MAIN TECHNICAL SPECIFICATIONS

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1 S4045P S4045P The S4045PD is suited for highspeed machines destined to mill complex surfaces. It is extremely fast and powerful and is equipped with the Intel PC CPU for the operator interface and also with a fast Master CPU with Motorola processor for the real-time control of the machine. In its basic configuration, it is equipped with a software module called Advanced TCPM 4 axes to manage the tool/piece contact with a rotary table or with an one-axis rotary head. In case of more rotary axes it is possible to install an optional specific module called TCPM4000. MAIN TECHNICAL SPECIFICATIONS Double CPU: PC CPU with Intel processor for the operator interface management High-speed Master CPU with Motorola processor for the axis management 20 simultaneously controlled axes (8 CNC, 8 PLC, 4 spindles) 8 interpolated axes 2000 blocks/sec 256 blocks look ahead 2 5 msec programmable axis sample time 384/288 max I/O 15-inch TFT color display with touch screen 128 MB RAM 30 GB min. Hard Disk Floppy Disk Ethernet board (SELNETWIN4000 network software optional) CD-ROM (optional) Advanced TCPM 4 axes: software module for the management of the tool/workpiece contact on machine with 3 linear axes and one rotary axis TCPM4000 optional module for the management of machines with more rotary axes Copying and Digitizing (optional) Max. level of the Selca Programming Software Remote diagnostic (optional) CNC available in Analog and Digital (D) version CNC also available in DDH version to manage linear and torque motors.

2 HIGH-SPEED MILLING The S4045P, with its read speed of more than 1500 blocks/sec and 2-5 msec programmable axis sample time, is the ideal CNC for high-speed die milling and finishing. PROGRAMMING The S4045P CNC offers the highest level of sophisticated and complete programming, that includes all levels of Selca programming. The function also allows machining on inclined planes by resetting the tool on the plane and in space. ISO Basic PARAMETRIC PROGET2 ADVANCED INTERACTIVE CONVERSATIONAL PGI It is also possible to install the SelCAM3D, SelCAM2D and SelDXF optional modules. ADVANCED TCPM - 4 axes The Advanced TCPM - 4 axes (Tool Center Point Management) software module permits to maintain automatically the tool/workpiece contact while moving a mono-birotary, orthogonal or angular head and rotary/tilting table, by compensating through the linear axis movement the rotary axis movements. The function also allows machining on inclined planes by resetting the tool on the plane and in space. The main features of the Advanced TCPM - 4 axes are the following: Management of 4 linear and rotary axes Look ahead on 4 axes Constant speed of the tool point Virtual sleeve axis Preventive software end run calculation Check of speed, acceleration and Jerk on all axes. In case of a large number of rotary axes, it is possible to install the optional module TCPM4000. VIRTUAL SLEEVE The S4045P offers a special function defined virtual sleeve. The virtual sleeve is a fictitious axis that moves in space along the direction of the tool, that depends on the rotation of the mono or birotary head. It is not necessary to program the function of the offset/rotation in space. The virtual sleeve can be used both in manual and in automatic mode and can be combined with the TCPM function.

3 S4045 S4045 The S4045 is the ideal CNC for tool and die milling machines and is the fruit of Selca s twentyfive-years of experience in the highspeed milling field. It offers, as the S4060D and S4045P, the highest level of complete programming of the S4000 Series. It is based on a PC Intel CPU dedicated to the operator interface and a Master CPU with Motorola processor for the real-time control of the machine. MAIN TECHNICAL SPECIFICATIONS Double CPU: PC CPU with Intel processor for the operator interface management High-speed Master CPU with Motorola processor for the axis management 20 simultaneously controlled axes (8 CNC, 8 PLC, 4 spindles) 8 interpolated axes 1500 blocks/sec 256 blocks look ahead 2 5 msec programmable axis sample time 384/288 max I/O 15-inch TFT color display with touch screen 128 MB RAM 30 GB min. Hard Disk Floppy Disk Ethernet board (SELNETWIN4000 network software optional) CD-ROM (optional) Copying and Digitizing (optional) Max. level of the Selca Programming Software Remote diagnostic (optional) CNC available in Analog and Digital (D) version

4 PROGRAMMING The S4045, like the S4060D and S4045P, is simple and intuitive to operate, and at the same time extremely complete and effective for CNC programming on board the machine. It offers all levels of Selca Programming. It is also possible to install the PGI (Interactive Graphic Programming) module as option. ISO Basic ADVANCED PARAMETRIC INTERACTIVE CONVERSATIONAL PROGET2 PGI (optional) SURFACES DEFINED BY A PLANE PROFILE AND SECTION PROFILES Machining of 2.5-D surfaces defined by an open or closed plane profile, and by one or more section profiles. Junctions with variable or constant section. Machining with toric or spherical mills with mono or bi-directional passes. SPIRAL MILLING Innovative solution that reduces the machining time and improves the surface finish. The final position is reached by a continuous contact with the surface of the workpiece. RULED SURFACES Machining of ruled surfaces defined by two profiles lying on parallel planes, with toric or spherical mills with mono or bidirectional passes. CYLINDRICAL AND POLAR PROGRAMMING Milling of front plane profiles or on a cylindrical surface by co-ordinating the motion of a rotary axis with a linear axis. NEW FUNCTIONS FOR POCKET MILLING AND FINISHING CYCLES Nowadays the high-speed milling imposes new strategies for pocket roughing and finishing cycles. The S4045P and S4045 offer new software macros for drilling and finishing circular and polygonal pockets with internal islands, also defined by plane and section profiles. PLANETARY MILLING It is a way of milling that combines the big volume of removed chips with the high-speed milling. It permits the operator to move the tool very deep in the piece, by avoiding the typical problems caused by the traditional milling.

5 CNC S4045/S4045P MAIN FEATURES AND PERFORMANCES OPERATOR INTERFACE 15 inch TFT color video with touch screen including touch screen pen Extended Alphanumeric Windows type Keyboard with special Selca keys PC board with Pentium II processor (K6-II 500 MHz or superior) 128 MByte dynamic RAM memory that can be expanded to 256 MByte 3.5 inch Floppy Disk MByte Minimum 20 GByte Hard Disk 2 serial RS-232 or RS-422 interfaces with external adapter CD-ROM (option) Parallel Interface PS2 interface for mouse (not supplied) Audio input and outputs Ethernet network connect between S4000 and Personal Computer using WINDOWS or UNIX operating systems Measurement inputs for Encoder and optical scales with or without reference marks coded with sinusoidal signals 1Vpp/11µA or with square wave signals, HEIDENHAIN ENDAT absolute encoders and optical scales Digital axis and spindle control with fiber optic interface Digital and analog Remote I/O systems with fiber optic interface. Windows 2000 Professional operating system Menu driven function keys that directly control all system and machine operations Reconfigurable screens that can be tailored to visualise the most important data for particular machine type Tool path display during programming, programmed path and actual path can be displayed during machining 2-D and 3-D interactive graphics, display program geometry and part dimension taking from current display Language selectable by operator 1

6 ISO BASIC PROGRAMMING Linear, circular and helical interpolation Teach-in programming Axis exchange Absolute/incremental programming, possible in the same block Cartesian/polar coordinates Cutter radius/tool length compensation Offset/rotation of work coordinates Mirror machining Scale factors different for each axis Polygonal/circular pocket programming Fixed cycles Inch/metric programming Tool bit compensation for heads, rotary tables and bi-rotators (static TCPM). PROGET2 PROGRAMMING High-level integrated geometric programming language that is an ideal tool for complex plane profile programming. Defines points, circles and straight lines without having to consult external automatic programming systems Geometric entity storing Curves defined by points Character string writing on a plan Fixed supercycles: permit the programming of fixed cycles or piece machining on linear or circular grids. PARAMETRIC PROGRAMMING Parameters can be used to perform complex arithmetical, trigonometrical and logical operations and to use control instructions to carry out repetitive cycles, conditional jumps, internal and external subprogram recalls Print commands for production reports, self-control certificates and CNC program creation. ADVANCED PROGRAMMING Offset/rotation of work coordinates in space 3-D surfaces defined by a profile plan and section profiles with plane or spiral milling TCPM 4-axis software (guarantees tool/piece contact during one head and/or table rotation) (S4045P) TCPM software for 5 or more axis (guarantees tool/piece contact during heads mono and double twist and table rotation) (option TCPM4000 only for S4045P) Ruled surfaces between profiles Inclined surface machining Cylindrical and polar programming Working zone delimitation Calculation of equidistant points on a profile and of the intersection points between a profile and a straight line Milling of profiled pockets with internal islands Tool radius compensation in space Reversal of profile direction Multiple scaling factors for different zones of the workpiece 2

7 Character string writing on cylindrical surfaces or inclined planes Spiral milling Origin displacements using an electronic handwheel Manual axis movements during automatic machining Subprogram modal recall Axis control by handwheels during machining (G846). CONVERSATIONAL PROGRAMMING Full series of interactive panels, which simplify data entry operations and parameter definition operations, required for the creation of a CNC program. PGI INTERACTIVE GRAPHIC PROGRAMMING (Option) The interactive graphic programming is the result of further perfecting of Selca's programming. It combines the simplicity of conversational programming with the most frequently used parametric programming machinings. A graph displayed on the screen indicates the order of machining. In comparison to CONVERSATIONAL programming, PGI has macro panels that coordinate data from other single panels. This is to speed up the programming of simple and repetitive machinings. The contents of the tree of machining can be quickly visualised in Selca's language by means of a special key. An automatic procedure saves both the initial project and the tool path on the HD. PART PROGRAM EXECUTION Graphic mode execution (without moving the machine s axes) Dry run with out the part being mounted (axis motion occurs in auto or semiautomatic mode and the feedrate may be adjusted using the Feedrate Override switch) Program editing and program transfer from/to peripherals can take place while a different program is being executed Automatic or assisted program restart Run-time update of geometric and technological data, as well as of program sequence, based on parameters entered by the operator or derived from PLC inputs Handwheels can be used during program execution to offset programmed moves with manual movements (origin shift), or to manually move selected axes while the others are under CNC control Manual movements can be executed in the Hold state or at block end during the execution of a program in semiautomatic mode TOOL AND ORIGIN MANAGEMENT Tool length compensation Tool radius compensation in space 200 different origins in space Tool radius and stock allowance definition Tool life monitoring with actual cutting time accumulation and continuous compensation based upon estimated tool wear Automatic tool change handling Table up to 300 tools 3

8 AXIS CONTROL Highspeed milling of surfaces by points with the speed ramp at S Simultaneous interpolation of up to 8 linear/rotary axes with linear, circular or helical interpolation Control of up to 16 independent asynchronous simultaneous PLC axes which can be synchronised with the CNC s main program Programmable resolution of 0.1 microns, depending on position feedback Control of a single axis positioned by two servo motors (DUAL DRIVE) Control of portal axes with double positioning control (GANTRY) Master Slave can be enabled by Part Program with the possibility of mirroring and scaling Dynamic pre-processing of up to 256 blocks (look ahead): automatically adjusts contouring speed to programmed tool path Feed forward and acceleration control features help minimize profile errors caused by continuous speed and direction changes of machine axes. It also optimizes accurate machining at very high feedrates Program execution speed in 3 dimensions with automatic machine adjusting Block reading: S4045 version, 1500 blocks per second; S4045P version, 2000 blocks per second Non-linear acceleration control helps minimize mechanical stress due to high axis accelerations (Jerk) Reversal error compensation automatically compensates for small positioning errors that may occur in circular interpolation, when machine axes reverse their direction at low speed and must overcome friction and backlash effects Temperature compensation uses thermistor sensor monitoring to compensate for thermal deformations in relation to the temperature of the machine s organs read by the sensors Feedback error compensation by continuous linear error compensation, cyclic error compensation, for rotary feedback devices and random error compensation along the axis travel Cross compensation applies to deformations caused by load changes as a result of changes in the relative positions of machine axes Cylindrical surface machining Cartesian machining with polar axes 3-D Tool/part contact management during movements with one rotary or scale table and with one orthogonal rotary head or at 45 degrees, TCPM function SPINDLE CONTROL Spindle speed ratio control Programmable spindle orient Constant speed cutting Rigid tapping Multiple spindle synchronization. PROBING CYCLES (PROBE option) Digital probe interface for high-precision measurements that can interact with the automatic machining correction program Optional software module for piece centering and measuring (MISURA option) Optional software module for presetting and checking tool integrity (PRESETTING option). 4

9 COPYING, DIGITIZING / TRACER MILLING (COPYING option) Continuous 3-D surface scanning with digital probe Automatic or manual scanning, with uni/bi-directional passes parallel to machine axes, inclined or radial. Capable of scanning even with rotary axes Scanning probe and scanning area can be inclined at any angle Model can be mounted (inclined) on rotary table Automatic 2-D or 3-D contouring along a programmed profile Automatic contouring with variable programmed depth. DIAGNOSTICS Self-diagnostics cycles at power up Specific diagnostic messages cover operator and system errors and help identify defective modules Application dependent diagnostics can be embedded in the PLC software to assist the operator during troubleshooting and system operation Monitoring and visualization of dynamic servo errors Possibility to change servosystem parameters in real time to optimize performance Log File records CNC activity on a file. The operator and programs in execution or editing provide input Telediagnostic via modem, telephone line link and Internet. Selca S.p.A. Corso Vercelli, IVREA (TO) - Italy Tel Fax comm@selca.it Selca S.p.A. reserves the right to alter, without prior notice, the features of the product described in this specification. 5