XIMOTION LLP MAXNC CLOSED LOOP (CL) Software Operation Manual Rev 8/31/12 MAXWIN

Transcription

1 XIMOTION LLP MAXNC CLOSED LOOP (CL) Software Rev 8/31/12 MAXWIN

2 Table of Contents Introduction... Safety Guidelines... 1 COMPUTER REQUIREMENTS: CONNECTING TO THE COMPUTER: Parallel Port Changing the Parallel Port Address INSTALLING THE SOFTWARE: START-UP: The Graphical User Interface Machine Position Running Conditions Machine I/O Mode, Motion, Jog Speed Program File Program Area Prompts Menu Area Start-up Menu Jogging AXES AND AXIS DIRECTIONS: Jogging X Jogging Y, Z, or A HOME i

3 6.3 Bypass OPERATION: Main Menu: Main Menu Commands Key 1.. LOAD Key 2..RUN Key 3..MDI Key 4..EDIT Key 5..JOG Key 6..ZERO Key 7..DNC Key. 8..RESET Key. 9..OFFSET TABLE ESC Other Commands (Main Menu and SLIDE HOLD mode) HOME (Main Menu only) Becoming Familiar CNC PROGRAMMING Supported Codes Explanation of G & M Codes G codes: M codes: Sample Program Included Trial Programs CNC Programming Learning Resources ii

4 8.6 CAD/CAM Software THE MAXNC CNC PROGRAM GENERATORS Creating a CNC Program from an AutoCAD drawing Utilities PLOT ENGRAVING Optional Accessories th AXIS: DIGITIZING PROBE Parts Breakdown Document Revisions Version Date Comments 1 8/29/2003 Released to document Windows XP support 2 8/31/2012 Updated and expanded Software functionality is the same as for Rev 8/29/2003 iii

5 MAXNC CLOSED LOOP SOFTWARE OPERATION MANUAL Rev 8/31/12 INTRODUCTION This operation manual focuses on the use of the MAXNC Closed Loop (CL) software to load numeric control (NC) programs into a computer to control a MAXNC machine, and to control the machine through the graphical user interface of the software. While the manual contains some basic instructions on Computer Numeric Control (CNC) programming and the operation of the machine, it is not a how-to guide of CNC operation and machining, nor of CNC, computer aided design (CAD) or computer aided manufacturing (CAM) programming; those are knowledge and skills the user is assumed to posses or acquire before using the machine SAFETY GUIDELINES Whether you are a novice or an expert CNC machinist, please do keep in mind the following safety guidelines: o o o o o o o Inspect the machine prior to use. Always keep the slides and lead screws clean and well lubricated with white lithium grease. Jog the X table and Z spindle head to expose the areas you want to lubricate, then turn the machine off before lubricating, repeat as necessary. Inspect all electrical and signal connections and cords to ensure that no broken wires are visible. Before you plug in the machine, make sure the power switch is off. Damaged or improper operation of the table can cause a work piece to be thrown from any mountings. Make sure that all work and fixtures are clamped securely before starting the machine. Improperly mounted vises can cause a work piece to be thrown from its

6 o o o o o o secure position. Wear safety goggles or safety glasses with side shields. Use a dust mask for dusty operations, and wear hearing protection if you ll be using the tool for an extended period of time. Do not wear loose-fitting clothing, no neckties, no jewelry, no dangling objects of any kind. Long hair must be tied back out of your way. Keep the area around the machine clear of obstacles. Turn off and unplug the tool before you make any adjustments or change accessories. Make sure cutters are clean, sharp and securely in place. Never use bent, broken, or warped cutters. i

7 1 COMPUTER REQUIREMENTS: The MAXNC CL software requires a PC running Windows XP, with one bi-directional parallel port installed. It is safe to say that any PC currently available will greatly exceed the absolute minimum requirements of a 66Mhz processor and 640Kb of RAM. Though no new PCs with Windows XP are being released, that operating system is stable and useful enough to be still favored by very many users, so there is an abundant supply of used and refurbished PCs in the after-market. Please note this software will not run adequately in a PC with post-windows XP versions of operating systems (Vista, Windows 7, etc.), and will not operate adequately through a USB port. If you want to know more about why is that, please see our article at (click on the More Info tab) 2 CONNECTING TO THE COMPUTER: 2.1 PARALLEL PORT The MAXNC servo controller connects to the computer by means of a parallel port cable (supplied), which connects to the parallel port in the PC. The addresses of the parallel port in the PC need to match the addresses written in the parameter file of the MAXNC software (378 Hex, 8888 decimal). (The contents of that parameter file can be viewed by running the MAXNC utility PR.EXE after installation of the MAXNC software). Caution: do not operate with the wrong port address, it can cause serious damage to the controller. 2.2 CHANGING THE PARALLEL PORT ADDRESS To change the address of a port in the MAXNC software, use the program PORT.EXE and write the starting address of your port in HEX numbers installation). (after software If you need to find the starting address of the parallel port already installed in your computer, use SETTINGS/SYSTEM from WINDOWS or MSD.EXE from DOS. 3 INSTALLING THE SOFTWARE: You might have received the software CD with your mill, or maybe you downloaded the software 1

8 from our online store ( ) If you are installing the software from the CD: Put the CD in your CD or DVD drive. Navigate to that drive Look for the file SETUP.BAT Double click on SETUP.BAT If you are installing the software from the downloaded ZIP file : Expand the ZIP file to a location (folder) of of your choice Navigate to that directory The SETUP batch file performs the following actions: Creates a \MAXWIN directory in your C: drive Copies all the contents of the CD (including this manual) into that directory Installs a Maxwin shortcut on your PC s Desktop from which you can start the software Installs he UserPort.sys driver in the C:\WINDOWS\SYSTEM32\DRIVERS\ folder. This kernel mode driver for Windows XP gives user-mode programs (such as the MAXNC software) access to I/O ports. This makes it possible to access hardware directly from a normal executable in the same way as under Windows 95/98/ME. Runs the MAXNC utility PPORT.EXE, to make sure the MAXNC software is able to access the parallel port. The following window comes up: In order to activate the port you need to respond by clicking Start, then clicking Exit. 2

9 4 START-UP: Upon installation, the MAXNC software starts in Full-Window mode. Though you can use Alt-Tab to switch to another program, DON T USE ALT-TAB TO SWITCH OUT OF THE MAXNC PROGRAM WHILE THE MILL IS RUNNING, and preferably do not run any other programs concurrently. Check that all motors and encoders are properly connected to the controller before applying power to the system. Also, make sure that the electric breaker switch (the button with the # 5) position. If it is out, push it in. is not in the out The driving program (MAX.EXE) can be started by double clicking the MAXNWIN icon Desktop, or by using MY COMPUTER : on the - find the MAXWIN folder - double click on MAX.EXE The program will ask you now to turn the power on and press a key to continue. Next, it will ask you to test the HOME/LIMIT switches response on your computer only once each switch to ensure that the parallel port is set to the correct address and that it has input capabilities. 3

10 If there is no response to the switches, exit the program (ESC) then refer to SETTING PORT ADDRESSES at the end of the manual. Note: There is a critical synchronization process between the ENCODERS and the drive motors. This process is done automatically every time the machine is turned on and the program starts. If for some reason the motors don t synchronize, the program will give you a SERVO ERROR when trying to move: Just press M a couple of times then R to reset. 4

11 5 THE GRAPHICAL USER INTERFACE You were introduced to the graphical user interface of the software upon start up. Let s take a tour of the different areas where information is communicated to the user, and the user communicates information to the software: 5.1 MACHINE POSITION The X, Y, Z and A positions are displayed here. The units depend on the running mode: Inch or Metric (MM). The 5

12 5.2 RUNNING CONDITIONS The running conditions area displays what G Code is being executed, the feed rate (IPM or MMPM), the Feed %, which H offset and which D offset (out of 20 possible, see ) are in effect, and their respective values, and the current RPM. 5.3 MACHINE I/O This area provides feedback about the I/O ports: The Limits light should be normally green. The limit switches are normally closed switches, and they are wired in series; when a slide pushes a limit (any limit), the limit switch circuit is opened (interrupted); the light turns off, and MAXNC recognizes an open switch. 6

13 The AUX OUTPUT 12 V. port is normally used to power the coolant pump. 5.4 MODE, MOTION, JOG SPEED Indicates whether the machine is running in Absolute or Relative mode, Single Step or Continuous, and the Jog Speed. 5.5 PROGRAM FILE Displays the name of the program in memory (running, or ready to run): 5.6 PROGRAM AREA This area displays the program in memory or gives feedback of the manual input (see MDI below) 7

14 5.7 PROMPTS The prompts ask the user to perform certain actions or provide warnings. 5.8 MENU AREA The Menu Area lists the available commands and the keyboard keys that execute them. It changes in context with the type of action being executed, such as: Start-up Menu Jog Axis Selection Menu Jog X Menu 8

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16 6 START-UP MENU Once the software has established communication with the machine, it asks you to And brings up the above START UP menu Press 5 in your keyboard to select the JOG function You will now see the JOG menu: Press X in your keyboard to select the Jog X function That brings up JOG X menu (the JOG Y, JOG Z, and JOG A menus are basically identical): 10

17 6.1 JOGGING AXES AND AXIS DIRECTIONS: Before studying the Jogging menu itself, here are some important considerations about axes and directions. In CNC programming, the X, Y, and Z axis are just the same as if you were to draw a X-Y Cartesian plane on a piece of paper on your desk; the positive X direction (X+)is towards the right of the origin, the positive Y direction (Y+) is away from you, and the positive Z direction (Z+) is up from the paper. So, just imagine you have moved that Cartesian plane from your desktop to the table of the mill, while you stand in front of it, and you will know what is X, Y, and Z, and which way is (+) and (-). BEWARE! THE POSITIVE (+) AND NEGATIVE (-) DIRECTIONS IN CNC PROGRAMMING REFER TO THE TOOL S MOVEMENTS WITH RESPECT TO THE PART OR TABLE. In a vertical mill the tool mounted on the spindle moves only vertically (Z), and the Y slide doesn t move at all, so the X table (or X slide) is responsible for accomplishing both the X and the Y movements. Please refer to the following table to relate the observable movements (what you see) to the CNC movements (the movements of the tool with respect to the part or table). AXIS JOG Key OBSERVABLE MOVEMENT X RShft (+ X) X table moves to the LEFT LShft (- X) X table moves to the RIGHT Y RShft (+ Y) X table moves TOWARDS you LShft (-Y) X table moves AWAY from you RShft (+ Z) Spindle head moves up Z Spindle head moves LShft (- Z) down CNC MOVEMENT TOOL moves to the RIGHT of the part TOOL moves to the LEFT of the part TOOL moves in the + Y direction TOOL moves in the - Y direction TOOL moves up (+ Z) TOOL moves down (- Z) 11

18 6.1.2 JOGGING X Use the right Shift key (RShft) to jog in the + X direction (table will move to the left) Use left Shift key (LShft) to jog in the - X direction (table will move to the right) Be careful not to allow the axis to over travel; at this stage software travel limits have not been established yet. **LIMIT SW. ** Warning - If anyone of the limit switches is pressed while jogging or attempting to jog, you will see this warning: As indicated, press the M key twice to go back to this menu: Next, examine the mill to see which of the limit switches is pressed. Press 5 for JOG Select the axis in which the limit switch is pressed Jog AWAY from the limit switch You can control the speed of the jogging movements with the following keys in your keyboard: 12

19 S Slow, the slowest available feed F Fast, the fastest available feed Number keys (1,2,3,4,5,6,7,8,9) jump to a higher (faster) or lower (slower) number. The Jog Speed bar in the screen shows your relative position between Slow and Fast To change the axis you want to jog, click the X, Y, Z, or A key on your keyboard: Complete the jogging operation by positioning the spindle head in such a way that it will be able to move freely when then HOME operation is performed (see 6.2 below). That position can come handy when you ZERO the machine (see below) Now select Main Menu by clicking the M key: Which will bring you back to the START UP menu: JOGGING Y, Z, OR A See above. 13

20 6.2 HOME CAUTION! During the HOME operation the machine will move to the positive end of travel first in Z, then in Y, and then in X as soon as the H key is pressed. The MAXNC CL machines are equipped with a combination home and limit switches on the + (plus) side of the X, Y and Z axes. The travel to the - (minus) side of the axes is limited by the software. The homing operation provides the program with the information needed to limit the travel to the opposite end of the switch, based on the travel distances written in the file SERVPR.DAT. These distances are written in steps (resolution X inches). If the slides move is OK, from the START UP menu proceed to HOME pressing H in your keyboard. the machine by Be ready to press the SPACE BAR to stop motion if something doesn t look right. 6.3 BYPASS Though this command (Ctrl + B) allows you to bypass the HOME operation, it will keep nagging you because without HOME MAXNC does not have the necessary reference to compute the maximum travel distance to the - (minus) side of the axes, so you better have a good reason to bypass. 14

21 7 OPERATION: 7.1 MAIN MENU: If HOME has been completed, the program will show the MAIN MENU of operations on a key bar at the bottom of the screen. The different functions are accessed via the keyboard (the mouse is not used). So, for example, to access function LOAD, the key 1 in the keyboard is pressed. To access RUN, key 2, etc. 7.2 MAIN MENU COMMANDS Instructions on the operation of the Main Menu keys are given as follows: KEY 1.. LOAD Is used to load a NC program into memory for MAXNC to execute. MAXNC prompts you to Answer with a path (if in a different directory), name, and extension in DOS format or press Enter without a name to view and scroll up and down the directory (using the up and down keys) to select the file. The default directory is defined in the FILEDIR.DAT file. When your program is highlighted in red, press Enter to select. The path and name of the selected program is then displayed 15

22 and a yellow bar is positioned over the first line of the program: KEY 2..RUN RUN will execute the NC program in memory, starting at the line shown with the yellow bar; it will run in continuous mode (executing one line after the other), and the following menu is displayed: The space bar can be used to interrupt the program and hold movement of the slides (do not use the Pause key in your keyboard). It pauses the tool feed, but does not stop the spindle motor. S activates the Single Line mode same as Single step or Single block. It stops the program at the completion of the current line, and the Menu changes to: 16

23 To execute the next line, press S again. To revert to continuous execution, press C. To alter the Feed Speed before the next line is executed, press F ; the prompt line will show the current feed rate. Press enter to confirm, or type the new feed rate without the % symbol and press Enter. It is possible to go to the Main Menu (M) during the Single Line mode. The prompt line warns PROGRAM STOPPED. To continue running the program and go back to the previous menu select RUN (2), or choose any other option KEY 3..MDI Manual Data Input is used to manually command a move one line at a time and without a program, by entering the desired G-code. When done, press ENTER to exit the MDI mode KEY 4..EDIT Used to edit the NC program. Use the arrows keys to scroll lines up or down. Press C or I to modify. It is also used to search, and to position the pointer to start the program at other than the first line KEY 5..JOG Is used to manually move the axes, in fast, slow or in the speed dictated by the number keys from 1 to 9 (see 0 above) KEY 6..ZERO This command allows you to define the origin or reference point for the movements of the tool during the operation of the machine in automatic control (running a NC program). Jog the cutting tool to the origin as defined in your program before using this command. If right now you are just testing and becoming familiar with the machine, simply jog all axis to approximately the mid point of their travel, and use that as the origin. When you select ZERO (Key 6), the following menu comes up: You can ZERO each axis individually by selecting X, Y, Z, or A, or you can zero them all simultaneously by selecting 0; the readings in the Machine Position area changed to 0. 17

24 7.2.7 KEY 7..DNC Direct Numerical Control (DNC) is used to run a program that is too large to fit in standard memory, reading the program directly from the hard drive. It is limited only by the capacity of the drive, no editing is allowed. Also, because no look ahead is possible, G41 and G42 are disregarded KEY. 8..RESET Is used to go to the top of the program (reset the NC program counter to the first line); it also cancels any tool offsets that may be active, and turn the spindle and the coolant off. RESET should be used before the restart of a program. RESET does not return the tool to the ZERO position assumed by the program; use MDI, and enter G0X0Y0Z0 or G0X0Y0Z0A KEY. 9..OFFSET TABLE Up to 20 offsets can be setup, and each one can be used for either H (tool height) or D (tool radius). For example, if the value of offset #1 is 0.125, H1 is interpreted as tool height offset, D1 is interpreted as tool radius offset. When selected, the offset table is loaded into the program area. Enter the offset number to change, press Enter, type the offset value, press enter to confirm. Press Enter to exit ESC Press ESC to exit the program. MAXNC will ask you to confirm. 7.3 OTHER COMMANDS (MAIN MENU AND SLIDE HOLD MODE) The following commands are also available from the main menu and from SLIDE HOLD mode: CTRL/S same as M3 (see below). A motor speed needs to have been set 18

25 with a S word for the spindle to start. CTRL/U Toggles G64 and G65. (see below) 7.4 HOME (MAIN MENU ONLY) The following command is available from the main menu only: CTRL/H HOME It will send the axes to the home switches and reset positions. 7.5 BECOMING FAMILIAR Play around with all the menu options to familiarize yourself with all the screens. 8 CNC PROGRAMMING A Computer Numeric Control (CNC) program consists of a set of sequenced instructions to achieve automatic machine tool operation. The instructions are written in G-code, the most widely used CNC programming language, and tell the machine where to move to, how fast to move, and through what path to move. G-codes are any word in a CNC program that begins with a letter, most commonly but not exclusively-the letter "G". Generally it is a code telling the machine tool what type of action to perform, and includes a list of Cartesian coordinates that indicate the positions that the tool will move to, together with other information needed such as linear or circular move, feed rate etc. The most common codes used in CNC programming are: G-codes (preparatory functions), and M codes (miscellaneous functions). Other commonly used letters are X, Y, Z, A,R, I, and J (see 8.1 below for codes supported by MAXNC) To write or modify an NC program use any text editor such as EDIT in DOS, or NOTEPAD in Windows. You can use the EDIT (4) function of MAXNC to edit an existing program. Nowadays, however, NC programming is most commonly accomplished using CAD/CAM software (see 8.6 below) 8.1 SUPPORTED CODES The following codes, the most common ones in the industry, are supported by MAXNC CL software (see 8.2 below for their meaning): 19

26 G00 Rapid move G01 Feed controlled move G02 Clockwise arc G03 C-clockwise arc G04 Dwell G12 Full circle clockwise G13 Full circle c-clockwise G20 Inch mode G21 Metric mode G43 Activate a tool offset G49 Deactivate tool offsets G40 Radius offset cancel G41 Radius offset left G42 Radius offset right G43 Tool length compensation active G49 Tool length comp. cancel G61 Switch detect command G53 Machine Coordinate System G64 Screen update disable G65 Screen update enable G81 to G86 Drilling cycles * G90 Absolute mode G91 Incremental mode G92 Absolute preset Fxx feed rate (speed) Hx Tool height offset # Dx Tool radius offset # Rx.x Drill rapid to move Xx.x X axis input Yx.x Y axis input Zx.x Z axis input Ax.x A axis input I x.x Distance in X to center of arc J x.x Distance in Y to center of arc M30 End of program and reset M00 Program stop M2 End of Prog (without reset) M3 Spindle Start M5 Spindle Stop M6 Tool Change prompt M8 Coolant on M9 Coolant Off M01 Optional stop 20

27 M99 Sxxxxx Lxx Repeat program Spindle Speed Line repeat 8.2 EXPLANATION OF G & M CODES G CODES: G0 Linear motion in any or all axes at the maximum speed. This is a Modal command, which means it stays active until changed. Requires one or more axis words. Can be written as G00 Example: G00X1.0 G0X1.525Y0.250 Z0.2 X2.000 G1 Linear motion in any or all axes at the speed specified by the F word. Requires one or more axis words and a feed rate. Example: G1X1.0F2.55 G1X1.525Y0.250 Z0.2 G2 Circular motion clockwise in X and Y axes at the speed specified by the F word. Requires an X word, a Y word, an I word, a J word and a F for feed rate (if the feed rate has not been assigned in a previous line). Example: N1G1 X1.0 Y0.0 F5.0 N2G2 X-1.0 Y0.0 I-1.0 J0.0 F4.0 N3G0Z0.2 X and Y (in line N2) are the coordinates of the end position of the arc. I is the incremental distance from the X starting point to the X coordinate of the center of the arc. J is the incremental distance from the Y starting point to the Y coordinate of the center of the arc. The starting point is the absolute position that the machine held when the arc was started (usually the previous line or 21

28 N1 in the example). G3 Circular motion c-clockwise in X and Y axes at the speed specified by the F word. Requires an X word, a Y word, an I word, a J word and a feed rate. Example: N1G1 X1.0 Y0.0 F5.0 N2G3 X-1.0 Y1.0 I-1.0 J0.0 F4.0 N3G0Z0.2 G4 Dwell. It requires a parameter in milliseconds with the word P. Example: N1 G0 X2.0 Y1.0 N2 G1 Z-0.1 F3.0 N3 G4 P2000 N4 G0 Z0.1 G10 Tool Table Preset. It allows the presetting of values in the tool table from the NC program rather than manual entry. Use the P word to specify the tool table number and the Q word to enter the value. Example: N1 G10 P3 Q1.500 This will place the value into the number 3 position of the table. G12 Special code to move from the center of a circle, out to the circumference, around a full circle clockwise and back to the center of the circle. It requires an I word with the radius of the circle and a feed rate. G13 Special code to move from the center of a circle, out to the circumference, around a full circle c-clockwise and back to the center of the circle. It requires an I word with the radius of the circle and a feed rate. G20 Turns the INCH mode on. G21 Turns the METRIC mode on. G40 Turns tool radius compensation off. The amount of the compensation will be removed at the next X or Y move. The G40 command does not produce a move by itself, but the same line can contain an X and/or Y move. The last move in X or Y before the G40 has to be a linear (G0 or G1) 22

29 move. G41 Turns left tool radius compensation on. Requires a D word with the number of the tool offset compensation table. The code will generate a move to an offset that is at 90 degrees to the left of the line, between the starting point, and the point of the next line that contains an X and/or Y move. The amount of the offset is the one from the tool table pointed to by the D word. Thereafter it will maintain this offset from the program path until the G40 word is commanded. The first move in X or Y after the line with the G41 code has to be a linear (G0 or G1) move. G42 Turns right tool radius compensation on. Requires a D word with the number of the tool offset compensation table. The code will generate a move to an offset that is at 90 degrees to the right of the line, between the starting point, and the point of the next line that contains an X and/or Y move. The amount of the offset is the one from the tool table pointed to by the D word. Thereafter it will maintaining this offset from the program path until the G40 word is commanded. The first move in X or Y after the line with the G42 code has to be a linear (G0 or G1) move. Example: G0X1.125Y2.0 G41D6 G0Z-.2 G1X1.125Y2.5F3.0 G2X1.875Y2.5I0.375J0.0 G1X1.875Y2.0 G40X2.0 G0X0Y0 Caution: Tool radius compensation needs to be used with care to avoid unpredictable moves. Make sure that the program contains a tool path that allows the computation of the offset path without resulting in extremely large or 0 distances. Some of the most common errors in the tool path are: o Reversing the direction of travel o Making a groove or notch that is too narrow for the amount of the offset o Making an arc with a radius smaller than the amount of the offset o Having an arc(g02,g03) as the first or last line between the G41/G42 and the G40. G43 Turns tool height offset compensation on. Requires an H word with the number from the tool offset compensation table. The amount from the table is added to any Z move from the program to arrive at the final Z move. It is used when programming tools with different lengths, while using the same Z zero reference. G43 needs to be canceled (with G49) before a new H number can be 23

30 activated. G49 Turns tool height compensation off. G61 Input sensing command. Requires one or more axes and a feed rate. It initiates a move until a change is sensed in the Probe connector (pin 13 of the port) or the destination is reached. If a change in the status of the Probe connector is sensed, motion will stop, after deceleration, and the program pointer will move to the next line. Uses for this code include the electronic edge-finder, the electronic tool setter, homing the axes and more. G64 Continuous contouring command. It disables the deceleration at the end of every line of code. It also disables the screen updates at the end of every line of code. Screen update is activated temporarily on SLIDE HOLD (pressing the space bar). A G64 code can be activated manually by pressing CTRL/U from the main menu or from the SLIDE HOLD mode. G65 G69 G64 cancel. Automatic switch to JOG mode from program mode G80 Cancels Drill Cycle codes. It creates a move to the Z position held when the drill cycle was initiated. G81 Drilling cycle. Requires the following words: R; rapid travel in Z before start feeding. Usually the absolute Z height just above the part being drilled Z; the depth of the drilling operation. F; feed rate. Required only if it is not active. X; Required only if different than present position. Y; Required only if different than present position. A; Required only if different than present position. Example: N30 G81 Z-0.25 R0.125 F5 N35 X2 N40 X3 N45 Y2 N50 X2 N55 X1 The code will stay on and repeat at every line with an axis command, until the G80 or any other G code is used. G82 Drilling cycle with the addition of a dwell. Requires the following words: 24

31 Example: R; rapid travel in Z before start feeding. Usually the absolute Z height just above the part being drilled Z; the depth of the drilling operation. P; dwell time in milliseconds F; feed rate. Required only if it is not active. X; Required only if different than present position. Y; Required only if different than present position. A; Required only if different than present position. N30 G81 Z-0.25 R0.125 F5 N35 X2 N40 X3 N45 Y2 N50 X2 N55 X1 G4 P2000 The code will stay on and repeat at every line with an axis command, until the G80 or any other G code is commanded. G83 Peck Drilling cycle. Requires the following words: R rapid travel in Z before start feeding. Usually the absolute Z height just above the part being drilled Z Q F X Y A the depth of the drilling operation. peck distance. Must be positive and smaller than total feed travel. feed rate. Required only if it is not active. Required only if different than present position. Required only if different than present position. Required only if different than present position. Example: N25 G83 Z-0.75 R0.125 Q F5 25

32 N30 X2 N35 X3 N40 Y2 N45 X2 N50 X1 The code will stay on and repeat at every line with an axis command, until the G80 or any other G code is commanded. G90 Absolute command mode. All commanded positions issued, from memory or MDI, after this command are regarded as absolute. G91 Incremental command mode. All commanded positions issued, from memory or MDI, after this command are regarded as incremental. G92 Register preset command. Requires one or more X, Y, Z or A words. The specified axes register will be set to the amount indicated after the axes M CODES: M0 Program stop. The program will resume with the "C" (continuous) or "S" (single step) key M1 Optional program stop. The program will resume with the "C" (continuous) or "S" (single step) key M2 End of program. Stops program execution only. Does not reset or move the program pointer. M3 Spindle start clockwise. Requires the S word with a value stating the spindle motor RPM. The S word is modal Example: M3S5000 M4 M5 Spindle start c-clockwise. Active in the software but is not included in the hardware Spindle stop. Active in the software but is available in hardware with the 4th axis option 26

33 only M6 Tool change. Stops program execution and asks for a tool change. Program flow will resume on manual restart. M8 Coolant on. Outputs a 12 Volts, 1 Amp signal out of the control box (connector below the parallel connector). M9 Coolant off. M30 End of program and reset. Stop program execution, turns spindle and coolant off and sets the pointer to the beginning of the program. M99 Program repeat. It can be given a P word with the number of repeats. After repeating the number of times indicated by P, it will continue with the rest of the program. M99 will repeat the program, from the beginning, or from the last line that started with the character "*" if used with the parameter P. 8.3 SAMPLE PROGRAM Let's look at a short program and analyze the commands: G00X0.5Y0.5 ( rapid move to the x-y position indicated) G00Z0.1 ( bring the tool to the height indicated) G01Z-0.250F5.0 ( feed the tool down to the depth indicated) Y0.0 (linear move in Y at feed rate ) G02X-0.5Y0.0I-0.5J0.0 ( make 1/2 a circle at same feed ) G01Y0.5 (linear move in Y at same feed ) G00Z0.1 ( rapid move up in Z ) G81X0.0Y0.0R0.020Z-0.300F2.0 drill cycle; rapid move in x-y then rapid to R height, drill to Z depth at feed and rapid back to R). X0.312Y0.312 ( rapid to x-y and drill again as before ) X ( same ) G80 ( cancel drilling cycle and return to Z0.1 ) G00X1.0Y1.0Z1.0 ( rapid move in all three axes simultaneously) M30 (end of program, move pointer to beginning) 8.4 INCLUDED TRIAL PROGRAMS A few trial NC programs have been provided that you can load and run to see the operation under automatic control. Study those sample programs while operating the machine in single step mode 27

34 (see above) and observing the movement of the axes. Most of those sample programs were designed with X0 and Y0 in the center of the stock, and the tool touching the surface for Z0. For example, to run the WEEEL.T program: - Prepare a 2 x2 piece of wood or aluminum, at least 1/8 thick - Clamp it in a small vise or on the table (if on the table, use a small piece of wood 1/8 thick under to avoid damaging your X table) - Install a 1/16 end mill on the spindle - Press 1 (LOAD), then 'ENTER' - Move up or down by using the up (^) and down (ˇ) keys - Select WHEEL.T from the list. - Jog to the center of the X and Y axes, bring down the Z axis to touch the material - Zero all axes - Press 2 (RUN) - Watch a small wheel being machined 8.5 CNC PROGRAMMING LEARNING RESOURCES CNC programming is not difficult to learn and the provided sample programs can help you get started, but the machine is capable of very complex operations that require a deep knowledge of this language to take full advantage of that capability. Here are some suggestions on books that deal with the subject: Benson, David - Easy CNC: A Beginner's Guide to CNC from Square 1. Square Electronics, 2005 Luggen, William W. - Computer Numerical Control: a first look primer. Delmar, Luggen, William W. Fundamentals of Computer Numerical Control. Delmar, Fitzpatric, Michel - Computer Control Simplified. McGraw Hill, 1988 Madison, James CNC Machining Handbook. Industrial Press Inc., CAD/CAM SOFTWARE A lot of CNC programming today is done with the help of computers running Computer Aided Design (CAD)/ Computer Aided Machining (CAM) programs. These programs are a great help to the programmer to go from CAD to G-code; they used to be very costly, but in recent years affordable packages have become available. Here are some options: BobCAD, DeskProto, Dolphin PartMaster CamBAM, (this application creates CAM files from CAD, it does not offer CAD functionality) 28

35 Most, if not all, of these software vendors offer trial versions, so do try and see which option gives you the best value for your needs. 8.7 THE MAXNC CNC PROGRAM GENERATORS If you are an accomplished CAD user and have a clear understanding of polylines, you might have enough with the mini-cam set of utilities provided with MAXNC, which gives you at least some tools to create programs from CAD. They convert DXF files created from a CAD system, into ready to run CNC programs: The DXF to NC program generators are: MILL.EXE Converts a 2.5D drawing (a contour map that gives the height i.e., thickness or depth of the object at each point) MILL4X.EXE Converts a CAD design that uses the 4th axis option DRILL.EXE Specifically for drilling operations. This program can be used without a CAD system by just entering the X-Y coordinates of the holes to be drilled. (press F-10 to exit this mode) ENG.EXE Text engraving (no font options, just length of engraving, engraving depth) ENG2.EXE Text engraving (no font options, just height of text, engraving depth) CREATING A CNC PROGRAM FROM AN AUTOCAD DRAWING The following simple instructions assume you know how to use AutoCAD, how to create or select polylines, and how to export an AutoCAD drawing to the DXF format. To create a CNC program in this mode: Create or load a drawing in AutoCAD create POLYLINES over the lines or arcs that you want the machine to cut (or convert these lines and arcs to POLYLINES). These POLYLINES will become the tool paths of your program and will have direction (only POLYLINES and points will be recognized by the generators ). Export a DXF file (DXFOUT) and pick the POLYLINE(S) that represent the tool path(s), in the same order in which you want them machined. Enter the name of the DXF file. Select AUTOCAD 13 format for output. To facilitate the handling you should include the MAXWIN directory as follows: 'DXFOUT' (enter) (file name?) \MAXWIN\HOOK.DXF (number of decimal places/e entities; ) E (enter) (select ) (enter), (enter). Exit AutoCAD, go to MAXWIN directory and type: MILL or MILL4X and answer the questions presented by the program. Use your text editor to do any editing or to merge several programs into one. For drilling or full circle operations, pick POINTS in the drawing and use DRILL instead of MILL to create the program. 29

36 30

37 9 UTILITIES 9.1 PLOT To view the tool paths on the screen, on the DOS prompt type PLOT followed by a space and the name of the NC program you want to view (example: PLOT \MAXNC\WHEEL.T ). From Windows Explorer, click on Plot and enter the NC program name to view the tool plot. Press M in order to see the menu. There is also a set of parameters that may need to be modified depending on the type of graphics display adapter in your system. Use the PLOTPR program to change them; the values provided are for a VGA 640x480 video mode ENGRAVING From the DOS prompt type ENG or click on ENG.EXE from windows, then follow directions. The resulting NC program can be merged with others and can be viewed with the PLOT program. The individual characters are in a sub directory named \E\ and are in the form of small NC programs of a 1" size. Only capital letters are provided. You can create your own fonts by making an NC program for every letter and saving it in disk with the prefix MTS for upper case or NTS for lower case. (The ENG.EXE program will fit the engraving to the specified length. For an engraving of a specific height, use ENG2.exe.) HOME SWITCH INPUT: 31

38 The home/limit switches are connected in series to pin 12 of the parallel port. (second connector above the parallel port connector in control box) After the initial HOME routine, all limits are activated by software, based on the travel distances writing in the file SERVPR.DAT. The values are in STEPS, or TRAVEL*RESOLUTION. (example: 10 inches * 4000 steps per inch = 40,000 steps) SWITCH DETECT COMMAND (G61): G61 is used to interrupt a move when a change of state happens in a switch connected to PIN 13 of the parallel port (first connector above the parallel port connector in control box). Typical use is as a HOME position locator or PROBE sensor. Example: G61X10.0 will move towards the X10.0 position until it reaches it, or the switch changes state. At this point it will continue with the next line on the program. This input is wired to a connector on the right side of the machine. A digitizing probe and software is available for applications such as saving a three dimensional contour shape in disk. 32

39 drive. PLOT.EXE Screen plot in 3D. Size of Files is limited only by the capacity of the hard PR.EXE Parameter setting program. Used to set-up and modify settings for the drive program. Using the PR.EXE program to change parameters. The PR.EXE program allows you to modify the PRMTRS.DAT file. Here is an explanation of these parameters: 1- JUMP START SPEED. This is the factor for the initial speed of the motors. The motors will accelerate from this speed if the program feed rate will allow it. Normally set at 3. Increase to slow down the starting speed. 2- MAXIMUM SPEED. Maximum speed in RAPID mode (G00) and in FEED mode (G01,G02,G03 etc.). Normally set at Decrease to slow down. 3- SLOW JOG. Controls the speed of the SLOW JOG MODE. Increase to slow down 4- ACCEL. FACTOR Controls the degree to which acceleration occurs between jump speed and maximum speed. Increase to accelerate faster. 5- X BACKLASH Play in the drive can be compensated with this parameter. It reads in steps. To convert, multiply inches by the resolution of that axis (ea " x 4000 = 9 steps). 6- Y BACKLASH Same as above but for Y axis. 33

40 7- Z BACKLASH Same as above but for Z axis. 8- FEED CONTROL Affects the proportion of the stated program feed rate. Change this if the programmed feed rate is not accurate (in inches per minute). 9- X RESOLUTION Sets the resolution for this axis. Is given in STEPS per INCH (or STEPS per MILIMETER for metric systems). To arrive at this number, multiply the STEPS per revolution of the motor by the revolutions per INCH of the drive (or screw). 10- Y RESOLUTION Same as above but for the Y axis. 11- Z RESOLUTION Same as above but for the Z axis. 12- PORT ADDRESS 1 X, Y, Z and A codes are output to this address. Is a decimal number, normally PORT ADDRESS 2 input signals. Normally PORT ADDRESS 3 other output signals. Normally PORT ADDRESS 4 auxiliary codes (future implementation). 16- PORT ADDRESS 5 auxiliary codes (future implementation). 17- PORT ADDRESS 6 auxiliary codes (future implementation). 18- PROMPT FOR TOOL CHANGE Setting this parameter to other than 0 will interrupt NC 34

41 program execution on any M6 in the program and prompt you for a tool change. 19- STOP FOR OPTIONAL STOP Setting this parameter to other than 0 will interrupt NC program execution on any M1 in the program. 20- INCH OR METRIC SETTING Setting this parameter to 0 will start the MAX program in INCH mode. A setting of 1 will start the program in METRIC mode. 21- A RESOLUTION Same as resolution for the other axes. 22- A BACKLASH Same as backlash for the other axes. 35

42 10 OPTIONAL ACCESSORIES TH AXIS: The Optional 4th. axis accessory for the MAXNC-10CL and 15CL CNC Machining Centers, expands the capabilities of the Machine with the ability to rotate the part being machined, under program control, in full interpolation with the other three axis. It includes a 4.0 diameter rotary table, which is normally mounted with the axis of rotation perpendicular to the spindle of the machine and parallel to the X axis. The resolution of the system is of one degree per step. INSTALLING THE PROGRAM: After inserting the 4 th axis disk in the "A" drive, type: A:SETUP The software will be copied into the MAXWIN directory. If the directory has not been created in the hard drive of your computer, then you need to install the original MAXNC CL software first, then install the 4th. axis software second. The 4th. axis software will activate the rotary axis in the controller by setting the proper parameters in the ACODE.DAT file. This software should be installed after the main MAXNC CL software. All the "A" axis functions operate in the same way as they do in the other axes. The register for the "A" axis is set to display to 3 decimal places. One revolution of the motor rotates the rotary table 36

43 5 degrees. Since there are 200 steps per revolution on the motor, the resolution of the 4th. axis is degrees. Rotation is clockwise for a positive move commanded in the program, or by manual jog. The faceplate of the rotary table is constructed with 4 T slots for mounting parts, fixtures, chucks etc. MOUNTING THE 4TH. AXIS ON THE MILL: Clamp the rotary axis on the left side of the table of the MAXNC MILL, using 4 T nuts, screws and hex nuts. Before tightening the nuts, indicate the faceplate of the 4th. axis to be parallel to the Y axis. Note: the rotary table is relatively heavy. This helps to dampen vibration very nicely but it also places a heavy burden on the "X" axis motor. Care should be taken that the rotary table is not operated too far to the left without some counterbalance on the right. Install the 2 connectors into the lower 2 sockets of the control box by removing the loop connector that was supplied with the machine. PROGRAMMING: Programming the 4th. axis is done with the "A" word. For example, a rapid move to an absolute position of degrees is done as follows: G00A90.0 A command to move all 4 axes simultaneously at a specified feed rate would look like this: G01X1.5000Y2.000Z0.2000A-180.0F3.0. Controlling the spindle is done with "M" commands: "M3" turns the spindle on; "M5" turns the 37

44 spindle off. "M30" (Program reset) will also turn the spindle off, as well as resetting from the main menu (8). USING THE MILL4X.EXE PROGRAM: The MILL4X.EXE program can be used to create rotary axis programs, automatically, from flat CAD drawing DXF files. Draw the tool paths in POLYLINES, or convert LINES and ARCS into POLYLINES, in the same way that you do with the three axis program generator. Export the drawing to a DXF file. Run the MILL4X.EXE program with the name of the DXF file as follows: "MILL4X dxfname.dxf" dxfname is the name you gave the DXF file when you created it in the CAD system. If the file is in a different directory, type the whole path name. Don't forget the space after MILL4X. If you are working in Windows, just drag the DXF file to the MILL4X.EXE program to execute. The "Y" axis values in the CAD drawing are converted to "A" values, after adjusting them for the the diameter of the part. If you need to machine a series of features around a cylinder, and you need to place them equally spaced, then draw the tool path (with POLYLINES) in your CAD system, then use COPY or ARRAY, separating the paths in the Y axis by an amount equal to the following formula: Y = DIA * PI / SPACES. Example: six pockets need to be milled around a 1.5 Dia. bar. Draw one pocket at X0 and Y0 then copy it 5 times along the "Y" axis a distance of : (1.5" X / 6) = " each. 38

45 When You run the DXF file with the MILL4X.EXE program, enter the same diameter that you use in the formula and the program will replace the "Y" linear values with the proper angular values. Since there is no circular interpolation in a rotary axis, polyline arcs are converted to a series of straight lines to simulate a curve around the diameter. Some sample NC programs are included to demonstrate the process of 4th axis programming, including the DWG. files (from AUTOCAD), the DXF files, and the CNC programs (with the T extension). 39

46 10.2 DIGITIZING PROBE The digitizing probe and software (Optional), allows the automatic input of 3D coordinates from any solid object into a computer file. The uses for this capability include the creation of NC programs for machining, importing data into CAD programs for modification, reverse engineering and many other. There are several programs included in the Digitizing package to allow modifications of the data once it has been stored. Now let s run the PROBES program: From the MAXWIN directory, type PROBES A screen similar to the screen for MAX will appear. Functions listed in the main menu with the same name, work in the same fashion as in the motion program. MENU KEYS: 1 TEACH 2 PROBE 3 MANUAL DATA INPUT 4 EDIT 5 JOG 6 ZERO AXIS 7 BACK 8 RESET KEY 1 TEACH is used to create a NC program by moving the machine in JOG and recording the coordinates by pressing the key T. KEY 2 PROBE will start the digitizing process. The probe should be positioned at the X0 Y0 Z0 position before selecting this function. Function 5 JOG can be used for this. KEY 3 MDI operates in the same way as it does in the MAX program. It can be used to position 40

47 the probe precisely anywhere around the working area. KEY 4 EDIT : Use the Arrow keys to highlight the digitizer parameter to edit: X DIMENSION: Distance in X that the digitizing probe will cover. Must be positive. Y DIMENSION. Same as above but for the Y distance. Z MAXIMUM DEPTH. This is the maximum depth that the probe is going to go to in the negative direction (down). If it has not touch anything when it reaches this depth, it will move horizontally until it touches something or it reaches one of the limits. This number must be negative. TEST DISTANCE. This is the distance to move before testing for a touch. SPACING BETWEEN PASSES. Distance between tool paths as the probe sweeps back and forth. RECORDING DISTANCE. The program will record the contact coordinates to the disk after this distance has been traveled. The smaller this number is, the higher the precision would be, but the disk file will be larger also, and it would take longer to run later. FEED RATE: The feed in INCHES/MINUTE recorded in the CNC program. DIRECTION. Three choices are available: Number 1 will sweep an area from left to right first, starting on X0Y0, then right to left and so on. Number 2 will sweep from front to back first, starting also on X0Y0 then back to front and so on. Number 3 is for digitizing using the 4 th axis.it will start at X0, Y0, Z0, and A0 then it will sweep first in X (positive) then A (positive) and so on. 41

48 CNC FILE NAME. Enter a file name and extension here. If you want the file to be in a different directory, then enter the PATH before the name (ea: \progs\car.t). This is the name of the CNC program that will be saved. KEY 5 JOG operates in the same way as in the MAX program. Used to move the table KEY 6 ZERO also operates in the same way as it does in the MAX program. It is used to preset the coordinates to zero at the position that the probe is in. If you want to preset a number other than zero, then the MDI (key 3) should be used to input a G92 code i.e.: G92X1.500 will preset on the X register. KEY 7 BACK will send the probe to the X0 Y0 Z0 position starting with a move up or down to Z0, then a move horizontally to X0 Y0. Its recommended to use this key just prior to using PROBE. ESC will exit the PROBES program As in MAX, the locations shown in the registers will be saved in the drive. Using The Probe Place the probe in the spindle using a 1/4 Dia. collet. Plug the connector into the socket provided on the left side of the MAXNC Machine. Use JOG to position the probe just above the highest point of the object you wish to digitize, then use 6 (zero axis) then Z to zero the Z axis. Move the X axis so the probe will be at the leftmost edge, and the Y axis to the nearest edge of the area that is to be digitized. Use 6 from the main menu to set X and Y to zero. 42

49 Measure the distances from that point to the right and to the back, and enter them with EDIT. For the first try, accept the defaults for the rest of the inputs. Press the 2 key to start the digitizing process. X, Y and Z zero The size of the point at the end of the probe is important for the intended use of the file. If you are creating a CNC program in order to machine the part later, then the size of the point should be the same as the diameter of the ball endmill or tool for a 1 to 1 scale. If the machined part is going to be twice the size of the digitized part, the point should be one half the size of the cutting tool. Otherwise corners may end up rounded. A 1/8" Dia. stylus point is included with the probe. A CNC program to turn a 1/16" Dia. stylus point is included in the disk. It shows the versatility of the mill in this use as a lathe. The conversion programs. Included in the Digitizing disk, is software to convert a CNC program into a DXF file to be imported to a CAD program. The name of this program is NCTODXF.EXE. When the program ask you, enter the CNC program name. The DXF file created will be named the same as tha CNC program but with the extension.dxf As a bonus, a program to create 3D CNC programs from 3D dxf files is also included. The program 43

50 name is 3DXF.EXE. Its a compiled program and it requires that all the elements exported to DXF be of "LINE" type. A prototype 3D drawing file (for AUTOCAD) and some sample 3D drawing files are included. CHECKLIST: 1 PLACE THE MAXNC CL2 DISK 1 IN THE FLOPPY DRIVE AND TYPE A:SETUP. IF THE COMPUTER IS RUNNING IN WINDOWS, CLICK ON THE START BUTTON THEN ON RUN THEN TYPE A:SETUP. 2 RUN THE MAIN PROGRAM "MAX", TURN THE MACHINE ON THEN PRESS ONE OF THE HOME/LIMIT SWITCHES TO SEE IF THE LIMITS LIGHT ON THE SCREEN CHANGES FROM GREEN TO BLACK. IF IT DOES, THEN TRY THE MODE JOG (5). RUN DIFFERENT AXES AND CHECK FOR FREEDOM OF MOVEMENT. TRY ALL THE COMMANDS AND SOME OF THE NC PROGRAMS PROVIDED. IF THERE IS NO CHANGE IN THE LIMITS LIGHT WHEN THE SWITCH IS PRESED, TURN THE MACHINE OFF, THEN REFER TO INSTRUCTIONS ON PRINTER PORT ADDRESS CHANGE ON PAGE

51 PARALLEL PORT ADDRESSES: The MAXNC CL2 driver programs are shipped with the parallel port addresses starting at 378 hex (888 decimal). Be sure to connect the parallel port cable to their appropriate port if your computer has more than one. If there is a need to change these addresses, it can be done using the program PORT.EXE. The electrical jumpers on the port cards will have to be changed to correspond to the software. To run programs larger than 300,000 bytes, the DNC (7) option from the menu needs to be used. This mode of operation works by reading the CNC file directly from the hard drive. For most computers there is no problem accessing the drive at the speed required. 45

52 CONTROL BOX CONNECTIONS SPINDLE MOTOR OUTPUT (110 V) LIMIT SW ITCH POWER SWITCH INTERLOCK PROBE COMPUTER CABLE SAFETY BREAKER SWITCH AUX OUTPUT 12 V. (COOLANT PUMP) 46

53 CONTROL BOX CONNECTIONS Z ENCODER ENCODERMA Z MOTOR X ENCODER ENCODERMA X MOTOR MOTORMAX Y ENCODER Y MOTOR A ENCONDER ENCODERMA A MOTOR MOTORMAX 47