the new default fixture number If there are no program events in current memory when you change the multiple fixture feature from NO to YES the prompt will be added to the end of every event you then program The default fixture number will be assumed if you press SET without specifying a different number If you do specify a different fixture number that fixture number will become the assumed input for subsequent events when SET is pressed 7 5 2 Fixtures and Running the Program To run the program first go to the DRO mode and set absolute 0 at the base fixture Fixture 1 In the Run mode the SHOW ABS displays the absolute position relative to the fixture in the event being run that is the absolute dimension that was programmed 7 5 3 Editing Fixtures With the Multiple Fixtures feature turned to YES you may edit the fixture number in the Program Mode event by event You may also use the Search Edit feature in the Edit Mode to change fixture numbers See Section 12 4 for setting up fixture offsets Assumed Inputs The ProtoTRAK SMX CNC will automatically program the following when you simply press SET either INC SET or ABS SET Tool Offset If the first event with an offset CENTER If not the first event with an offset the same as the last event if that event was a Mill or Arc event Feedrate same as last event if that event was a Mill Arc Pocket Frame or Helix Tool same as last event or Tool
191. r Accounts iselect system 101139 Figure 14 12 2 Double click on the System icon 5 Select the Computer Name tab 6 Do not enter the computer description here Instead click the Change button 143 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual System Properties TAL 1630 01137 Figure 14 12 3 Click on the Change button to enter the name 7 Enter a name for the ProtoTRAK SX in the Computer Name box We suggest something descriptive for example TRAK SX3 8 Enter a workgroup This workgroup must match the name of the workgroup on your desktop computer Assigning a workgroup name for your computer is discussed above If you have not selected a workgroup for your computer we suggest shop or toolroom 144 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Computer Name Changes 2 xi You can change the name and the membership of this computer Changes may affect access to network resources Computer name TRL1630 Full computer name TRL1630 More m Member of C Domain p Workgroup work Cancel 101134 Figure 14 12 4 Enter the computer name and workgroup name 9 Keep clicking OK until you get back to the Select a Mode screen 10 You must now save the changes so t
192. r For the connection and the Folder that you want to connect to Drive fE Folder Example server share Browse Connect Using Different User Name Mapped drive will not be persistent User name User password mooo cme 101136 Figure 14 12 6 Enter E in the Drive box and Browse for the file you shared on your computer 5 Click OK The shared drive on the computer should now be accessible in the Program In Out Mode under drive E 146 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 6 Once complete you must now save all changes made To do so simply click on the Save button at the network utility window See figure 14 12 5 Note If you have an older version of the ProtoTRAK SMX or SLX control it is possible that the SAVE option is not visible If this is the case then disregard this step Otherwise if the SAVE option is visible then you must click on it in order to persist any and all changes done in the previous steps To connect other ProtoTRAKs on this simple network repeat the process starting with assigning a name Each ProtoTRAK must have a unique name and use the same workgroup Note however that our ProtoTRAK controls are NOT able to share their contents with each other Think of it as a one way street the ProtoTRAKs are able to access regular PC s and save retrieve files but the
193. r of the arc incremental is from X End Y Center is the Y dimension to the center of the arc incremental is from Y End Z Center is the Z dimension to the center of the arc incremental is from Z End The Z Center dimension is programmed only if the Advanced Features Option is active Conrad is the dimension of a tangential radius to the next event which must lie in the same plane Direction is the clockwise input 1 or counterclockwise input 2 direction of the arc as viewed looking down for an arc in the XY plane looking from the front for a vertical plane or looking from the right for a vertical YZ plane Tool Offset is the selection of the tool offset to right input 1 offset to left input 2 or tool center no offset input 0 relative to the programmed edge and direction of tool cutter movement and as projected in the XY plane RPM is the spindle RPM for the event INC SET will use the RPM of the previous event RPM programming is available only if the Programmable Electronic Head Option is active Z Feedrate is the Z feedrate from Z Rapid to Z Begin XYZ Feedrate is the milling feedrate from Begin to End in in min from 1 to 100 or mm min from 5 to 2540 Tool is the tool number you assign Continue Yes or no This prompt appears when the Advanced Features Option is not active in order to program a continuous tool path without stops and eliminate repetitive prompts in the next event If the Advanced Features
194. r rotated without changing the original events e Connect so that the quill will not move up to the Z Rapid position and back down unnecessarily However to be connective you must be certain that the X Y Z begin of the first event once offset or rotated coincides with the X Y Z end of the last event e Program an event parallel to X or Y where the geometry is the easiest to describe rotate it to the desired position and then delete the original Use the Clipboard to paste previously stored events from another program into the current program After you press the Clipboard key you will enter the offset from the previous program s absolute zero to the current program s absolute zero see figure below For information about putting events into the clipboard see Section 11 4 69 Southwestern Industries Inc TRAK SX Knee Mill amp Proto TRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual DESTINATION PROGRAM i00965 Figure 8 10 In the above example the offset that puts the group of holes in the desired location is X 1 50 and Y 1 00 8 11 Finishing Teach Events Teach events are either POSN DRILL or MILL events that are originated in the DRO Mode see Section 6 7 The Teach events that are started in the DRO Mode must be finished in the Program Mode before running Teach events are of these different types TEACH POSN DRILL See Section 8 1 for a description of Position Drill event
195. r send files to the machine that the machinist can then work with in the familiar ProtoTRAK interface The machinist can modify the program as necessary without having to go back to the CAD CAM programmer In order to be able to convert the program from a CAM system to a ProtoTRAK program the CAM program must be two or 2 axis A 2 axis program is defined as a program where the Z axis is stationary while X and Y is moving If you want to run a full three axis program you should run a G Code or GCD program see section 14 11 The above 2 axis restriction does not mean that the ProtoTRAK is not capable of running three axis simultaneous programs written in ProtoTRAK events as some ill informed competitors would have you believe This restriction is a matter of practicality Because the ProtoTRAK allows you to program in part geometry and therefore will figure out the tool path for you the process of converting a three axis program gives the ProtoTRAK a tool position problem that it cannot resolve without a lot more data from you The other reason is that the output from a CAM systems for three axis shapes is in the form of thousands and thousands of straight line G01 moves that would convert into the equal number of ProtoTRAK Mill events This is hardly a manageable program Instead of forcing the issue in a silly way we give you the more elegant solution of running GCD files To our competitors we respectfully point out that the thread and
196. reverse is not true 14 12 4 General Information For Advanced Networks The ProtoTRAK SMX SLX CNC is a PC but for setting up a network it is more useful to think of it as a device such as a printer While the ProtoTRAK has many similarities to a desktop computer it is different in that the use of the computer s resources have been optimized for running part programs and the resulting motor sensor feedback in real time In order to avoid causing a slow down or instability in the operating system of the control keep the following in mind when setting up the network Do not use a resource intensive networking program such as SMS Use the Windows XP utilities in the ProtoTRAK SX instead Avoid loading programs that direct background tasks Some examples are e mail web browsers and anti virus programs Virus Protection As a device ProtoTRAK CNCs are not generally susceptible to viral infections The part programs they run are non executable text files You can further assure protection by avoiding e mail programs and web browser programs loaded onto the ProtoTRAK and by using a router with a firewall An anti virus program is not necessary since the virus risk is low and is not recommended because the background tasks may cause damage by interfering with ProtoTRAK real time operation 14 12 4 1 Network Tools On The ProtoTRAK SX There are a handful of utilities on the ProtoTRAK SX in order to aid network set up for Network
197. rful Auto Geometry Engine to define a shape made up of straight lines Mills and arcs The Irregular Profile is a series of events that are programmed to machine continuously The first event of the series will be called an IRR PROFILE and it will define the beginning point of the profile and other information that applies to the entire profile X Begin is the X dimension of the beginning of the profile Y Begin is the Y dimension of the beginning of the profile Z Rapid is the Z dimension to transition from rapid to feed Z End is the Z dimension of the depth of the profile Tool Offset is the selection of the tool offset to right input 1 offset to left input 2 or tool center no offset input 0 relative to the programmed edge and direction of tool cutter movement 83 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 9 9 Passes is the number of cycles to machine to the final depth spaced equally from Z rapid to Z end hint keep Z Rapid small Z Feedrate is the Z feedrate from Z rapid to Z end XYZ Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Fin Cut is the width of the finish cut If 0 is input there will be no finish cut RPM is the spindle RPM for the event INC SET will use the RPM of the previous event RPM programming is available only if the Programmable Electronic Head Option is acti
198. ro at the current position Note This will also reset the incremental dimension if the absolute position is being displayed when it is reset Preset Absolute Reference Press X or Y or Z numeric data ABS SET to set the selected axis absolute to a preset location for the current machine position 43 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 6 3 6 4 Note This will also reset the incremental dimension if the absolute position is being displayed when it is preset Recall Absolute Position of All Axes Press INC ABS Note the dimension for each axis is labeled INC or ABS Press INC ABS again to revert to the original reading Recall Absolute Position of One Axis Press X or Y or Z INC ABS Note the INC or ABS label for each axis Repeat to get selected axis back to original reading Jog The servomotors can be used to jog the table saddle and ram a Press the JOG soft key b A flashing message will appear saying CAUTION JOG KEYS ARE ACTIVE c To jog press the X Y or Z hard keys d To stop jogging release the key e The speed of jog is displayed in the box next to the words Feed Rate on the lower left side of the LCD screen f Press the hard key to reverse direction When the number in the Feed rate box is negative this indicates the minus direction g Press the RATE keys to reduce and to increase the jog speed
199. rogram absolute zero is under the quill centerline ABS SET this position as absolute zero in the DRO mode In addition load the tool for Event 1 and position it at Z absolute zero If this is impossible position the tool some known distance above absolute zero and ABS SET this dimension The program may be started in the two ways identified as soft keys in the screen in Section 13 1 Pressing the START soft key begins the program at Event 1 and assumes that the absolute zero that was last set in the DRO mode corresponds to the part program zero That is if you were in the DRO mode and you moved the table to X 0 ABS and Y 0 ABS the part program zero would be directly under the quill centerline Pressing the START EVNT soft key allows you to start in the middle of a program When you press the START EVNT soft key the conversation line will prompt Input Event Input the number of the first event you wish to run and press SET If the START EVNT is a Repeat or Rotate the conversation line will prompt Starting Repeat Number asking which repeat or pass you wish to start 122 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 13 4 Program Run When you have started by any of the means above the display will show RUN PIN BALLPRK1122 TOOL 1 3 AXIS INCH Event 1 RUN Repeat 0 X 0 0000 ves Y 0 0000 ves Z 0 0000 ves SPINDLE RPM
200. rom Z rapid to Z end XYZ Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Fin Feedrate is the milling feedrate for the finish cut Tool is the tool number you assign 9 6 3 Irregular Pocket Advanced Features Option Press the IRREG PCKT soft key if you wish to mill a pocket other than a rectangle or circle The Irregular Pocket event gives you the powerful Auto Geometry Engine to define a shape made up of straight lines Mills and arcs The first screen in an irregular pocket event will define the beginning point and some of its general parameters The last event of the irregular pocket must end at the same point as defined in the first event X Begin is the X dimension of the beginning of the pocket Y Begin is the Y dimension of the beginning of the pocket Z Rapid is the Z dimension to transition from rapid to feed Z End is the Z dimension of the depth of the pocket Passes is the number of cycles to machine to the final depth spaced equally from Z rapid to Z end hint keep Z Rapid small Entry mode choose between a zigzag ramp and a plunge The plunge will machine straight down Z to the appropriate Z depth The zigzag ramp will move in a zigzag pattern to depth See Section 9 6 5 for more information about the zigzag ramp 76 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Z Feedrate is
201. s In order to run a program must make sense geometrically For example you can t machine a 250 inch diameter circular pocket using a 500 inch end mill Data errors will nearly always be detected when the ProtoTRAK SMX CNC runs through a program either as a Trial Run or on an actual part run They may also be detected in the Set Up mode when using the Tool Path Graphics routines Whenever the ProtoTRAK SMX CNC detects a data error a message will appear that will tell you the error number you may wish to record this number for troubleshooting purposes and the event where the error was detected This is not necessarily the event that is in error since the system often looks ahead to make sure there is compatibility from one event to another In addition an explanation is given for each data error type as well as a suggested solution Press the RETURN soft key to go back to the Select Mode screen correct your error and proceed 13 11 Fault Messages The ProtoTRAK SMX CNC performs a number of automatic checks or self diagnostics If problems are found a message will appear Fault __ ______ The information area will display an explanation and suggested solution 125 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 14 0 Program In Out Mode From the Select Mode screen press the PROG IN OUT softkey The first screen you see will ask LIST S
202. s Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 6 5 Do One The Do One routines in the DRO mode allow you to do one CNC operation while machining manually without having to write a program The programming and tool path of the events in Do One are nearly identical to those in the Program Mode See Section 8 for instructions for programming 6 6 Go To TRAKing Electronic Handwheels Option The Go To function in the DRO mode allows you to set a dimension in X Y or Z at which you want the machine to stop moving when you are cranking manually For example if you wanted to machine manually exactly 2 of table motion you would input Go To X 2 Inc Set While the Go To window is displayed the ProtoTRAK SMX will not let you pass that 2 dimension you set a Press the Go To key b Enter the axis X Y Z or any combination Input the dimension s c Press Inc Set or Abs Set d Crank the handwheel Motion will stop at the entered dimension even if you continue to crank the handwheel 6 6 1 GoTo for Three Axis CNC Models Whether or not the TRAKing Electronic Handwheels Option is active TRAK Knee Mills and ProtoTRAK SMX retrofits with the Z axis ballscrew and motor assembly installed for three axis CNC will have this feature enabled for manual quill operation Simply follow the instructions above If the TRAKing Electronic Handwheels Option is not active only the Z
203. s not necessary to program a spindle off 7 5 Coolant Air on and off is automatically programmed for tool changes If you want the air or coolant pump on while cutting the entire part you need only program the Aux begin in the first event and Aux end in the last event The coolant pump or air solenoid will turn on at the beginning of the programmed event and will turn off during tool changes The Indexer function is designed to operate with a standard indexer Programming an Aux 3 at the beginning or end of an event will cause the ProtoTRAK SMX CNC to stop machining at the beginning or end of the event and wait for a signal from the indexer The signal notifies the CNC that the indexer has finished its programmed move The CNC will then automatically resume the program Make sure your tool is clear of the workpiece before commanding an index If need be add an Aux 3 to the end of a position event Multiple Fixtures This function is part of the Advanced Features Option You may run your program using up to six fixtures plus a base A fixture is a location on your machine with a defined offset from your absolute 0 When you program an event to have a fixture it will treat the offset as if it were absolute zero shift The programmed X Y and Z absolute dimensions are relative to the absolute reference for the specified fixture For example say you had two vises on the table On the first vise you established the lower left jaw as the abs
204. set the highlight will not go into the Z Offset column because setting a Z offset before the Z reference is set has no meaning Z modifier a value you enter to make adjustments for the tool depth See 12 1 7 below Tool Type allows you to select the type of tool from a list Input the number that corresponds to the desired name eg 1 Drill and press SET The tool name will be in the prompt at the beginning of the program Run Ref the reference position for the Z offset Before the reference position is set and the Ref row reads NOT SET the highlight will not go into the Z Offset column Once set the highlight will not go into the Ref row that is you will not be able to highlight and reset your reference once it says SET The soft keys in the tool table DATA DOWN DATA UP DATA LEFT DATA RIGHT move the highlight around the table ERASE TABLE clears all tool information so you can start over See 12 1 4 below JOG puts the ProtoTRAK SMX CNC into the DRO jog operation see Section 6 3 RETURN reverts to the SET UP mode screen The electronic handwheels are active including the fine coarse selection while you are in the tool table 12 1 2 The Logic of the Tool Table For three axis CNC models the diameters and Z Offsets must be set up for each tool For two axis CNC models the diameter is essential for the tool compensation to work but the Z Offset information is not mandatory However even in two axis or DRO operati
205. soft keys change to Fi F2 F3 Fa F5 F F FS THREAD EN e a a a a 101146 FIGURE 7 9 2 When the More soft key is selected these additional event types are available for three axis CNC models If the Advanced Features or E Head Option are not active relevant functions will be grayed out After an event type is selected from the soft keys the prompts for that event will appear on the right side of the screen The data you need to enter to program the event will appear in the Data Input Line As soon as you enter one piece of data by pressing the INC SET or ABS SET key the next prompt will appear in the Data Input Line 54 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual PROG PINO806 BRACKET 3 AXIS INCH EVENT 0 EVENT 1 BOLT HOLE PROGRAM NAME 0806 BRAC DRILL OR BORE DRILL SCALE 1 000 HOLES DWELL REQUEST NO X CENTER AUXILIARY FUNCTION NO Y CENTER EVENT COMMENTS NO Z RAPID MULTIPLE FIXTURES NO Z END DIMENSION DEFINITION PART GEO RADIUS ANGLE PECKS FOR DRILL Z FEEDRATE TOOL HOLES JJ i01061 FIGURE 7 9 3 Here a Bolt Hole event was selected for three axis CNC For two axis Z programming prompts do not appear The ProtoTRAK SMX CNC is prompting you to enter the number of holes 7 10 Editing Data While Programming While programming an event all data is entered by pressing the appropriate numeric
206. stries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual The other way to tell if the Advanced Features Option is active is to go to Service Code 318 The Advanced Features Option is active if the letters are in black inactive if they are in gray With the Advanced Features Option you get the following Auto Geometry Engine see Section 10 0 3 axis conversational programming three axis CNC models Additional Canned Cycles Irregular Pocket Face Mill Circle Island Rectangular Island Irregular Island Irregular Profile Helix three axis CNC models Thread milling three axis CNC models Engrave Tapping G Code editor Countdown clock to next pause or tool change Total program time estimator Spreadsheet editing Global data change Scaling of print data Multiple fixture offsets Event comments Tool path conversational programming Mirror of programmed events Copy with or without offsets Copy Rotate Copy Mirror Clipboard to copy events between programs If the Advanced Features Option is not active you may purchase it easily The Advanced Features Option is a software option so it is simply a matter of entering the Activation Password into the ProtoTRAK To obtain the Password see the instructions in section 3 1 8 below 3 1 3 Networking Option The Networking Option gives you powerful choices in program storage and handling T
207. tangent sharp not tangent For the A G E the tangent mill or arc is assumed to continue in the same direction and not double back on the previous event like this not this 100 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 11 0 Edit Mode Within Program Mode you can recall and re input specific data prompt by prompt When the Advanced Features Option is active the Edit Mode contains powerful routines for more extensive program changes The changes you make in the Edit Mode affect only the program in current memory In order to preserve the changes for future use the program must be stored again under the same name in the In Out Mode 11 1 Delete Events To delete a group of events in the program press Delete Events The Data Input Line will prompt for the first event to be deleted Input the event number of the first event and press set Next the Data Input Line will prompt for the last event number to be deleted Put in the last number and press Set The remaining events will be renumbered 11 2 Spreadsheet Editing Advanced Features Option Spreadsheet Editing allows you to view program inputs in a table and make global changes to the program This is particularly useful if you are working with a large program and you need to make a change to many events When you press the SEARCH EDIT softkey the screen will load a table that c
208. tected This means any changes to the registry are thrown away across a power down The Domain Login system requires that security keys be renewed and saved from time to time It also requires that even Master Key values must time out and be renegotiated at some point in time When these events occur automatically the new keys are placed in the temporary registry which will be thrown away on power down unless some special action is taken For all these reasons we will not be able to support any system that encounters network connectivity problems when logged into a domain using a domain logon Use the Workgroup connectivity instead It is also important to note that our ProtoTRAK control is not a full blown workstation It is not designed to hook up to the internet download MS updates or run any additional third party software in the background not unless you want to sacrifice machine performance It is also not able to share its contents to the rest of the network It also must be excluded from services such as Windows Server Update Service which tries to force Microsoft Updates and other downloads into the control An ideal setup would be to purchase a router and have it connected directly to the ProtoTRAK control and have it handle communications between it and your desktop computer Several ProtoTRAKs can be hooked up simultaneously with minimal effort The simplest scenario is to have the ProtoTRAK control and desktop computer both s
209. ter no offset input 0 relative to the programmed edge and direction of the cutter movement Passes is the number of cycles to machine to the final depth spaced equally from Z Rapid to Z End hint keep Z Rapid small Fin Cut is the width of the finish cut If 0 is input there will be no finish cut RPM is the spindle RPM for the event INC SET will use the RPM of the previous event RPM programming is available only if the Programmable Electronic Head Option is active FIN RPM is the spindle RPM for the finish cut FIN RPM programming is available only if the Programmable Electronic Head Option is active Z Feedrate is the Z feedrate from Z rapid to Z end XYZ Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Finish Feedrate is the milling feedrate for the finish cut Tool is the tool number you assign 82 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 9 8 2 Rectangular Profile Press the RECTANGLE soft key if you wish to mill a rectangular frame all corners are 90 right angles Prompts for the rectangular profile X1 is the X dimension to any corner Y1 is the Y dimension to the same corner as X1 X3 is the X dimension to the corner opposite X1 incremental is from X1 Y3 is the Y dimension to the same corner as X3 incremental is from Y1 Z Rapid is the Z dimension to transit
210. tern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 9 16 Finishing Teach Events Teach events are either POSN DRILL or MILL events that are originated in the DRO Mode see Section 6 7 The Teach events that are started in the DRO Mode must be finished in the Program Mode before running Teach events are of these different types TEACH POSN for two axis operation the Position and Drill event types are combined See Section 9 1 for a description of Position event prompts TEACH DRILL this may also be made into a bore event See Section 9 2 for a description of Drill event prompts TEACH MILL a straight line that specifies the beginning and the end When TEACH MILL events are defined using the CONT MILL softkey the prompts for information that cannot change will be suppressed See Section 9 4 for a description of Mill event prompts When a Teach event is unfinished the words NOT OK will appear next to the event type Once the prompts are completed the words NOT OK and Teach will disappear The event will become a normal MILL DRILL or POSN event 93 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 10 0 Auto Geometry Engine A G E Programming This entire section deals with the Auto Geometry Engine which is part of the Advanced Features Option If the Advanced Fea
211. ters you will need to purchase the option to activate it The DXF Option Consists of additional software and an Activation Password The software can be shipped to you See Section 3 1 8 below for instructions on ordering and obtaining your Activation Password The DXF Option has its own manual which is shipped with the software You may also view a copy of the manual on our web site at www southwesternindustries com 3 1 6 Converter Options Optional converters are available for running programs created on other CNCs on the ProtoTRAK and vice versa See section 14 9 for instructions on using converters If the converter you want is not active you may purchase it easily Converters are software options so it is simply a matter of entering the correct Activation Password into the ProtoTRAK To obtain the Password see the instructions in section 3 1 8 below 3 1 7 TRAKing Electronic Handwheels Option The TRAKing Electronic Handwheels Option extends the power of the ProtoTRAK SMX CNC beyond the ordinary by combining the electronic handwheels with software routines in the DRO and RUN Modes If you did not buy this option with the original machine you may add it later The option includes e Electronic Handwheels on X and Y replaces the mechanical handwheels see Section 3 4 1 e TRAKing of programs during program run see Section 13 5 e Go To Dimensions see Section 6 6 e Selectable Fine Coarse handwheel resolution see Section 3
212. ters that are available in the Engrave Event When programming with the Engrave Event the ProtoTRAK will construct a box to contain the text you define This box is oriented along the X axis like the text in this sentence and you may program up to 40 characters per event although you will only be able to see 20 characters on the prompts screen To machine text in a direction other than the X axis simply use multiple Engrave Events and place the lower left corner of the box wherever you would like The numbers and letters you program will always have a standard orientation like the letters on this page you cannot program tilted or inverted letters with the Engrave Event The letters are of the font shown in the figure and all capitals Prompts for the Engrave Event First define the lower left corner of the box that will contain your text X BEGIN The X coordinate of where you want your text to begin Y BEGIN The Y coordinate of where you want your text to begin Z RAPID The Z dimension where the Z rapid feed slows to Z program feed Z END The Z dimension to the bottom of your text 91 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual HEIGHT The height of your text Each character varies in width the set height of the character will change the width in order to keep the overall size of the character proportional TEXT The text to be m
213. that in Copy the events are rewritten into subsequent events If for example in event 11 you Copy Repeated events 6 7 8 9 10 with 2 repeats events 6 10 would be copied with the input offsets into events 11 15 and recopied into 16 20 Copy Events may be Repeat Mirror Rotate or Drill to Tap Copy is very useful With Copy you can Edit the events that are being repeated mirrored or rotated without changing the original events e Connect so that the quill will not move up to the Z Rapid position and back down unnecessarily However to be connective you must be certain that the X Y Z begin of the first event once offset or rotated coincides with the X Y Z end of the last event e Program an event parallel to X or Y where the geometry is the easiest to describe rotate it to the desired position then delete the original Use the Clipboard to paste previously stored events from another program into the current program After you press the Clipboard key you will enter the offset from the previous program s absolute zero to the current program s absolute zero see 87 Southwestern Industries Inc TRAK SX Knee Mill amp Proto TRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual figure below For information about putting events into the clipboard see Section 11 4 SOURCE PROGRAM DESTINATION PROGRAM i00965 Figure 9 11 In the above example the offset that puts the group of holes i
214. the finish radius of the circle Direction is the clockwise input 1 or counterclockwise input 2 direction for milling Passes number of cycles to machine to the final depth spaced equally from Z Rapid to Z End hint keep Z Rapid small Entry mode choose between a zigzag ramp and a plunge The plunge will machine straight down Z to the appropriate Z depth The zigzag ramp will move in a zigzag pattern to depth See Section 9 6 5 for more information about the zigzag ramp Fin Cut is the width of the finish cut If 0 is input there will be no finish cut See Section 9 6 7 for a bottom finish cut RPM is the spindle RPM for the event INC SET will use the RPM of the previous event RPM programming is available only if the Programmable Electronic Head Option is active FIN RPM is the spindle RPM for the finish cut FIN RPM programming is available only if the Programmable Electronic Head Option is active Z Feedrate is the Z feedrate from Z rapid to Z end XYZ Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Fin Feedrate is the milling feedrate for the finish cut Tool is the tool number you assign 9 6 2 Rectangular Pocket Press RECTANGLE soft key if you wish to mill a rectangular pocket all corners are 90 right angles and the sides are parallel to the X and Y axes 75 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming
215. the pattern in X Y Offset 5 inc set Offset the pattern in Y by 0 5 Z Rapid Offset inc set Does not change the Z Rapid plane Z Offset inc set Does not change the Z depth Repeats 6 abs Copies the selected events 6 times Feed inc set Leaves the feedrate where it was Tool inc set Leaves the previous tool as the current tool Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Select More then Copy then Repeat to do the drilling using Event 3 thru 9 info EVENT 10 COPY REPEAT NOTES for the drill 0 1 operation First Event 3 abs Selects the first event to copy from Last Event 9 abs Selects the last event to copy to X Offset 5 5 inc set Offset the pattern in X by 5 5 Y Offset inc set Does not offset the pattern in Y Z Rapid Offset inc set Does not change the Z Rapid plane Z Offset inc set Does not change the Z depth Repeats 1 inc set Copies the selected events 1 time Feed inc set Leaves the feedrate where it was Tool inc set Leaves the previous tool as the current tool EVENT 17 BOLT HOTE NOTES drill for 0 5 bolt pattern Drill or Bore 1 Selects Drill Function of Holes 5 abs Known print value X Center abs Defaults to X zero Y Center abs Defaults to Y zero Z Rapid 1 abs Sets the rapid plane to 0 1 Z End 75 abs Sets the drill depth to 0 75 Radius 1 625 abs The radius of
216. tically from the router That means that the computers are probably connected when you turn them on and plug the cables into the routers You can confirm that the ProtoTRAK and computer are connected by looking at the lights on the front of the router Once the connection is made you still need to do a couple more steps before the network is useful 14 12 2 Assigning a Name and Selecting a Workgroup No matter what kind of network you establish you must assign a name and select a workgroup for your ProtoTRAK SX CNC On The Desktop Computer You Want To Network There are differences in the process of setting up a network between Windows 98 Windows 2000 Windows XP and other operating systems Fortunately there are just a couple of things you need to do and the instructions for these are already on your computer 1 Set your computer to automatically obtain IP addresses For instructions on how to do this go to Windows Help and search for the topic IP Addresses If the lights above the cable on the router are on you don t have to do this 2 Create a Workgroup name for your computer For instructions on how to do this go to Windows Help and search for the topic Workgroup Names If there is a workgroup name already write it down We will make the ProtoTRAK match the existing name in the next steps below 3 Share a part of your computer This will allow the ProtoTRAK SX to look into the drives or folders you share For ins
217. tine does not check for programming errors Use Tool Path in the SET UP Mode to check movement of the tool 7 12 Finish Cuts The Pocket and Profile events are designed with built in finish cut routines because they are complete and stand alone pieces of geometry Shapes machined with a series of Mill or Arc events either with or without A G E Profile don t have an automatic routine for making finish cuts There is however a very simple technique that can be used a Program the shape using the print dimensions and ignore the need to leave material for a finish cut b Using a subroutine event Repeat all the events in a but call out a different tool number C In Set Up Mode lie about the tool diameter for the tool called out in events in a Input a tool diameter equal to the actual tool diameter plus 2 times the finish cut you wish to leave The ProtoTRAK SMX CNC will think the tool is bigger than it really is and therefore shift a little further away from the machined shape d In Set Up Mode input the actual diameter for the tool called in the Repeat event b This will produce the final dimensioned cut 56 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 7 13 Two Versus Three Axis Programming for Three Axis CNC Models For TRAK Knee Mills and retrofits with the Z axis ballscrew and motor assembly installed the ProtoTRAK SMX
218. ting amp Care Manual 7 4 Auxiliary AUX Functions Three Axis CNC Models Only When the Auxiliary Function Option is installed and active the ProtoTRAK SMX CNC can control four different auxiliary functions You can select whether to activate or deactivate these functions at the beginning or end of each event If Auxiliary Functions are selected on the program header the system will prompt for AUX BEG and AUX END in each event When running programs with Auxiliary functions the ACCESSORY hard key on the front panel must be in the correct position If you want the program to automatically turn the Auxiliary functions on and off press the ACCESSORY key until the light is on in the AUTO position AUX BEG Options Input Function Comments None No Auxiliary functions will begin when this event begins to run Coolant Air The coolant pump or air solenoid will be turned on when this event begins to run Indexer Activates an electronic signal at the beginning of the event See note below AUX END Options None No Auxiliary functions will turn off at the end of this event Coolant Air Off Turns the coolant or air solenoid off at the end of this event Indexer Activates an electronic signal at the end of this event See note below Spindle Turns off the spindle at the end of this event Note the spindle automatically turns off for each tool change it i
219. tool table The numbers for the tools that are used in the program are in red The diameters Z Offsets and Z modifiers that were saved with the program will overwrite any information that was in the tool table before the program was opened If these tools were not set very recently we recommend that you check them before running the program The Ref row will read NOT SET A reference may be set at this point If you do not go into the tool table after opening a program and before running you will get a reminder message to check your tools 12 1 11 Making Tool Set Ups Easy We highly recommend the following to make tool set ups easy 1 Always use the same tool to set your reference Preferably you should use a tool you don t use to machine something that you keep in your toolbox 2 Don t use a tool that you use to machine your part as a reference If your reference tool breaks you have to reset all your tools 3 Always use the same surface for touching your tools to Use the machine table a gage block or the vice something you can always count on being there If you use the top of the part your reference is changing all the time 12 1 12 The Tool Table and Two Axis CNC Operation The information entered in the tool table will also be used when operating the ProtoTRAK SMX CNC as a two axis CNC Instead of positioning the head the DRO information seen in the Run Mode will be adjusted for the differences in tools When a new to
220. transition from rapid to feed Z End is the bottom of the hole Radius is the radius of the hole pattern from the center to the center of the holes Angle is the angle from the positive X axes that is 3 o clock to any hole positive angle is measured counterclockwise from 0 000 to 359 999 degrees negative angles measured clockwise Pitch is the pitch of the tap that is used if the Tap option is chosen Tap is available only if the Programmable Electronic Head Option is active PECKS is the number of tool withdrawal cycles Each cycle drills and then retracts to the Z rapid position The factory setting is for each peck to be successively smaller taking the largest cuts at the beginning and the smallest at the end Variable You may change this to equal pecks To do this press the HELP key when the highlight is on this prompt This will take you to a screen where you may choose to have the same amount of material taken per peck Fixed You can also choose Chip Break where the tool will perform fixed pecks but only rapid out about 020 after each peck instead of going back to the Z rapid position after every peck This new setting will remain until you change it again RPM is the spindle RPM for the event INC SET will use the RPM of the previous event RPM programming is available only if the Programmable Electronic Head Option is active Z Feedrate is the drilling feedrate Tool is the tool number you assign 72
221. tructions on how to do this go to Windows Help and search for the topic Sharing or How to Share a Folder In order to allow the ProtoTRAK SX to read and write programs to this folder select Full Access On the ProtoTRAK Control 1 Plug a keyboard and mouse into your ProtoTRAK SX CNC and turn it on Go to the Select a Mode screen 2 On the keyboard press simultaneously Ctrl Esc This will show the Start Menu 3 Select Settings from the Start menu and then select Control Panel 142 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual SLX a 5 00 BETA 10 102204 15 5064 eatures YES A e Network Connections SS YES Printers and Faxes ol YES Help and Support di Taskbar and Start Menu YES E Run Figure 14 12 1 Settings then Control Panel 101138 4 Double click on the System icon E Control Panel E 18 xj Fie Edit View Favorites Tools Help ae E Back EI JO Search i Folders E Address contona SS e va Control Panel x gJ cS ETE 2 Add Hardware Add or Administrative Date and Time CG Switch to Category View Remov Tools a RB p De gt gt Display Folder Options Fonts Internet Keyboard amp Windows Update Options Help and Support aan wo Gia cn cS 5 2 Mouse Network Printers and System Taskbar and Connections Faxes Start Menu Use
222. ttom Finish Cut 9 6 8 Face Mill Islands 9 7 1 Circular Island 9 7 2 Rectangular Island 9 7 3 Irregular Island PROFILE Events 9 8 1 Circle Profile 9 8 2 Rectangular Profile 9 8 3 Irregular Profile Helix Events Subroutine Events 9 10 1 Repeat 9 10 2 Mirror 9 10 3 Rotate COPY Events Thread Mill Event PAUSE Events Tap Events 9 14 1 SX Knee Mill Tapping Speed Recommendations 9 14 2 Tapping Notes amp Recommendations Engrave Event Finishing Teach Events Auto Geometry Engine A G E 94 Programming Starting the A G E A G E Mill Prompts A G E Arc Prompts Skipping Over Prompts The OK NOT OK Flag Ending A G E Guessing Data LOOK amp Guess Calculated Data Arcs amp Conrads Tangency Edit Mode 101 Delete Events Spreadsheet Editing 11 2 1 Selecting Data to be Displayed on the Search Edit Table 11 2 2 Sorting Data 11 2 3 Making Global Changes to Data Erase Program Clipboard G Code Editor Set Up Mode 108 The Tool Table 12 1 1 The Tool Table Screen 12 1 2 The Logic of the Tool Table 12 1 3 Initial Tool Set Up 12 1 4 Starting Over Erasing Tool Info TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 12 3 12 4 12 6 13 0 13 1 13 2 13 3 13 4 13 5 13 6 13 7 13 8 13 9 13 10 13 11 14 0 14 1 14 2 14 3 14 4 14 5 14 6 14 7 14 8 14 9 14 10 14 11 12 1 5 12 1 6 12 1 7 Adding a Tool Replacing a Tool
223. ture OFFSETS much like tool offsets fixture offset 4 are defined conversationally at our fixture offset 5 control fixture offset 6 Be Z final depth Drilling cycle G81 X0 YO Z 1 R 1 F15 R rapid position Drilling cycle dwell at bottom peeve a Peleoud P dwell time in milliseconds Peck drilling cycle oes ae eo ice Q depth of peck 5 For machines with programmable Tapping cycle OSTAO TONE E p00 spindle only S defines RPM F15 Pitth F S Boring cycle G85 X0 Yo Z1 R1 F15 Boring cycle dwell at bottom G83 0 ers ene P dwell time in milliseconds Note that this only calls out which i 00 01 02 03 20 21 40 41 42 54 55 56 57 58 59 80 81 82 83 84 85 89 90 91 G G G G G G G G G G G G G G G G G G G G G G G G 152 Southwestern Industries Inc TRAK SX Knee Mill amp Proto TRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Moo Pause event Moo M05 Spindle Off M05 M06 Tool Change T1 M06 M08 Coolant On M08 M09 Coolant Off Mog M12 Indexer pulse beginning of event M12 M20 Indexer pulse end of event M20 14 13 3 Supported Addresses CAM information is communicated through the use of ADDRESS WORD pairs For example in the line NO1GOX1 Y2 N G X and Y are addresses The other information 01 1 and 2 are Data Words The line starts with the Address N and the data word 01 T
224. tures Option is not active the Auto Geometry Engine is not available on your control If you sometimes need to program prints with data missing the Auto Geometry Engine alone is worth the price of the Advanced Features Option See Section 3 1 2 for more information about the Advanced Features Option When you program an Irregular Pocket or an Irregular Profile the Auto Geometry Engine or A G E is automatically started The A G E is powerful software that works behind the easy to use geometry programming of the ProtoTRAK SMX CNC It is treated in its own section because it works differently than the other event types Unlike other events the A G E allows you to e Enter the data you know and skip the prompts you don t e Use different types of data like angles that may be available from the print e Enter guesses for the X and Y ends and centers not available on the print With the A G E you can easily overcome limitations in the data the print provides without having to spend time in laborious calculations 10 1 Starting the A G E The A G E is started automatically when you enter the Irregular Pocket or Irregular Profile event The first set of prompts you encounter will be the header information Once that information is entered you will see the following screen PROG PIN PIN 0812 2 TOOL 1 3 AXIS INCH EVENT 1 IRR PROFILE EVENT 2 X BEGIN 0 0000 abs Y BEGIN 0 0000 abs Z RAPID 0 0500 abs Z END 0 2500 abs TOOL
225. u input the numerical value of the tangentially connecting radius r K3 The system will calculate the tangent points T1 and T2 and direct the tool cutter to move continuously from X1 Y1 through T1 r k3 T2 to X3 Y3 FIGURE 5 10 1 A Conrad is added between the two intersecting lines Note Conrad must always be the same as or larger than the tool radius for inside corners If Conrad is less than the tool radius and an inside corner is machined the ProtoTRAK SMX CNC will ignore the Conrad For the figure below you program an Arc event from X1 Z1 to X2 Z2 and a Mill to X3 Z3 During the programming of the Arc event the system will prompt for Conrad at which time you input the numerical value of the tangentially connecting radius r k The system will calculate the tangent points T1 and T2 and direct the tool cutter to move continuously from X1 Z1 through T1 r k T2 and on to X3 Z3 X2 Z2 T2 X3 Z3 r K CONRAD Z XZ VERTICAL PLANE X1 Z1 des X FIGURE 5 10 2 A Conrad is added between an arc and a line 41 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 5 11 Memory amp Storage Computers can hold information in two ways Information can be in current memory or in storage Current memory also known as RAM is where the ProtoTRAK SMX CNC holds the operating system and any part program that is ready to run While a progr
226. unt of the finish cut before it raises out of the part 9 7 1 Circular Island Advanced Features Option Press the Circle Island soft key if you wish to mill a circular island Prompts for the Circular Island X CENTER is the X dimension of the center of the Island Y CENTER is the Y dimension of the center of the Island Z RAPID is the Z dimension of the transition from rapid to feed Z END is the Z dimension at the bottom of the pocket incremental is from the previous event RADIUS is the finish radius of the Island DIRECTION is the milling direction clockwise or counterclockwise PASSES the number of roughing passes to the depth ENTRY MODE choose between zigzag ramp and plunge The plunge will machine straight down Z to the appropriate Z depth The zigzag ramp will move in a zigzag pattern to depth See the previous section for more information about the zigzag ramp FIN CUT ISL Finish cut for the Island If 0 is input there will be no finish cut See the previous section for a bottom finish cut X1 POCKET X dimension for one corner of the rectangular pocket that surrounds the island Y1 POCKET Y dimension for one corner of the rectangular pocket that surrounds the island X3 POCKET X dimension for the opposite corner of the rectangular pocket that surrounds the island Y3 POCKET Y dimension for the opposite corner of the rectangular pocket that surrounds the island 79 Southwestern Industries Inc TRA
227. ustries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 6 8 6 9 On the first Teach screen the softkeys are POSN a position move For two axis programming the POSN and DRILL events are combined DRILL a drill or bore MILL BEGIN the beginning of a straight line or MILL event END TEACH ends the teaching process and returns you to the main DRO screen If you press the POSN or DRILL key the event counter will go up by one and the screen remains the same If you press the MILL BEGIN key the event counter stays on the same number That is because you have given the beginning point of the line but not yet the end The softkey selections will change to MILL END the last point of the Mill event Press this to end the Mill event and select a POSN DRILL or new MILL event MILL CONT the last point of the current Mill event but the beginning of the next Mill event You may enter successive Mill events by pressing the MILL CONT key Pressing either of the above softkeys will cause the event counter to increase by one At any time you may exit the Teach and return to the DRO screen The events you have defined with their X and Y dimensions are finished in the Program Mode See Section 8 11 Return To Absolute Zero At any time during manual DRO operation you may automatically move the table to your absolute zero location in X and Y by pressing the RETURN ABS O soft key W
228. ut 0 relative to the programmed edge and direction of tool cutter movement XY Feedrate is the milling feedrate from Begin to End in in min from 1 to 100 or mm min from 5 to 2540 Tool is the tool number you assign Continue input 1 for Yes if you want to mill continuously from this line to the next event input 2 for No if you want the ProtoTRAK SMX to stop at the end of the event POCKET Event This event selection gives you a choice between circle pocket rectangular pocket and irregular pocket Pockets include machining the circumference as well as all the material inside the circumference of the programmed shape If a finished cut is programmed it will be made at the completion of the final pass The cutter will arc in and arc out of the finish cut and position itself the finish cut dimension away from the part before moving the tool out of the part 59 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual The factory setting for tool stepover while machining a pocket is 70 This may be changed When you first enter the pocket event the blue will appear next to the help key Pressing Help will give you the choice of entering a new tool stepover percentage The value you enter here will remain the same until you change it again 8 5 1 Circular Pocket Press the CIRCLE PCKT soft key if you wish to mill a circular pocket Prompts for the c
229. ut with the following exceptions Event or feature Comment Result Hidden Areas in Irregular Pocket The ProtoTRAK or TRAK CNC does not recognize Hidden Areas in Irregular Pockets The Irregular Pocket will be converted to an Irregular Pocket however the ProtoTRAK or TRAK CNC will display an error message that there are Hidden Areas in the Irregular Pocket We recommend that you separate the Irregular Pocket into two or more Irregular Pockets using the ProtoTRAK SMX before conversion Tap Events This routine does not exist in all models of the ProtoTRAK or TRAK CNC The routine will be ignored in the converted program We recommend that you reprogram the Tap Events into Drill or Position events before conversion Copy Repeat Subroutines with Feed or RPM The Feed or RPM function does not exist in all models of the ProtoTRAK or TRAK CNC The Feed or RPM information will be removed from the Copy Repeat Subroutines The programmed feed rates will be run We recommend that you inspect the feed rates before running the program on the ProtoTRAK or TRAK CNC when the s are other than 100 Tool Path Programming Only Part Geometry programming is supported on the ProtoTRAK or TRAK CNC You can only transfer Part Geometry programs to the ProtoTRAK or TRAK CNC Zig Zag Entry Mode Ramps This routine does not exist in the ProtoTRAK or TRAK CNC The routine will be converted to a
230. ution Course feed moves 800 inches per revolution 3 4 2 Electronic Head no longer an available option as of 1 1 11 When ordered as the Programmable Electronic Head Option the electronic head replaces the mechanical head and manual vari speed control The electronic head retains manual quill control down feed selection knobs and the manual forward off reverse switch The Tap Event is also activated with this option Section 9 14 22 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual Spindle speed settings and overrides are performed using the ProtoTRAK SMX CNC See Sections 6 9 and 13 8 In addition the spindle speed becomes part of the programming of the canned cycles Sections 8 and 9 Program Events See the Knee Mill specifications table above for the different electrical requirements for the electronic head This option is available factory installed on TRAK Knee Mills only It is not available after shipment or on retrofit products 3 4 3 Position Encoders The ProtoTRAK SMX CNC may be configured to run either with or without independent position encoders for X and Y travel Optional encoders are glass scales each with 0002 underlying resolution 3 4 4 Auxiliary Functions Three Axis CNC Models Only Auxiliary functions are controlled through the ProtoTRAK SMX CNC either in the program or with the accessory key on the front panel
231. v outlet in the electrical cabinet 3 4 8 Coolant Pump The optional coolant pump is mounted in the back of the machine column Itis plugged into the electrical cabinet and may be configured to operate as commanded by the auxiliary functions or with a separate switch 23 Southwestern Industries Inc TRAK SX Knee Mill amp Proto TRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 3 4 9 Spray Coolant The Fog Buster spray coolant option consists of a one gallon holding tank nozzle air lines and an air regulator for attaching compressed air Coolant flow is adjusted by a needle valve at the sprayer head Air flow is adjusted at the air pressure regulator with gage Once flows are set sprayer operation is controlled by an air toggle switch or by interface with the optional Auxiliary Functions 3 4 10 Limit Switches There are optional limit switches for the saddle and table travel 3 4 11 Chip Pan TRAK Knee Mills Only The Chip Pan option is available for TRAK Knee Mills only not available for retrofits 3 4 12 Table Guard TRAK Knee Mills Only The Table guard option provides an enclosed workspace mounted on the table The sliding door is switched to prevent operation of the CNC Run with the door open While it will aid in the control of chips and coolant it is not a full waterproof enclosure The Table Guard is available for TRAK Knee Mills only it is not available for retrofits 3 4 13 Auto Lu
232. ve FIN RPM is the spindle RPM for the finish cut FIN RPM programming is available only if the Programmable Electronic Head Option is active Fin Feedrate is the finish cut milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Tool is the tool number you assign When the initial Irregular Profile screen is complete the rest of the profile is programmed using A G E Mill and A G E Arc events Programming with the Auto Geometry Engine is explained in Section 10 Helix Events Advanced Features Option The Helix Event is found after you press the MORE softkey from the Select Event screen It allows you to machine in a circular path in the XY plane while you simultaneously move the Z axis linearly Press the HELIX soft key X Center is the X dimension to the center of rotation of the helix Y Center is the Y dimension to the center of rotation of the helix Z Rapid is the Z dimension to transition from rapid to feed Z Begin is the Z dimension to the beginning of the helix Z End is the Z dimension at the end of the helix Radius is the radius from the center of rotation to the helix Angle is the angle from the positive X axis that is 3 o clock to the starting position of the helix Rev is the number of revolutions in the helix for example 0 75 would be 270 degrees or 3 25 would be three times around plus 90 degrees Direction is the clockwise input 1 or counterclockwise input 2 directio
233. vents Erase program 0000000 0 Set Up Mode Features Program diagnostics Advanced tool library Tool names Tool length offset with modifiers three axis CNC models Advanced diagnostic routines Software travel limits Tool path graphics with adjustable views Run Mode Features e Trial run at rapid 3D CAM file program run three axis CNC models 3D G code file run with tool comp three axis CNC models Real time run graphics with tool icon Z Go To for two axis run on three axis CNC models Program In Out Mode Features Simple program storage to floppy CAM program converter Converter for prior generation ProtoTRAK programs 3 1 2 Advanced Features Option The Advanced Features Option may be purchased with the original order or purchased later Note the Advanced Features Option is included in the ProtoTRAK Offline Software but must be purchased separately for the ProtoTRAK SMX CNC as a retrofit or on the TRAK Knee Mill It is easy to tell if you have the Advanced Features Option If you have the Advanced Features Option the features listed below will be active If you do not the features listed below will not be active and any Softkey for that feature will be grayed out For example in the Program Mode under Pocket check the Softkey labeled IRREG PCKT If the words IRREG PCKT are black the Advanced Feature Option is active If they are gray the Advanced Feature Option is not active 9 Southwestern Indu
234. will allow only one program in current memory To write a new program you must first erase the one in current memory you may want to first store the program for use in the future If there is already a program in current memory entering the Program mode will allow you to edit or add to that program PRoc PNO TOOL 1 3AxIS INCH Program Name Scale 1 000 Dwell Request NO Auxiliary Function Request NO Event Comments NO Multiple Fixtures Dimension Definition PART GEOMETRY 2 Program Name Fi F2 F3 F4 F5 F F Fs pata pata coto GoTo GOTO FWD BACK BEGIN END FIGURE 7 2 The Program Mode header screen Most selections above relate to the Advanced Features Option If your screen shows only Program Name and Dwell The Advanced Features Option is not active 47 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual 7 3 Program Header Screen The first screen you see when you enter the Program Mode is the Program Header Screen The Program Header Screen gives you options that apply to the entire program The softkey selections allow you to enter the program at any point The program name and general programming options you choose in the Program Header Screen will be summarized in the program as Event 0 7 3 1 Program Name Programs written on the ProtoTRAK SMX CNC are usually named for the part that is to be mach
235. xtension 4 Press either RENAME FILE or RENAME FOLDER PROG vO l PIN 0807 l F 3 AXIS INCH RENAME Look In Er B SWI 2615 PT4 New Name New Extension swi PT4 Fi F2 F3 F4 F5 F F7 FS DATA DATA OPEN RENAME RENAME TAB FWD BACK FOLDER FOUDER Fle RETURN FIGURE 14 7 Renaming a file Press the Help hard key to call up the alpha keys Additional parts of the screen appear once the RENAME softkey is pressed New Name When a file or folder is highlighted the name will appear here When the TAB the RENAME FILE or RENAME FOLDER softkey is pressed the highlight will move here and you will then be able to write in a new name New Extension A new extension can be given to the file picking from the ones available If the file name already contains an extension you will have to erase the old one before giving it a new one Additional softkeys 131 Southwestern Industries Inc TRAK SX Knee Mill amp ProtoTRAK SMX CNC Retrofit Safety Programming Operating amp Care Manual RENAME FOLDER Press once a new name has been entered into the New Name and New Extension areas to change the name of the folder RENAME FILE Press once a new name has been entered into the New Name and New Extension areas to change the name of the file RETURN Returns to the Program In Out Mode screen 14 8 Backing Up In order to protect your important programs it is a good idea to back them up regularly

Programming Knee Mill - Southwestern Industries, Inc.

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