Operation Manual. V3.3 December, Wuhan Huazhong Numerical Control Co., Ltd

Century Star Milling CNC System Operation Manual V3.3 December, 2007 Wuhan Huazhong Numerical Control Co., Ltd 2007 Wuhan Huazhong Numerical Control Co., Ltd

Preface Preface Organization of documentation 1. Introduction 2. Setting up 3. Manual Operation 4. Automatic Operation 5. Program File Operation 6. Setting and Displaying 7. Network Services 8. Diagnosis 9. PLC Function 10. Parameters Applicability This Operation Guide is applicable to the following CNC system: HNC-21MD/22MD v05.62.07.10 Internet Address http://www.huazhongcnc.com/ i

Table of Contents Table of Contents Preface...i Safety Precautions... v 1 Introduction... 1 1.1 Overall Layout...1 1.2 LCD Screen... 2 1.3 Soft Keys... 4 1.3.1 Main Menu... 4 1.3.2 PROG Submenu...5 1.3.3 RUN Submenu...6 1.3.4 MDI Menu... 7 1.3.5 TOOL Submenu...8 1.3.6 SET Submenu... 9 1.3.7 Diagnosis Submenu... 10 1.3.8 EXTEND MENU Submenu...11 1.4 Manual Data Input Keyboard... 13 1.5 Machine Control Keys...15 1.5.1 Mode Selection Switches...15 1.5.2 Verify Key...16 1.5.3 Multiple Step Keys... 16 1.5.4 Other Control Keys...17 1.5.5 Spindle and Auxiliary Operation Keys... 18 1.5.6 Speed Adjustment Keys...19 1.5.7 Axis Operation Keys...20 1.6 Other Control Keys...21 1.6.1 Emergency Stop...21 1.6.2 Cycle Run... 21 1.6.3 Feed Hold... 21 1.7 Auxiliary Devices... 22 1.7.1 Hand Pendant...22 1.7.2 Data Exchange Port... 22 2 Setting Up...23 2.1 Power-on...24 2.2 Reset/Emergency Stop...25 2.3 Homing (Reference-point Approach)... 26 2.4 Hardware Limit and Software Limit...28 2.5 Setting Tool Data... 30 2.5.1 Tool Magazine... 30 2.5.2 Tool Data Table...31 2.6 Coordinate System...32 3 Manual Operation... 33 3.1 Jog Feed...34 3.1.1 Requirements... 34 3.1.2 JOG Feedrate... 35 3.1.3 Adjusting JOG Feedrate... 36 3.1.4 Rapid Traverse Feedrate... 37 3.1.5 Adjusting Rapid Traverse Speed...38 3.2 Incremental Feed... 39 3.2.1 Requirement...39 3.2.2 Incremental Feedrate... 40 ii

iii Table of Contents 3.2.3 Step Length...41 3.3 Manual Handwheel...42 3.3.1 Requirement...42 3.3.2 Axis Selection/Off Knob... 43 3.3.3 Magnification Selection Knob... 43 3.3.4 Handwheel Rotation... 44 3.4 Spindle Operation... 45 3.4.1 Requirements... 45 3.4.2 Spindle Control Keys...46 3.4.3 Adjusting Spindle Speed...47 3.5 Auxiliary Operation...48 3.5.1 Requirements... 48 3.5.2 Auxiliary Keys...48 4 Automatic Operation... 49 4.1 Requirements... 50 4.2 Program Loading... 51 4.3 Program Verifying... 53 4.4 Running Control... 55 4.4.1 Cycle Run... 57 4.4.2 Feed Hold... 58 4.4.3 Pause Processing...59 4.4.4 Restart...60 4.4.5 Pick Start Block... 61 4.4.6 B.P. Save...63 4.4.7 B.P. LOAD...64 4.4.8 B.P. Recovery...66 4.4.9 Align Tool...67 4.5 MDI Operation... 68 5 Program File Operation... 70 5.1 Opening a Program...71 5.2 Creating a new Program File... 72 5.2.1 Program Format... 72 5.3 Editing a Program File...73 5.3.1 Editing an existing Program File... 73 5.3.2 Editing a new Program File... 74 5.3.3 Keys for Editing...75 5.3.4 Deleting a Block... 75 5.3.5 Making a Blocks Group...76 5.3.6 Deleting a Blocks Group...76 5.3.7 Cutting a Blocks Group... 77 5.3.8 Copying a Blocks Group... 77 5.3.9 Pasting a Blocks Group... 78 5.3.10 Finding a String... 79 5.3.11 Replacing a String...80 5.3.12 Background Editing (Optional)... 80 5.4 Saving a Program File... 81 5.5 Deleting an existing Program File... 82 5.6 Changing a Program File Name... 83 6 Setting and Displaying...84 6.1 Setting Coordinates...85 6.2 Workpiece Size... 86

Table of Contents 6.3 Position and Coordinate Choice... 87 6.4 System Time... 88 6.5 View Switch...89 7 Network Services (Optional)... 91 7.1 Ethernet Connection... 91 7.2 Network Connection...92 7.3 RS232 Connection...95 7.3.1 Setting the Parameters... 95 7.3.2 Setting Up the Connection...96 7.4 Sending Serial Procedures... 97 7.5 Receiving Serial Procedures... 98 8 Diagnosis... 99 9 PLC Function...100 9.1 F3: I/O Status...101 9.2 F4: Watch...102 10 Parameters... 104 10.1 F1: Parameter Index...105 10.1.1 Machine Parameters...106 10.1.2 Axis Parameters... 107 10.1.3 Servo Parameters... 109 10.1.4 Compensation Parameters...110 10.1.5 PMC User Parameters...111 10.2 F2: Password Change...112 10.3 F3: Password Input... 113 10.4 F5: Load Default...113 10.5 F6: Back to Last...113 10.6 F7: Backup...114 10.7 F8: Load...115 iv

Safety Precautions Safety Precautions This section enumerates the safety precautions for protecting the user and preventing damage to the machine. Read the contents of this part thoroughly before attempting to use the machine. 1. Operation Manual While this operation manual supplied with an numerical control unit provides an overall description of the machine s functions, some functions are specific for that machine alone and may not be available for another model. Check the specification of the machine if in doubt as to its machine-specific functions. 2. Working Environment Working temperature: 0 C - 45 C (32 F to 113 F), no freezing Temperature variation: less than 1.1 C/min (2 F/min) Humidity: below 90% Relative Humidity, non-condensing and without frost Less than 75% Relative Humidity is more desirable. 95% Relative Humidity is for the shot-term use (within one month) Storage: 20 C to 60 C (-4 F to 140 F), non-condensing and without frost. Environment: All devices should be placed indoors and away from sunshine, dust, eroding gases and moisture. Height: 1000 meter above the sea level (2000meter) Vibration: Impact during transportation or other situations should be less than 5.9m/s (0.6g) for vibrations in the range between 10 to 60Hz. 3. Grounding Correct grounding is critical for the numerical control unit and other electrical devices. No grounding or incorrect grounding may injure the operator or damage components of the numerical control devices. If the devices are not correctly grounded, inductive interference from electric motors and appliances can lead to errors and unexpected results. v

Safety Precautions 4. Power Electronic control tank is to supply the power for the milling machine. Please refer to the machine installation instruction manual. 5. Filter Filters are used on cooling fans to prevent dust from entering into devices. However, it would prevent adequate cooling if the filters become clogged. It is recommended that the user clean the filters every three months. In dusty environments such as wood routers, clean the filters more often. 6. Non-Operation After a long period of non-operation, numerical control devices should be cleaned and dried. Also check the wiring and ground connections. Once power is resumed after non-operation, observe the operation for several hours to make sure there is no unexpected behavior. 7. Manual Data Input (MDI) panel After turning on the power immediately, do not touch any of the keys on the Manual Data Input (MDI) panel until the position display or alarm screen appears on the numerical control unit. Since some of the keys on the MDI panel are dedicated to the maintenance or other special operations, pressing any of these keys may prevent the numerical control unit from entering its normal state. Starting the machine in the wrong state may cause unexpected motion or behavior. 8. Check Before operating the machine, thoroughly check the entered data, including parameters, program and settings. Operating the machine with incorrectly specified data may also result in unexpected motion or behavior that can damage the workpiece, damage the machine, or injure the operator. vi

Safety Precautions 9. Trial Run Never machine a workpiece without checking the machine's status at first. Before using the machine for a production run, make sure that the machine operates correctly by doing a trial run including, for example, a single block with a feedrate override or a machine lock function. Another possibility is to do the trial run without a tool or workpiece mounted. Failure to confirm the correct operation with a trial run may result in unexpected motion or behavior that can damage the workpiece, damage the machine, or injure the operator. 10. Feedrate Ensure that the specified feedrate is appropriate for the intended operation. The appropriate feedrate varies with the operation. Generally each machine has a maximum allowable feedrate found in the machine's operation manual. If a machine is run at other than the correct feedrate or if the maximum allowable feedrate is exceeded, unexpected motion or behavior may result that can damage the workpiece, damage the machine, or injure the operator. 11. Tool compensation function When using the tool compensation function, thoroughly check the direction and amount of compensation for each tool. Operating the machine with incorrectly specified data may produce unexpected motion or behavior that can damage the workpiece, damage the machine, or injure the operator. 12. Parameters Usually, there is no need to change the factory-set parameters of the NC unit and PMC. However, when there is no choice other than to change a parameter, be sure you fully understand the function of the parameter before making any change. Failure to set a parameter correctly may produce unexpected motion or behavior that can damage the workpiece, damage the machine, or injure the operator. vii

1. Introduction 1 Introduction 1.1 Overall Layout The user operates the milling either through the Machine Control Panel (Figure 1.1) or a Hand Pendant (optional) (Figure 1.2). A Data Exchange Port (optional) (Figure 1.3) allows the user to exchange data between the NCU and other computers through an Ethernet connection, RS232 or floppy disk. A PS/2 connector in the Data Exchange Port let the user plug in a keyboard. LCD Screen MDI keyboard Soft keys Machine control keys Figure 1.1 Machine Control Panel Figure 1.2 Hand Pendant Figure 1.3 Data Exchange Port 1

1. Introduction As it is shown in Figure 1.1, there four main areas on the Machine Control Panel: LCD Screen, Soft keys, Manual Data Input (MDI) keyboard and Machine Control keys. These are shown in detail below. 1.2 LCD Screen The LCD screen displays the machine s status, the tool s position, the program s content and other information. 1 2 5 6 3 7 8 4 9 Figure 1.4 LCD screen on the MCP 1) Machine information Mode: automatic, single block, manual, incremental, reference, emergency stop. Current status: running or error. System time: current system time. 2) Current block information It shows the current block in the program. 2

1. Introduction 3) View Different views can be selected: graphical figure, numerical figure, overall positions, and G code. 4) Diameter or Radius Programming, Metric/Inch, feedrate per minute, feedrate per revolution, rapid traverse speed, feedrate override, spindle override. 5) Program Index It shows the program name and the program block number 6) Position and Coordinate system Different position value can be shown: the command position, actual position, distance to go, trace error, or compensation. Different coordinate systems can be selected: Machine coordinate system, Workpiece coordinate system, and Relative coordinate system. 7) Origin Position It shows the origin position of the workpiece in the machine coordinate system. 8) Auxiliary Information It shows the M code, S code, and T code in the program. 9) Menu It is corresponded to the soft keys on the machine control panel. 3

1.3 Soft Keys 1. Introduction Beneath the LCD screen are the Soft keys from F1 to F10. Their functions change depending on which main menu or submenu is active. 1.3.1 Main Menu Figure 1.5 Soft keys on the machine control panel The following figure shows the main soft key menu. The keys display the function of that key in the abbreviated notation. PROG F1 RUN F2 MDI F3 TOOL F4 SET F5 DIAG F6 DNC F7 VIEW F9 MORE F10 Figure 1.6 Main Menu PROG is the key that selects the programming function. RUN selects the submenu which let the operator control the program running interactively. MDI stands for Manual Data Input; it let the operator manually write G-code programs and input data. TOOL selects the tool submenu to let the operator choose tool offsets and parameters. SET picks the setting submenu letting the operator set axis and machine parameters. DIAG selects the diagnosis submenu to alter alarms and machining statistics. DNC stands for Direct Numerical Control, letting a program load from another computer. VIEW selects one of several ways to view the screen display. MORE picks an extended menu with more commands. 4

1.3.2 PROG Submenu 1. Introduction PROG. F1 OPEN F1 EDIT F2 NEW F3 SAVE F4 VER F5 PAUSE F6 RE- START F7 VIEW -->> F9 BACK F10 Figure 1.7 PROG Submenu OPEN picks which program is to be run or edited. EDIT allows the opened program to be edited. NEW creates a new program while SAVE stores an edited program in memory. VER verifies whether the opened program has correct syntax and tool path. PAUSE temporarily halts a running program immediately. RESTART resumes program running. VIEW selects one of several ways to view the screen display. BACK goes back to the main menu. 5

1.3.3 RUN Submenu 1. Introduction RUN CTRL. F2 PICK BLOCK F1 BP SAVE F5 BP LOAD F6 VIEW -->> F9 BACK F10 From the red line From the specified line From the current line F1 F2 F3 Figure 1.8 RUN Submenu PICK BLOCK picks a block of the selected program and let the program run from this block. BP stands for break point, is used for operator to suspend and resume the machining process. BP SAVE allows the operator to save information at the current break point to memory. B.P LOAD is to load the information at the saved breakpoint so that the program can be executed at the break point. VIEW selects one of several ways to view the screen display. BACK goes back to the main menu. 6

1.3.4 MDI Menu 1. Introduction The MDI submenu has five soft keys. MDI F3 MDI STOP F1 MDI CLEAR F2 GOTO B.P. F7 ALIGN TOOL F9 BACK F10 Figure 1.9 MDI menu MDI STOP stops the executing of the MDI command. MDI CLEAR clears all the dimensional data manually input. GOTO BP let the tool go back to the breakpoint after an interactive intervention during automatic machining. ALIGN TOOL allows operator to re-align the tool s dimension. BACK goes back to the main menu. 7

1. Introduction 1.3.5 TOOL Submenu TOOL Data F4 Magazine F1 DATA F2 VIEW -->> F9 BACKTO MAIN F10 Figure 1.10 TOOL Submenu Magazine allows the user to group the tools to magazine. DATA let the operator type the tool s parameter such as length, radius, life expectancy and group number. VIEW selects one of several ways to view the screen display. BACK goes back to the main menu. 8

1. Introduction 1.3.6 SET Submenu The SET submenu has six soft keys. SETT F5 W.C.S. F1 DISP. PARA F2 POS. TYPE F3 DNC PARA. F6 VIEW -->> F9 BACKTO MAIN F10 Position Coordinates Command Actual Dist. to Go M.C.S W.C.S R.C.S Trace Error Compensation G54 F1 G55 F2 G56 F3 G57 F4 G58 F5 G59 F6 CURR. W.C.S. F7 REL. ORIGIN F8 BACKTO MAIN F10 Figure 1.11 SET Submenu WCS, stands for Workpiece Coordinate System, is used for user to define the origin position of workpiece coordinates. PART SIZE let the operator provide the workpiece dimension for graphical. POS TYPE is to select the position type to be displayed on the screen. DNC PARA allows the user to change the communication parameters for RS232. VIEW selects one of several ways to view the screen display. BACK goes back to the main menu. 9

1.3.7 Diagnosis Submenu 1. Introduction The Diagnosis or DIAG submenu has six soft keys. DIAG F6 STAT F2 INIT F3 ALARM F6 ALARM List F7 VIEW -->> F9 BACK F10 Figure 1.12 Diagnosis Submenu STAT, allows the user to check the statistics information. INIT let the operator set initial value for statistics. ALARM is used to display the causes of an alarm if it occurs. ALARM LIST lists all the alarms happened before. VIEW selects one of several ways to view the screen display. BACK goes back to the main menu. 10

1.3.8 EXTEND MENU Submenu 1. Introduction There four more soft keys under EXTEND MENU submenu. PLC, stands for Programmable Logic Circuits, and allows the user to do PLC operations. PARA is used to set/change parameters. ABOUT let the user check the software s version information. REG, stands for register, let the operator register the software. VIEW selects one of several ways to view the screen display. BACK goes back to the main menu. 11

1. Introduction EXTEND MENU F10 PARAM. INDEX F1 PASSW. CHANGE F2 PASSW. INPUT F3 LOAD DEFAULT F5 BACKUP PREVAL F6 BACKUP PARAM. F7 LOAD PARAM. F8 Back to MAIN F10 Machine Parameters Axis Parameters Servo Parameters Axis Compensation Parameters PMC User Parameters Trans-quadrant Compensation F1 F2 F3 F4 F5 F6 System F1 Optional F2 PLC F1 PARA. F3 ABOUT F4 REGI. F6 BACK, EDIT. F8 VIEW -->> F9 BACK F10 LOAD F1 Modify F2 I/O F3 Watch F4 BACK UP F7 VIEW -->> F9 BACK F10 X:[Mac->PMC] Y:[PMC->Mac] F:[CNC->PMC] G:[PMC->CNC] R:[REGIN PMC] P:[Parameter] B:[BLIFFER] Cancel F1 F2 F3 F4 F5 F6 F8 F9 Figure 1.13 MORE Submenu 12

1. Introduction 1.4 Manual Data Input Keyboard On the right side of the LCD screen is the Manual Data Input keyboard. These keys are used for editing a program, as well as changing or viewing parameters. Figure 1.14 Manual Data Input keyboard on the machine control panel 13

The following table is the description of the MDI keys. Table 1 1 Description of MDI Keyboard 1. Introduction KEY Delete keys Page change keys Cursor keys DESCRIPTION Backspace key deletes the character in front of the cursor. Delete key deletes the character at the cursor PageUp key moves the page one screen up PageDown key moves the page one screen down. Right key: moves the cursor to the right, selects a soft key to the right or selects a column to the right. Left key: moves the cursor to the left, selects a soft key to the left or selects a column to the left. Down key: moves the cursor down, selects a soft key on the bottom or selects a row on the bottom. Up key: moves the cursor up, selects a soft key on the top or selects a row on the top. Shift Up key The Shift Up key toggles the status of double-character keys on the manual data input keyboard. The LED light in the upper-left corner indicates whether the upper character is selected. When the LED light is on, the upper character is selected, otherwise the lower character will be input. For example, X will be input if is pressed when LED light of be input when the LED light is on. is off, while A will 14

1.5 Machine Control Keys 1. Introduction At the bottom of the machine control panel are the Machine Control keys. These keys operate the machine directly. Figure 1.15 Machine control keys on the machine control panel 1.5.1 Mode Selection Switches The following figure shows the five switches that select the operation mode of the machine. Note that the small LED activation light on the upper left of each key indicates in which mode the machine is working. Activation light Figure 1.16 Mode Selection Switches The following table is the description of the mode selection keys. Table 1 2 Description of Mode Selection Keys KEY DESCRIPTION Automatic (AUTO) mode key: Pressing this key switches to Auto mode. In AUTO mode, workpiece can be machined automatically from a program. Single Block (SBL) mode key: Pressing this key switches to SBL mode. In SBL mode, a program can be run block by block. Manual (MAN) mode key: Pressing this key switches to manual operation or jog mode. In manual mode, any axis of the tool can be manually controlled. Incremental (INC) mode key: Pressing this key switches to INC operation mode. In INC mode, the tool can be moved a number of steps along any axis by either the Axis keys or the hand wheel (Manual Pulse Generator). The number of steps depends on which of the multiple-step keys is selected. Reference (REF) mode key: Pressing this key switches to Reference mode. In Reference mode, each motion axis can home exactly on its reference position. 15

1.5.2 Verify Key 1. Introduction Verify key shown in the following figure is used in conjunction with the Automatic Mode key. Figure 1.17 Verify Key When the Verify key is activated, a program runs at a higher speed than normal machining. The operator can run a program quickly, but the operator should be sure the program performs the proper function. 1.5.3 Multiple Step Keys A step is equal to one micrometer (1 µm) for each linear axis (X, Y, Z) and 0.001 degrees for each rotational axis. The following figure are the four multiple step selection keys used during incremental operation. Again, the LED light on the key s upper-left corner indicates the selected multiple step. First the INC key is pushed to set the Incremental Mode, then the desired number of multiple steps is pressed, and finally the desired Axis key is pressed. Figure 1.18 Multiple Step Keys The following table shows the description of multiple step keys. Table 1 3 Description of Multiple Step Keys KEY DESCRIPTION Each key push moves that axis one step Each key push moves that axis 10 steps Each key push moves that axis 100 steps Each key push moves that axis 1000 steps 16

1.5.4 Other Control Keys 1. Introduction The five keys below are other keys that control various machining functions. Figure 1.19 Other Control Keys The following table is the description of other control keys. Table 1 4 Description of Other Control Keys KEY DESCRIPTION Over-travel release key: When mechanical over-travel on any axis occurs, press this key until the system is reset, then move the axis out of over-travel. Not used Block Bypass key: Activating this key bypasses program blocks that start with a / character. Program Stop key: Activating this key enables the M01 G-code stop function, stopping the program at a desired block. Machine Lock key: Activating this key prevents any motion from the spindle, the tool turret change or any axis; it is used for system testing. 17

1. Introduction 1.5.5 Spindle and Auxiliary Operation Keys These nine keys are usually available in Manual mode. They control spindle, turret tool selection, and coolant function. These functions are activated only when no program is running. Figure 1.20 Spindle and Auxiliary Operation Keys Details of the keys are shown in the following table: Table 1 5 Description of Spindle and Auxiliary Keys KEY DESCRIPTION Coolant Switch key: This key opens or closes the coolant flow Tool exchange enable key: Press this key to enable or disable tool exchange operation. Tool lock/unlock: After pressing this key, the tool will be release if it is locked before and will be locked if it is to be replaced in. Spindle orientation: Pressing this key to let the spindle approach a certain position that can align the spindle to its seat. Spindle jog key: This key rotates the spindle for a short time after each press. Spindle brake: Pressing down this key will brake the spindle. Spindle Clockwise Rotation key: Pressing this key begins spindle rotation in the clockwise direction (top of workpiece moves toward operator). Spindle Stop key: Stop the spindle rotation by pressing this key. Spindle Counter-clockwise Rotation key: Pressing this key begins spindle rotation in the counter-clockwise direction (top of workpiece moves away from operator). 18

1. Introduction 1.5.6 Speed Adjustment Keys By pressing these keys, the spindle speed, rapid traverse speed and feed rate (machining speed) can be adjusted. The first row controls the spindle speed, the second row controls the rapid traverse speed and the bottom row controls feed rate. Figure 1.21 Speed Adjustment Keys These keys work by adjusting the speed relative to a base speed. Different modes (Automatic, Single Block and Manual) may have different base speeds. The base speed is set by the G-code program or the parameter. For each row, pressing the center key sets the speed at 100% of the base speed; the LED light in the key s upper-left corner is lit to signify that the machine is running at 100 percent of the base speed. Pressing the minus (-) key, decreases the base speed by a fixed percent; pressing the plus (+) key, increases the base speed by a fixed percent. Below is an example where the speeds are changed by 2%: Table 1 6 Description of Speed Adjustment Keys KEY DESCRIPTION Pressing this key decreases the speed 2% for each press. The current speed or rate is displayed on the LCD screen. Once this key is pressed, the override ratio is set to 100%. The LED light indicates that the current speed is the base speed. Pressing this key increases the speed 2% for each press. The current speed or rate is displayed on the LCD screen. 19

1. Introduction 1.5.7 Axis Operation Keys These nine keys are to select the desired axis and the direction of motion in various modes. These keys only function in Manual Mode, INC Mode and Reference Mode. The LED light in the upper-left corner specifies which axis or direction is selected. Figure 1.22 Axis Operation Keys Table 1 7 Description of Axis Operation Keys KEY DESCRIPTION In INC mode or Manual Mode, the tool moves the X axis in the positive direction while +X is pressed, and in the negative direction while X is pressed. In Reference mode, pressing the +X key homes the X axis (finds the machine reference on the X axis). In INC mode or Manual Mode, the tool moves the Y axis in the positive direction while +Y is pressed, and in the negative direction while Y is pressed. In Reference mode, pressing the +Y key homes the Y axis (finds the machine reference on the Y axis). In INC mode or Manual Mode, the tool moves the Z axis in the positive direction while +Z is pressed, and in the negative direction while Z is pressed. In Reference mode, pressing the +Z key homes the Z axis (finds machine reference on the Z axis). The 4TH axis is only valid for servo-driven spindle mills. In INC mode or Manual Mode, the spindle moves in the positive direction while +4TH is pressed and in the negative direction while 4TH is pressed. In Reference mode, pressing the +4TH key homes the spindle (finds the spindle reference). This key speeds up tool motion in Manual mode. It must be pressed in conjunction with one of the Axis keys. 20

1. Introduction 1.6 Other Control Keys 1.6.1 Emergency Stop An emergency stop button is on MCP to deal with abnormal situations. Pushing down the button stops the machine from any further motion and sets the electronic to brake the motor axes and spindle. Pulling upon this emergency button resets the software system and the machine can operate again under computer or manual control. 1.6.2 Cycle Run Figure 1.23 Emergency Stop button A green Cycle Run button starts the automatic machining process. 1.6.3 Feed Hold Figure 1.24 Cycle Run button A red Feed Hold button pauses machining under computer control. Figure 1.25 Feed Hold button 21

1. Introduction 1.7 Auxiliary Devices 1.7.1 Hand Pendant Usually a handwheel, an emergency stop button and override switches are assembled on a Hand Pendant. Emergency Stop 1.7.2 Data Exchange Port Manual Pulse Generator Figure 1.26 Hand Pendant Data exchange port is for inputting or outputting program data to the NC unit. LAN, RS232 are used for communication with other computer via cable. Floppy drive is for the floppy disk. PC keyboard can be plugged in to operate the controller. LAN PC Keyboard Floppy Drive RS232 Figure 1.27 Data Exchange Port 22

2. Setting Up 2 Setting Up Before machining a part, the operator needs to set up the machine coordinates and the workpiece coordinates, define tools parameters and other machine preparations. The general setup procedure includes six steps: 1) Power On 2) Reset 3) Reference home (point approach) 4) Define software limits 5) Set tool data 6) Set workpiece coordinates The first three steps are always necessary once the machine is powered on. Step 4 is necessary only when the machine is set up for the first time. Step 5 is done for each tool cutter before it is used to cut the parts. Step 6 is done each time if a new program is used. Let s go through these steps in detail: 23

2. Setting Up 2.1 Power-on The procedure to turn the power on: 1) Check and make sure the machine is safe to run. 2) Press down the Emergency Stop button on MCP. 3) Turn on the power of the machine (usually located in back of the machine and/or beneath the control panel). 4) Make sure the fans run normally 5) Make sure the lamps on the machine control panel have been lighted on. 24

2. Setting Up 2.2 Reset/Emergency Stop After Power-on, reset the control unit by twisting the Reset Button clockwise. Resetting the servo and spindle power is to enable the machine. Pushing the RESET button down generates an Emergency stop event and disables the servo and spindle. Reset button Turn clock-wise Figure 2.1 Emergency Stop Feed motion from the axis motors and the spindle motor will stop immediately when the Emergency Stop (ES) button is pressed. This button can be used: when there is a machine malfunction before turning the power on or off Once the ES button is pressed, the system enters into the ES Mode. In this mode, no operation except reset is allowed. After curing the cause of the machine malfunction, or the machine is turned on, the emergency stop button can be released by the RESET operation (twisting the ES button clockwise). 25

2. Setting Up 2.3 Homing (Reference-point Approach) In homing (sometimes called reference point approach), there is a reference point for each axis. These reference points are used to set up the machine s coordinate system. Since the axis original positions are the same as the previous time, homing should always be performed once the machine is turned on. The following figure shows a diagram of a typical axis homing. The present location in red is a distance from the Origin. When the axis homes, the axis motion moves the present location toward the origin until it touches the Reference Switch (RSW). Motion Axis Present location Origin Reference Switch (RSW) Figure 2.2 Reference Position As it is shown in Figure 2.3, it is roughly located near the origin. Next, machine control moves the tool very slowly until the home signal encoder signal is triggered. This is the exact location of the origin, accurate to the resolution of the encoder. Tool location Origin Motion Axis Reference Switch (RSW) Figure 2.3 Reference Position Return For proper homing, the direction for reference point approach must first be defined for each axis. This setup is done once only in the parameters (see setting Parameters, Chapter 10). 26

2. Setting Up The sequence for homing is as follows (Figure 2.4). First switch the mode to Reference mode by pushing the Home key on the control panel. Next, press +X to home the X axis, and press +Y to home the Y axis. At last, press +Z to home the Z axis. Switch the mode to home mode by pressing the home key on the MCP. Press +X to approach reference point of x axis Press +Y to approach reference point of y axis Press +Z to approach reference point of z axis Figure 2.4 Approach for Reference Point Return 27

2. Setting Up 2.4 Hardware Limit and Software Limit Each axis has a hardware limit and a software limit on each end of the axis. In the figure below, the hardware switches (shown in black) are at the extreme left and right of the axis. Software switches (shown in white) are interior to the hardware switches. The limits on one end of the axis are the negative limits, those at the other end are the positive limits. By convention, the positive X axis moves the workpiece left, the positive Y axis moves the workpiece in the cross direction, while the positive Z axis moves the cutter away from the workpiece along the spindle (i.e., milling) axis. Tool location Motion Hardware Limit (-) Software Limit (-) Software Limit (+) Hardware Limit (+) Figure 2.5 Hardware Limit and Software Limit When the axis is commanded to go beyond these limits (over-travel), first the software switch will be encountered (Figure 2.5). At this point the motion ceases and no further motion in this direction is permitted. The tool can be retrieved from a software over-travel by using manual or incremental commands to move the tool back towards the middle of the axis. The sequence of releasing the software over-travel is as follows: 1) Press the mode key: Manual mode key or Automatic mode key 2) Press the over-travel release key until the system is reset. 3) Move the axis out of over-travel Software limits are defined for each axis using machine parameters. With the software limits set, the control unit can decelerate and stop the tool safely before the tool gets to the hardware limit switches. 28

2. Setting Up If the tool goes beyond the software limit, the hardware limit switch is encountered. This can occur if the software switches are not set properly, or if the tool is moving too fast to stop when the software limit is reached. Tool location Motion Software Limit (-) Software Limit (+) Hardware Limit (-) Hardware Limit (+) Figure 2.6 Over-travel 29

2.5 Setting Tool Data 2. Setting Up There are two kinds of tool data (magazine list and tool features) to be registered before the tool can be used to cut a workpiece. Magazine list and tool features are used for registering tool numbers, tool position in ATC, length and radius, life expectancy etc. Each tool is identified by its own tool number (T number). 2.5.1 Tool Magazine Magazine list enables the user to register a tool to the ATC magazine. The following steps are to get the ATC magazine: Main menu F4[Tool Data] F1[Magazine]. Figure 2.7 ATC magazine There are three columns of data: 1) Tool index: T code number. 2) Position: position of the tool in the ATC magazine. This column is fixed and can not be edited. 3) Group NO: Identify the tool s group in the machine s magazine 30

2. Setting Up The procedure for operating the ATC magazine: 1) Use to select the column. 2) Use to select the tool s row. 3) Press Enter to input the tool index or the tool s group number. 2.5.2 Tool Data Table Figure 2.8 Operating the magazine This function enables the user to define the tool s parameters. There are five parameters: Group NO. length, radius, life and position. Figure 2.9 Tool Data Table 1) Tool Index: The tool s T code number. This column is fixed and can t be edited. 2) Group NO: Identify the tool s group in the machine s magazine. 3) Length: length of the tool 4) Radius: radius of the tool 5) Life: life expectancy of the tool 6) Position: position index of the tool in the ATC magazine. 31

2. Setting Up 2.6 Coordinate System Usually workpiece coordinates system (WCS) instead of machine coordinates system(mcs) are used to simplify the programming. User can define six workpiece coordinates with G54~G59. To use these six workpiece coordinates, user needs to define the offset of their origin to the machine coordinates origin. The sequence of setting the coordinate system is as follows: 1) Main menu F5 [SETT] F1 [W.C.S] 2) Select the W.C.S you want to set the offset by F1~F8 G54 G59: Offset of G54 G59 in M.C.S Curr. W.C.S: offset of the W.C.S current being used Rel. Origin: Origin of relative coordinates system 3) Input the offset value on the command row. For example, if the offset of G54 is 100 and 100, type in X100 Z100 4) Press Enter to confirm 5) The new origin position of the W.C.S will be displayed on the screen. Figure 2.10 Setting the Coordinate System 32

3. Manual Operation 3 Manual Operation Manual Operation (MAN MAN) uses various input devices to carry out operations much like those of a manual milling. While the internal computer is actually controlling the machine tool during these operations, they are familiar to an operator that has machined parts on a manual milling. MAN operations are primarily used for setting up parts. In MAN mode, the cutter can be moved into position near the workpiece where sample facing and turning cuts can be made for setting the workpiece reference. In addition the cutter can be moved out of the way to get access to the part for measuring. For an experienced milling operator that has little or no experience on an NC milling, these operations are a good place to start. You can understand how familiar operations are implemented on an NC machine. The five MAN operations include: 1) Jog feed: Move the cutting tool along a motion axis while an axis key is being pressed. 2) Inc ncremental feed: Move the cutting tool a fixed amount along a motion axis 3) Manual Handwheel: Move the cutting tool by manually rotating the handwheel 4) Spindle operation: Turn spindle rotation clockwise, counter-clockwise or off. 5) Auxiliary operation: Change other devices such as tool selection and coolant. 33

3. Manual Operation 3.1 Jog Feed JOG feed is used to move the cutting tool along a motion axis. The motion continues as long as the axis key is pressed. In jog feed mode, pressing a feed axis with its direction on the machine control panel continuously moves the tool along the selected axis in the selected direction. 3.1.1 Requirements Figure 3.1 shows the Jog Feed Mode key. JOG mode LED indicator light JOG mode key Figure 3.1 Jog Feed Mode Switch to JOG mode by pressing on the Machine Control Panel After pressing the JOG mode button, the LED indicator light on that key lights to verify that you are in the JOG mode. 34

3. Manual Operation 3.1.2 JOG Feedrate Figure 3.2 shows the feed axis keys in Jog mode. This key moves the X axis continuously in the positive direction (away from the workpiece) This key moves the X axis continuously in the negative direction (toward the workpiece) Figure 3.2 Feed Axis Keys in Jog Mode Press one of the feed axis keys: +X, -X, +Y,-Y -Y, +Z or -Z (Figure 3.2). If your milling has a fourth axis control (4TH axis), you can also press the +4TH or -4TH keys. For moving the cutting tool toward the workpiece use a minus key (-X, -Y, -Z, -4TH). For moving the cutting tool away from the workpiece use a plus key (+X, +Y, +Z, +4TH). The tool will continue to move at a fixed speed along the selected axis so long as the key is pressed. The tool motion stops when the axis key is released. The tool moves at a fixed speed along the selected axis. This fixed speed is called JOG feedrate. The JOG feedrate is a fixed fraction of the rapid traverse rate. The factory default JOG feedrate is one third (1/3) of the rapid traverse speed. For example, if the rapid traverse feedrate were set at 600 inch/min, the JOG feedrate would be 200 inch/min using the factory default setting. Moreover, this default JOG feedrate for each axis can be set by the axis parameter (See Chapter 10). 35

3. Manual Operation 3.1.3 Adjusting JOG Feedrate The JOG feedrate can be adjusted with the manual feed "override ratio". Figure 3.3 shows the three override keys that control the JOG feedrate and an LED light LED light shows when feedrate is 100% of full value Feedrate icon Decrease the JOG feedrate by 2%. Set the JOG feedrate to its full value 1/3 of the axis s rapid traverse speed. Increase the JOG feedrate by 2% Figure 3.3 Jog Feedrate Adjustment Keys The feedrate icon tells that the JOG feedrate is being adjusted. Pressing the 100% key sets the JOG feedrate at full value (i.e., 1/3 the rapid traverse value for factory default). The LED light in the upper left corner of the 100% key specifies that the feedrate is set to full value. Pressing the minus (-) key reduces the feedrate by 2% of the factory default amount of the 100% JOG feedrate. Pressing the minus (+) key increases the feedrate by 2% of the factory default amount of the 100% JOG feedrate. For example if the JOG feedrate were 200 in/min and you pressed the plus (+) key, the new feedrate would be 204 in/min. The override ratio could be 10%, 7%, 4%, 2%, 1%, 0%, the range of adjustment is 0-150%. 36

3. Manual Operation 3.1.4 Rapid Traverse Feedrate Rapid Traverse speed is the maximum feedrate on each axis that the machine can move. By contrast, the feedrate for JOG functions is usually set at a small fraction of the Rapid Traverse speed (factory default set at 1/3). Figure 3.4 shows the Rapid Traverse key. Rapid Traverse Key Figure 3.4 Rapid Traverse Key To move the cutting tool at the Rapid Traverse speed, press the Rapid Traverse key while simultaneously pressing one of the feed axis keys: +X, -X, +Y, -Y, +Z, -Z, +4TH or -4TH. The minus key (-X, -Y, -Z, -4TH) moves the cutting tool toward the workpiece, while the plus key (+X, +Y, +Z, +4TH) moves the cutting tool away from the workpiece. In either case, the motion will be at the Rapid Traverse speed. 37

3.1.5 Adjusting Rapid Traverse Speed 3. Manual Operation The rapid traverse feedrate can be adjusted with the manual feed "override ratio". Figure 3.5 shows the three override keys that control the rapid traverse feedrate and an LED light. LED light shows when feedrate is 100% of full value Rapid Traverse icon Decrease the Rapid Traverse speed by 2%. Increase the Rapid Traverse speed by 2%. Set the Rapid Traverse speed to its full value Figure 3.5 Rapid Traverse Speed Adjustment Keys The rapid traverse feedrate icon tells that it is being adjusted. Pressing the 100% key sets the rapid traverse feedrate at full value. The LED light in the upper left corner of the 100% key specifies that the feedrate is set to full value. Pressing the minus (-) key reduces the feedrate by 2% of the 100% rapid traverse speed. Pressing the minus (+) key increases the feedrate by 2% of the 100% rapid traverse speed. The override ratio could be 10%, 7%, 4%, 2%, 1%, 0%, the range of adjustment is 0-100%. 38

3. Manual Operation 3.2 Incremental Feed The INC feed is useful for adjusting the cutting tool a small fixed amount from a surface being turned or faced. For example, in making a sample turning cut, the cutting tool can be adjusted toward the workpiece until it just begins to cut. Then using a small (say 5 thou) incremental -X movement let the operator clean up surface of the workpiece by removing 5 thou from the diameter. 3.2.1 Requirement Figure 3.6 shows the increment mode key. INC mode LED indicator light INC mode key Figure 3.6 Incremental Mode Key Switch to INC mode by pressing the INC mode key on the Machine Control Panel. After pressing the INC mode button, the LED indicator light on that key lights to verify that it is in the INC mode. 39

3. Manual Operation 3.2.2 Incremental Feedrate Incremental feed is used to move an axis at a fixed increment of travel. In INC mode, the cutting tool moves at the JOG feedrate. Pressing an axis key in incremental or INC mode, moves the cutting tool one increment in that axis and direction. Figure 3.7 shows the feed axis keys in incremental mode. This key moves the X axis one step in the positive direction (away from the workpiece) This key moves the X axis one step in the negative direction (toward the workpiece) Figure 3.7 Feed Axis Keys in Incremental Mode For each press of the feed axis keys: +X, -X, +Y, -Y, +Z or -Z, the tool cutter moves a certain distance. If your milling has a fourth axis (4TH axis), you can also press the +4TH or -4TH keys. To move the cutting tool toward the workpiece use a minus key (-X, -Y, -Z, -4TH). For moving the cutting tool away from the workpiece use a plus key (+X, +Y, +Z, +4TH). The distance is the number of minimum steps multiplied by the magnifier value. For example, if the magnifier were set at 1 and you pressed the +X key twice, the distance moved would be 1 2 = 2 minimum step. In inch units, that's a tenth of a thou, in metric units that's 2 microns. But if the magnifier were set at 100, the distance moved would be 100 2 = 200 minimumstep. In inch units, it moves ten thou (0.012inch), in metric units it moves 200 microns (0.2mm). 40

3.2.3 Step Length 3. Manual Operation As it is mentioned above, in incremental mode, pressing an axis key on the Machine Control Panel moves the tool one step along the selected axis in the selected direction. The step length is a magnified length. The distance moved in a step length is the minimum step multiplied by the magnifier value: step length = minimum step magnifier Minimum step The minimum step is the shortest distance that an axis can move. The minimum step is a certain rotation of the ball screw moving each axis. It is determined by the machine's encoder. Depending on the number of steps on that axes' encoder, the step size is either in inch or metric units. For an inch unit encoder, the minimum step is 50 millionths of an inch (half a tenth of a thou). For a metric unit encoder, the minimum step is 1 micron (0.001 mm). Magnifier The four keys below (Figure 3.8) are the step length magnification in the INC mode. Pressing any key changes the magnification of the corresponding distance. The minimum step can be magnified by 1, 10, 100, or 1000 times giving a "step length". As before, the LED light associated with the selection lights up indicating which magnification is chosen. LED light shows which magnification is selected Magnifier No magnification; each key press moves one minimum step. Each key press moves ten minimum steps. Each key press moves one hundred minimum steps. Each key press moves one thousand minimum steps. Figure 3.8 Step Length Magnification 41

3.3 Manual Handwheel 3. Manual Operation In the handwheel mode, the cutting tool can be moved at the small amounts by rotating the handwheel on the handwheel unit (Figure 3.9). During part setup with the handwheel, the operator can adjust the cutting tool closer to the workpiece than from the machine control panel. There are two selection knob on the handwheel unit: one is for axis selection (X, Y, Z, 4TH) and the other is for magnification (X1, X10, X100, X1000). Handwheel unit Magnification selection knob Axis selection/off knob 3.3.1 Requirement Handwheel Figure 3.9 Hand Pendant To use the handwheel unit, the machine should be in the incremental mode. press the INC mode key. When the handwheel is enabled, the INC mode on the machine control panel is disabled (i.e., the incremental feed operation is disabled). Once in INC mode, the handwheel unit is activated by turning the Axis Selection knob from the OFF position to one of the milling's axes. 42

3.3.2 Axis Selection/O election/off Knob 3. Manual Operation The following figure shows the Axis selection/off knob on the handwheel unit. By rotating the knob, you both turn on the Handwheel unit and also select the axis of handwheel motion. OFF: The handwheel unit is disabled; control is through the incremental mode on the machine control panel. X: Handwheel movement controls the X axis Y: Handwheel movement controls the Y axis Z: Handwheel movement controls the Z axis. 4TH: Handwheel movement controls the 4TH axis (if available). Figure 3.10 Axis Selection/Off Knob 3.3.3 Magnification Selection Knob The right knob on the Handwheel unit is the Magnification Selection knob (Figure 3.11). By rotating the knob, you select the amount of magnification to the step length for each increment of handwheel motion. The amount of magnification can be 1, 10, 100 or 1000. X1: No magnification; each click of the handwheel moves one minimum step. X10: Each click of the handwheel moves ten minimum steps. X100: Each click of the handwheel moves a hundred minimum steps. X1000: Each click of the handwheel moves a thousand minimum steps. Figure 3.11 Magnification Selection Knob Note: A minimum step for linear axes is 0.5 tenths (inch encoders), one micron (metric encoders) or 0.001 degrees for rotational axes. 43

3.3.4 Handwheel Rotation 3. Manual Operation Rotating the handwheel on the handwheel unit moves the selected axis one step length (minimum step * magnifier) for each click of the handwheel. Clockwise rotation moves the selected axis away from the workpiece (positive axis direction: +X, +Y, +Z, +4TH 4TH). Counter-clockwise rotation moves the selected axis toward the workpiece (negative axis direction: -X, -Y, -Z, -4TH 4TH). Always be cautious when moving the handwheel counter-clockwise because you are moving it toward the cutting zone. Clockwise Rotation (CW): Moves the cutting tool away from the workpiece (i.e., positive axis direction) on the selected axis. Counter-clockwise Rotation (CCW): Moves the cutting tool toward the workpiece (i.e. negative axis direction) on the selected axis. Step length: The motion is one step length (minimum step times the magnifier) per click of the handwheel. Figure 3.12 Handwheel 44

3.4 Spindle Operation 3. Manual Operation The spindle is the most important of these keys since no cutting takes place unless the spindle is rotating. For most millings, the spindle can be manually operated when the milling is not machining. However, some milling manufacturers do not allow manual operation of the spindle except in JOG mode. 3.4.1 Requirements The machine should be in JOG mode. Switch to Jog mode by pressing the JOG mode key. After pressing the Jog mode button, the LED indicator light on that key lights to verify that you are in the Jog mode. Make sure there is no potential danger from the spindle turning before you run the spindle manually. 45

3.4.2 Spindle Control Keys 3. Manual Operation The four keys shown below (Figure 3.13) control the spindle operation. The lower left key starts spindle rotation in the clockwise (CW CW) direction, the middle key stops the spindle manually and the right key starts spindle rotation in the counter-clockwise (CCW CCW) direction. The upper spindle key turns on the spindle as long as it is pressed. SPINDLE ORIENTATION: Press this key to let the spindle approach a certain position that can align the spindle to its seat. SPINDLE JOG: Spindle rotates only while pressing this key. Spindle stops when key is released. SPINDLE BRAKE: Pressing down this key will brake the spindle. RUN SPINDLE CW: Rotate the spindle in clockwise direction. The LED is lit if the spindle is running. STOP SPINDLE: Stop the spindle manually. RUN SPINDLE CCW: Rotate the spindle in counter-clockwise direction. The LED is lit if the spindle is running. Figure 3.13 Spindle Control Keys Note: If the spindle is turning one way and you want to change the rotation direction to the other way, you must first stop it and then press the desired rotation direction. 46

3.4.3 Adjusting Spindle Speed 3. Manual Operation The spindle speed can be adjusted with the manual feed "override ratio". Figure 3.14 shows the three override keys that control the spindle speed and an LED light. LED light shows when feedrate is 100% of full value Spindle icon Decrease the spindle speed by 2%. Increase the spindle speed by 2%. Set the spindle speed to its full value Figure 3.14 Spindle Speed Adjustment Keys The spindle icon tells that it is being adjusted. Pressing the 100% key sets the spindle speed at full value. The LED light in the upper left corner of the 100% key specifies that the spindle speed is set to full value. Pressing the minus (-) key reduces the speed by 2% of the factory default amount of the 100% spindle speed. Pressing the minus (+) key increases the speed by 2% of the factory default amount of the 100% spindle speed. The override ratio could be 10%, 7%, 4%, 2%, 1%, 0%, the range of adjustment is 0-150%. 47

3.5 Auxiliary Operation 3. Manual Operation To operate the auxiliary devices: coolant, and tool selection, there are three keys. 3.5.1 Requirements The machine must be in JOG mode. Switch to JOG mode by pressing on the JOG key. After pressing the JOG mode button, the LED indicator light on that key lights to verify that it is in the JOG mode. 3.5.2 Auxiliary Keys The three keys shown below control auxiliary operation. The first key turns coolant flow on/off. The other two keys are for the tool exchange and tool lock/unlock. Coolant key Tool exchange keys COOLANT ON/OFF: Press this key to start coolant flow. Coolant flow is ON if the LED light is lit and OFF if the LED light is off. TOOL EXCHANGE ENABLE: This key is to enable or disable the tool exchange operation. The tool is exchangeable while the LED lamp on this key s upper left corner is on. Otherwise, the tool exchange operation is not permitted. TOOL LOCK/UNLOCK: Provided the tool is exchangeable, once this key is pressed, the tool will be released if it is locked before and will be locked if it is to be replaced. Figure 3.15 Auxiliary Keys 48

4. Automatic Operation 4 Automatic Operation Automatic (AUTO AUTO) operation is used to machine parts under program control. In an NC machine tool, most production machining is done as an AUTO operation. In Automatic mode, you can execute part programs automatically. If you are a manual milling operator, it is the AUTO operations that will be most unfamiliar to you. AUTO operation requires a program to execute. Several sample programs are already included in the controller's memory. If you are a beginner, execute one of the sample programs in AUTO mode. If you are an advanced NC operator, execute a program that you have written yourself. Automatic operation includes four parts: 1) Program Loading: putting the program into the milling s computer memory 2) Program Verifying: finding errors in a new program 3) Running Control: running part of the program to debug it 4) Manual Data Input (MDI): operating the milling by typing blocks into the milling s computer manually. 49

4. Automatic Operation 4.1 Requirements The requirements below are all necessary before the milling can be run automatically. Programming functions require soft keys. These are keys whose function changes depending on the key s description on the LCD screen. The physical keys are located just below the LCD screen. Each soft key function shown on the LCD screen is actuated by pushing the corresponding physical key just below. After pressing the physical key, the soft key descriptions will change to bring in functions only available when the physical key is pressed. Soft key description on LCD screen LCD Screen Physical keys Corresponding physical key Figure 4.1 Soft Keys The milling has already been homed. That is, the Reference Point Approach procedure has been completed. You have verified or entered tool data (offset and compensation values), zero offsets and other necessary data. Machine lock is off. Machine should be in AUTO mode. AUTO mode LED indicator light AUTO mode key Figure 4.2 Automatic Mode Key 50

4.2 Program Loading 4. Automatic Operation A program file must be loaded into the milling s memory before it can be executed (i.e., cut a part or do some other operations automatically). The program file itself is a series of program lines called blocks that direct the milling through a series of various operations automatically. The programmer who writes the program file sets these operations. Only one program at a time can be loaded for execution by the milling. Usually many programs that have been written are stored in the milling s computer. Loading is the process of picking one of these programs to be executed. The following steps are to load a program for execution. 1) From the physical Menu keys located just below the LCD screen, press the F1 physical key just below the F1 [PROG PROG] soft key on the LCD screen. Then the soft keys would change to Program Functions and Program Sources. These functions only appear after pressing the F1 PROG key. F1 PROG soft key LCD Screen Program sources Program Functions Figure 4.3 The sequence of program loading (1) 51

4. Automatic Operation 2) Now press the F1 physical key again, corresponding to the F1 [OPEN OPEN] soft key. F1 OPEN soft key Figure 4.4 The sequence of program loading (2) 3) When pressing the OPEN soft key, the LCD screen shows a file directory: a list of program files is like the ones below. The left column shows the name of the program file, the middle column shows the size of the file and the rightmost file shows the last date the file was changed. Note that program files always start with the letter O. The example below shows 10 different program files, each 1K long (one kilobyte) and last changed in Dec. 2006. Program file directory Figure 4.5 The sequence of program loading (3) 4) Use the left-right keys (located on the keyboard area just to the right of the LCD screen) to change the selected item from among the Program Sources: CF (hard disk or memory chip), DNC and floppy disk. Selected source shows in blue color Figure 4.6 The sequence of program loading (4) 5) Once the source is selected, use the up-down keys to select one of the program files from the program file directory. Each press of the down key moves the blue selected line to the next file down in the file listing. 6) Last, press the Enter key in lower right corner of the keyboard area to load the selected program to memory. 52

4.3 Program Verifying 4. Automatic Operation A program which has just been created or changed should be verified before it is actually used to cut parts. Program verifying can find errors in the program without actually running the machine and possibly damaging the milling or the workpiece. The following steps are used to verify a program: 1) Load the program to the milling s computer memory as shown above. 2) To verify, you must be in either AUTO mode (Automatic mode) or SBL mode (Single Block mode). 3) Press the F5 key corresponding to VERIFY in the Program Functions menu. F5 VERIFY soft key Program Functions Figure 4.7 The sequence of program verifying (1) 4) In VERIFY mode, the soft key display changes to the one below where the functions VERIFY and PAUSE are in bold type. The other functions are in light type, signifying that they can not be used during the VERIFY process. Figure 4.8 The sequence of program verifying (2) 5) Press the Cycle Run button on the Machine Control Panel (MCP) to start the VERIFY process. Figure 4.9 The sequence of program verifying (3) 53

4. Automatic Operation 6) As the program is verified, the lines of the program are displayed. The line being verified is highlighted in yellow. As the verification progresses, the yellow line moves line-by-line from the top to the bottom of the program. The LCD screen will display an error message if an error is found. Otherwise the cursor (yellow highlighted line) will return to the start of the program. Figure 4.10 The sequence of program verifying (4) 7) Note that there is no motion of the cutter or any other action that takes place. The VERIFY process is a simulation of the motion or action that would take place. 8) View different settings of the LCD display using Program Function F9 VIEW. For example, you can observe the cutting tool motion with the graphics display view or you can observe the position of the axes and feedrate with the axis display view. 54

4. Automatic Operation 4.4 Running Control Once verified successfully, the program can be executed automatically with AUTO mode or by stepping through each block of the program in SBL mode. Most operators will step through the program in Single Block (SBL SBL) mode before trying it in AUTO mode. The program running process either verifying or executing can be paused, canceled or run from the start again. You can also run the program from a specific location in the program other than from its start to more easily confirm the program section at a time. The following steps are used to run a program: 1) From the Main Menu, press the F2 RUN CTRL soft key. F2 RUN CTRL soft key LCD Screen Figure 4.11 The sequence of running a program (1) 2) If you are in a submenu, press the F10 BACKTO MAIN soft key (the rightmost key on all submenus). For example, from the VERIFY submenu below, press F10 BACKTO MAIN to return to the Main Menu above. F10 BACKTO MAIN soft key Figure 4.12 The sequence of running a program (2) 55

Running Control has nine different operations available: 4. Automatic Operation 1) Cycle Run: cycles through the program 2) Feed Hold: stop the motion of the program with a soft key press 3) Pause Processing: pause the program s operation 4) Restart: begin the program operation again after a pause 5) Pick Start Block: begin the program at any line 6) Save Break Point: shut down the machine and save the restart point 7) Load Break Point: load the restart point after machine shutdown 8) Break Point recover: restart after machine shutdown 9) Align Tool: change tools and realign the new cutter at the same location 56

4.4.1 Cycle Run 4. Automatic Operation This function begins program execution. Requirements 1) The program has been successfully verified 2) The machine is in Single Block (SBL SBL) mode or Automatic (AUTO AUTO) mode. Sequence 1) Press the green Cycle Run button and the program will be executed. 2) If the machine is in AUTO mode, the machine will keep running until it is finished or until the Feed Hold button is pressed to cancel the AUTO mode. 3) If the machine is in SBL mode, the machine stops after each block of the program is executed. Press Cycle Run again and the next block in the program will be executed. 57

4.4.2 Feed Hold 4. Automatic Operation Requirement 1) The program has been successfully verified. 2) The machine is in Single Block (SBL SBL) mode or Automatic (AUTO AUTO) mode. Sequence 1) During execution, pressing the red Feed Hold button pauses the program. Pressing the Cycle Run button recovers the running process again. These two Cycle Run and Feed Hold work together to stop and restart the program being executed. 2) After the Feed Hold button is pressed, you can stop all action by pressing the Emergency Stop button. If you just want to exit the program, cancel it with the PAUSE operation below. 58

4.4.3 Pause Processing 4. Automatic Operation The milling s computer begins processing the program once it is loaded into the memory. You can pause the processing by pressing F6 [PAUSE PAUSE] in the Program Functions submenu. Prompt on blue background PAUSE soft key pressed Figure 4.13 Pause Processing 1) Press F6 PAUSE and the program pauses and issues a prompt (words in green with blue background) asking the operator a question. 2) Pressing the Y (Yes) key on the NC keyboard cancels the program. All the current mode information will be unloaded. The program can not run from this point 3) Pressing the N (No) key pauses the program; it can be run again from the stopping point by pressing the RESTART soft key. 59

4.4.4 Restart 4. Automatic Operation If the program has been canceled by pressing Y (Yes) after the Pause soft key prompt, restart from the program beginning by pressing the RESTART soft key. RESTART prompt Press RESTART soft key Figure 4.14 Restart a Program 1) Press F7 RESTART 2) Press N (No) to cancel RESTART. 3) Answer Y (Yes) on the NC keyboard to run the program again from the beginning. 4) Now press the Cycle Run button on the Manual Control Panel (MCP) and the program will be executed from the beginning. 60

4.4.5 Pick Start Block 4. Automatic Operation Usually a program is executed from the beginning of the program - the first line of program instructions. But for debugging or testing modifications, you may want to run a program starting from other locations in the program. A milling program can be executed from any location (besides the start block) by using PICK BLOCK. The PICK BLOCK function picks the next block in the program to be executed; we call this next block the start block. The following steps are used to pick the start block: 1) From the Main Menu, press the F2 RUN CTRL soft key to get the Block submenu: Main menu Block submenu Figure 4.15 The sequence of picking a start block (1) 2) From the Block submenu, press F1 PICK BLOCK PICK BLOCK soft key Figure 4.16 The sequence of picking a start block (2) 61

4. Automatic Operation 3) A dialog window appears on the LCD screen giving instructions for the next operation. Now you have three choices. Press the F1 soft key to use the red line as the start block Press the F2 soft key to specify the start block Press the F3 soft key to use the current line as the start block Figure 4.17 The sequence of picking a start block (3) Press F1: Start block is shown by the red bar. Use the Up/Down keys to move the red bar up or down to the desired start block. Figure 4.18 The sequence of picking a start block (4) Press F2: Start block specified by its line (row) number. For example, in the program above, to select G80 X25 Z-20 F2000 as the start block, type 7 (seventh line) after pressing F2 Figure 4.19 The sequence of picking a start block (5) Press F3: Start block is the current block shown by the blue bar 4) Press the F9 VIEW key to cycle through different views until you come to the program view shown above. 5) Press the Cycle Run button to begin execution at the start block 62

4. Automatic Operation For complex or large parts, more than one day may be required to finish machining. You may need to turn off the machine before it s done. In this case, the milling s memory should store the current block location and recover from this location to continue machining later. Break point functions do this. In order to save the location for restarting the program later, you need to know three procedures: saving the break point when you stop, loading the saved break point and recovering from the break. 4.4.6 B.P. Save The first of the three break point functions is saving the break point when you stop the milling. The following steps are to save the break point: 1) Press Feed Hold button to pause the machine. 2) Press F2 RUN CTRL from the Main Menu to get the Block submenu Main menu Block submenu Figure 4.20 The sequence of saving a break point (1) 3) Press the F5 B.P. SAVE soft key to save the break point. Notice that the soft key turns green when the function is entered. B.P. SAVE soft key Figure 4.21 The sequence of saving a break point (2) 63

4. Automatic Operation 4) Type the break point file name using the keyboard to the right of the LCD screen. In the example below, the file is named 03453.BP1 perhaps naming the part number being machined. Figure 4.22 The sequence of saving a break point (3) 5) Press Enter to confirm the operation. The milling will store the current status information to the typed file. 4.4.7 B.P. LOAD If you haven t turned the milling power off after the B.P. SAVE, you can restore the breakpoint directly with B.P. LOAD. For example, if you just leave for a lunch break, you can do a B.P. SAVE before you leave and then resume again quickly when you return. However, if machine has been powered off after a B.P. SAVE operation, you must recover the break point: first the milling must be homed (i.e., perform the Reference Point Approach procedure) after turning the power on. Since the workpiece will still be in the chuck, you should be careful on which axis you home first (X, Z and perhaps C) to avoid a collision between the cutting tool and the workpiece. The following steps are to load a break point: 1) The break point program has been loaded into memory 2) Press F2 RUN CTRL from the Main Menu to get the Block submenu. Main menu Block submenu Figure 4.23 The sequence of loading a break point (1) 64

3) Press the F6 B.P. LOAD soft key to load the break point file. 4. Automatic Operation B.P. LOAD soft key Figure 4.24 The sequence of loading a break point (2) 4) After pressing the B.P. LOAD soft key, a table of break point files is displayed. The first column is the name of the file, the second is the size of the file in Kilobytes and the last column is the date on which the break point file was last saved. Date last saved Break point file name Size in Kilobytes B.P. LOAD function Figure 4.25 The sequence of loading a break point (3) 5) Use the up/down keys to select the desired break point file. 6) Press Enter to confirm your selection 7) If there were absolutely no changes since the B.P. SAVE operation, press Cycle Run button to continue the machining process. Otherwise switch to the MDI mode to recover the breakpoint. 65

4.4.8 B.P. Recovery 4. Automatic Operation If there have been ANY manual operations of the milling or if the milling power has been turned off, you must move the tool back to where it was before the break point in order to run the machine again using the break point file. The following steps are to recover a break point: 1) Move the cutting tool near its position at the break point, making sure there won t be a collision during this operation. 2) Switch to the MDI mode by first returning to the Main Menu. Press F10 BACK TO MAIN, then press F3 MDI. F10 BACK TO MAIN soft key F3 MDI soft key Figure 4.26 The sequence of recovering a break point F7 GO TO B.P. soft key 3) Press the F7 GO TO B.P. soft key 4) Now press the Cycle Run button on the Manual Control Panel (MCP). The milling will go automatically to the break point position when it was saved before power-off. 5) Press F10 BACK TO MAIN again to exit the MDI mode. 6) After the machine has stopped at the saved break point, press the Cycle Run button to continue machining from the saved break point. 66

4.4.9 Align Tool 4. Automatic Operation Another use of break points is when the cutter gets dull and the milling must be stopped to change cutters. To install a new cutter you first stop the milling and B.P. SAVE before you remove the old cutter. However, when you put the new cutter back into the tool holder, the tool must be realigned so the new cutter is at the same position as the old one. The following steps are to align tool: 1) Move the new tool near the position of the break point, making sure the cutter could not collide with the workpiece or fixture during this operation. 2) Switch to the MDI mode from the Main Menu and press F8 ALIGN TOOL: F3 MDI soft key F8 ALIGN TOOL soft key Figure 4.27 Align Tool 3) Press the Cycle Run button on the Manual Control Panel (MCP). The milling will align the tool automatically and update the tool data. 4) Press F10 BACK TO MAIN in order to exit the MDI mode. 5) After the machine has finished the tool alignment operation, press the Cycle Run button to continue machining from the break point. 67

4.5 MDI Operation 4. Automatic Operation The Manual Data Input (MDI MDI) mode is used to set milling data values and operations without using a program. G-codes, M-codes and T-codes can all be entered manually through the keyboard. The MDI mode is useful not only for break point recovery as was done above. The following steps are about MDI operation. 1) From the Main Menu, press F3 MDI and the milling will enter into MDI mode. F3 MDI soft key Figure 4.28 MDI mode 2) The MDI screen shows the previously executed G-codes which set the function of the milling. Also shown are values of different parameters such as feedrate, spindle speed and axis position. MDI screen Previously executed G-code list Parameter values MDI RUN Command Input line Figure 4.29 MDI screen 68

4. Automatic Operation 3) Input one or several commands representing one block of data on the MDI RUN command input line. In this example, the manually input G-code commands will set the milling for linear interpolation (G01), set the X position from zero to 100 (X100), and set the feedrate from 500 to 1000 (F1000). Note that only one block of commands can be executed for each cycle run. MDI RUN command Input line Multiple commands form one block of data Figure 4.30 MDI RUN command 4) Press Enter to confirm the commands. In the example from above, the G01 command replaces the previous G00 command, the X axis has a new position of 100 instead of zero and the feedrate has a new value of 1000 instead of 500. New G-code New X axis position value New feedrate value Figure 4.31 new MDI screen 5) Press Cycle Run button to execute the commands. 69

5 Program File Operation 5. Program File Operation Program can be stored in CF, floppy Disk and hard disk. From Main menu, press F1, the program file management menu is displayed. Figure 5.1 Program File Management Functions: 1) F1[OPEN]: Open a program file saved in CF, DNC or floppy disk. 2) F2 [EDIT] F3[NEW]: Create a new file. 3) F2[EDIT]: Edit the current program file. 4) F4[SAVE]: Save the current program file. If you specify another name as, this function is Save as. 70

5.1 Opening a Program 5. Program File Operation A program should be loaded to memory before editing, verifying or automatic machining. The following steps are to open a program: 1) From file operation menu, press F1[OPEN]. Screen looks like: Figure 5.2 The sequence to open a program (1) 2) Use to select the program source: CF(or hard disk or memory chip), DNC or floppy disk. Figure 5.3 The sequence to open a program (2) 3) Use to select an existing file at the source directory. 4) Press Enter to open the file. Figure 5.4 The sequence to open a program (3) 71

5.2 Creating a new Program File 5. Program File Operation Create a new file at a specified directory on a specified disk. The name of the new file should be different from the existing files. The following steps are to create a new program file: 1) From file operation menu, press F2[Edit], then F3[New]. Figure 5.5 The sequence to create a new program file (1) 2) Type a file name for the new file. 3) Confirm the name by Enter 4) Edit the new file. Figure 5.6 The sequence to create a new program file (2) 5) Once finish editing, just Press F4[Save] and Enter to save it. 5.2.1 Program Format A program must have its start symbol and end symbol: The start symbol should be % or O following by a program number. The end symbol should be M02 or M30. Letters and symbols are printed in white color and numbers are in yellow. Characters after ; or between ( and ) are interpreted as comments. All the comments are printed in green color. 72

5.3 Editing a Program File 5. Program File Operation Editing a program file involves deleting, finding and replacing a program. User can either edit an existing program file or create a new one and then edit it. 5.3.1 Editing an existing Program File The following steps are to edit an existing program file: 1) From the main menu, press F1[PROG], enter into the file program submenu. 2) Press F1[OPEN] to open an existing file from the file list. 3) Press Enter to confirm the selection. 4) Press F2[EDIT], the content of the program file will be displayed on the window. It can be edited now. Figure 5.7 Editing an existing Program File 73

5.3.2 Editing a new Program File 5. Program File Operation The following steps are to edit a new program file: 1) From the main menu, press F1[PROG], enter into the file program submenu. 2) Press F2[EDIT] to enable the new function. Notice: the current program in memory will be displayed in the window. Just ignore it. 3) Press F3[NEW] to create a new file. 4) Input the name for the new file. Figure 5.8 Editing a new Program File (1) Figure 5.9 Editing a new Program File (2) 5) Press Enter to confirm the name and it is ready for editing now. Figure 5.10 Editing a new Program File (3) 74

5.3.3 Keys for Editing 5. Program File Operation The following table is the keys for edit. Table 5 1 The Keys for Editing Name Key Explanation Delete BS PageUp Delete a char that is behind the cursor. The cursor is holding still and the other chars which are behind it move a char to left. Delete a char that is before the cursor. The cursor and the other chars which are behind it move a char to left. Roll the program upward, while the cursor is holding still. PageDown Roll the program downward, while the cursor is holding still. Left Left-move the cursor on the screen; Right Right-move the cursor on the screen; UP Up-move the cursor on the screen; Down Down-move the cursor on the screen; 5.3.4 Deleting a Block The following steps are to delete a block: 1) Press or to move cursor to one row. 2) Press and simultaneously. Figure 5.11 Deleting a Block 75

5. Program File Operation 5.3.5 Making a Blocks Group The following steps are to make blocks as a group: 1) Press or to move cursor to the start block 2) Press + B to mark the start row of the blocks group 3) Press to move cursor to the end row 4) Press + E to mark the end of blocks 5.3.6 Deleting a Blocks Group Figure 5.12 Making a Blocks Group The following steps are to delete blocks as a group: 1) Make a blocks group first D 2) Press + 3) The blocks group will be deleted. Figure 5.13 Deleting a Blocks Group 76

5. Program File Operation 5.3.7 Cutting a Blocks Group The following steps are to cut blocks as a group: 1) Make a blocks group first X 2) Press +. The blocks group will be cut. Different from the deleting operation, the blocks group will be saved in clipboard when the cutting operation is used. 5.3.8 Copying a Blocks Group Figure 5.14 Cutting a Blocks Group The following steps are to copy blocks as a group: 1) Make a blocks group first C 2) Press + 3) The blocks group will be copied to the clipboard. Figure 5.15 Copying a Blocks Group 77

5.3.9 Pasting a Blocks Group 5. Program File Operation The following steps are to paste blocks as a group: 1) Move the cursor to position you want to settle. V 2) Press + 3) The blocks group you have copied or cut to the clipboard before will be pasted here. Figure 5.16 Pasting a Blocks Group 78

5.3.10Finding a String 5. Program File Operation The following steps are to find a string: 1) Select Edit mode 2) Press + 3) Input the string F Figure 5.17 Finding a String 4) Press Note: 1. If the string to find is in the current program, the cursor will stop at front of the first string. At the same time, the color of the string and its background will be changed; otherwise, there would be a prompt: Figure 5.18 Finding a String a Prompt 2. Press + L to find the next string. 79

5. Program File Operation 5.3.11Replacing a String The following steps are to replace a string: R 1) Press + 2) Input the string to be replaced 3) Press Figure 5.19 Replacing a String (1) 4) Input a string to replace that string input at the second step 5) Press Figure 5.20 Replacing a String (2) 6) Press Y to replace; Press N to cancel. Figure 5.21 Replacing a String (3) Note: At each time, CNC system replaces only one string. If there re several strings to be replaced, please press + L to replace the next string. 5.3.12Background Editing (Optional) To save time, two program file can be executing at the same time. 1) Press F10 [EXTEND MENU] from main menu 2) Press F8 [BACK, EDIT.] to get the background editing menu. Figure 5.22 Background Editing Menu 80

5.4 Saving a Program File 5. Program File Operation The following steps are to save a program file: 1) From file operation menu, press F4[Save]. Or from file edit menu, press F4[Save]. Figure 5.23 Saving a Program File 2) Type a new file name or keep the file name to save. 3) Confirm the name by Enter Note: If you want to cancel any of the above operation, just press ESC. 81

5.5 Deleting an existing Program File 5. Program File Operation The following steps are to delete an existing program file: 1) From file operation menu, press F1[Open]. Figure 5.24 Deleting an existing Program File (1) 2) Select the file you want to delete from the list with. Figure 5.25 Deleting an existing Program File (2) 3) Press Del key on the NC keyboard area. 4) Type Y to confirm the operation. The file will be deleted from the media. Figure 5.26 Deleting an existing Program File (3) 82

5.6 Changing a Program File Name 5. Program File Operation Changing a program file name is a combination of Save as and Delete operation. The following steps are to change a program file name: 1) From file operation menu, press F1[Open]. Select the file you want to change its name from the list with. 2) Press Enter to open the file. 3) Press F4[Save] 4) Type the new name for the file. 5) Press Enter to confirm the new name. 6) Press F1[Open] to navigate the file list. Select the file with the old name from the list with. 7) Press Del key. 8) Type Y to confirm the operation. The file will be deleted from the media. 83

6 Setting and Displaying 6. Setting and displaying Machine tool s status is changing dynamically during operation, user can select the certain information to focus or choose his favorite visualization style. There are four kinds of information which can be displayed to show the machining progress: graphical figure, numerical figure, overall positions and G code. Different positions or value such as command position, actual feedback position, distance to go, track error and compensation value are available for choosing. Also, the tool s position can be expressed in either workpiece coordinates system(w.c.s), machine coordinates system(m.c.s) or relative coordinates system(r.c.s). From Main menu, press F5[SETT.], Setting and Displaying menu is displayed. Figure 6.1 Setting and Displaying menu Functions: 1) F1[W.C.S]: Define the origin offset of W.C.S and R.C.S. in M.C.S. 2) F2[PART SIZE]: Set the workpiece size 3) F3[POS. TYPE]: Select position type and coordinates type. 4) F5[NET]: Set the network (optional) 5) F6[DNC PARA.]: DNC parameters. 6) F9[System Time]: Set the system time 7) F9[View switch]: Switch the display content among graphical figure, numerical figure overall positions and G code. 84

6. Setting and displaying 6.1 Setting Coordinates From Setting and displaying menu, press F1 (W.C.S). Enter into coordinate setting menu: Figure 6.2 Setting Coordinates Menu Functions: 1) F1-F6: Set origin offset of G54-G59 in M.C.S 2) F7: Set origin offset of the current workpiece coordinates system 3) F8: Set origin offset of the relative coordinates system. 85

6.2 Workpiece Size 6. Setting and displaying To display the graphic figure in the viewpoint, viewpoint parameters should be set correctly. In Setting and displaying menu, F2[DISP. PARA] is for setting the viewpoint parameters. Three groups of parameters are needed to set the viewpoint step by step. 1) Coordinate(x, y, z): Offset of the displaying coordinates origin. Figure 6.3 Workpiece Size - Coordinate 2) Zoom In(x, y, z): Scale factor in x, y and z direction. Figure 6.4 Workpiece Size Zoom In 3) Angle(x, y, z): Parameters that used to change the view angle about x, y and z axis. Figure 6.5 Workpiece Size - Angle 86

6.3 Position and Coordinate Choice 6. Setting and displaying From Setting and displaying menu, press F3[POS.TYPE] to choose the position and coordinates type. Figure 6.6 Position and Coordinate Choice The procedure for setting the position and coordinate type: 1) Use or to switch between position radios and coordinates radios. 2) Use or to select different position or coordinates type. 87

6.4 System Time 6. Setting and displaying To set the system time: 1) Press F5[SETT.] from the main menu 2) Then press F9[System Time] to set the system time. Figure 6.7 Setting System Time 88

6.5 View Switch 6. Setting and displaying Four kinds of information contents are available for choosing to be displayed in the center of LCD screen. They are graphical figure, numerical figure, overall positions and G code. Press F9 (View) to switch among these four options. These four kinds of displaying status will be switched from one to another by pressing F9. Graphic View Figure 6.8 Graphic View Numerical View Figure 6.9 Numerical View 89

Overall Positions View 6. Setting and displaying G code View Figure 6.10 Overall Position View Figure 6.11 G code View 90

7. Network Services 7 Network Services (Optional) 7.1 Ethernet Connection The procedures for the Ethernet connection is as follows: 1) Connect the Ethernet cables to the HUB 2) Connect the Ethernet cable to the Ethernet interface on CNC machine. 3) Turn the power on to check the connection. It is connected if the indicator light on the Ethernet interface is on. Otherwise, it is not connected. 4) Install the Network Services of HNC NetDnc (v1.0). 91

7.2 Network Connection 7. Network Services The procedure for the network connection is: 1) Press F5[SETT.] from the main menu 2) Then press F5[NET] to get the network connection menu Figure 7.1 Network Connection Menu 3) Set the server IP address. This step can be skipped if the server IP address has been set at last time. 4) Press F1 to connect the network. Figure 7.2 Setting the server IP address If it is connected, the screen would be as follows: Figure 7.3 Successful Connection 92

If it can not be connected, the screen would be as follows: 7. Network Services Figure 7.4 Failed Connection 5) Use to reset the server IP address or the client IP address if it is necessary. Figure 7.5 Resetting the server IP address 93

7. Network Services Figure 7.6 Resetting the client IP address 6) If the connection is failed, there will be black screen. And then the system is returned to the initial status. 94

7.3 RS232 Connection 7. Network Services 7.3.1 Setting the Parameters The procedure for the RS232 connection: 1) Press F5[SETT.] from the main menu 2) Then press F6[DNC PARA.] to set the parameters. Figure 7.7 Setting COM Parameters Port Number it is for the COM connection. It could be 1 or 2. The default value is 1. Baud Rate it is the speed during the COM transmission. It could be 300,, 9600, 19200, 38400,, 115200. The default value is 115200. 95

7.3.2 Setting Up the Connection 7. Network Services The procedure for setting up the connection is as follows: 1) Press F7[DNC] from the main menu Figure 7.8 DNC 2) Press Y or Enter to get the DNC mode. Figure 7.9 DNC Mode 3) Depending on the command from the client, three main services can be offered: Get/Receive G code Get/Receive the parameters of CNC system Get/Receive CNC PLC 96

7.4 Sending Serial Procedures 7. Network Services The following example is about sending G code from the numerical control unit to the personal computer. 1) Press F7[DNC] to get the DNC mode 2) Click Download G code. (For more detailed information, please refer to HNC communication software operation manual) Figure 7.10 The snapshot on the personal computer 3) If it is connected, G code would be sent. Figure 7.11 Sending Data 97

7.5 Receiving Serial Procedures 7. Network Services The following example is about receiving G code from the personal computer. 1) Press F7[DNC] to get the DNC mode 2) Click Send G code. (For more detailed information, please refer to HNC communication software operation manual v1.0) 3) If it is connected, G code would be sent. Figure 7.12 Receiving Data 4) When it is done, the following figure would be shown. Figure 7.13 Data is finished receiving 98

8 Diagnosis 8. Diagnosis When a fault occurs, the CNC system will give an alarm message. User can read these message to analyze the reason of the fault. From Main menu, press F6[DIAGNOSIS], enter into diagnosis menu. Figure 8.1 Diagnosis Menu Functions: 1) F6[Alarm list]: Display the current alarm message. Figure 8.2 Alarm List 2) F7[Alarm record]: Display all the alarm information occurred before. Figure 8.3 Alarm Record 99

9 PLC Function 9. PLC Function From Main Menu, press F10[EXTEND MENU]. Press F1[PLC] to enter into PLC functions. Functions: Figure 9.1 PLC function 1) F1: Load a PLC program 2) F2: Modify a PLC program 3) F3: I/O status 4) F4: Watch all registers value. 5) F7: Backup a PLC program 100

9.1 F3: I/O Status 9. PLC Function This function enables the user to check the I/O status. Status of Input points from machine to PMC (X register) and output points from PMC to machine (Y register) can be monitored in this window. On indicates the I/O points is on. Off indicates the I/O points is off. Figure 9.2 I/O Status 101

9.2 F4: Watch 9. PLC Function The status of all registers can be monitored with this function. When F4 (Watch) is pressed, a window as following will pop up. As it is shown in the figure, there are seven registers: 1) X: PMC Machine 2) Y: Machine PMC 3) F: CNC PMC 4) G: PMC CNC 5) R: Intermediate register in PMC 6) P: Parameters 7) B: Buffer to store system status information in case of unexpected power-off Figure 9.3 PLC Register 102

The procedure is as follows: 9. PLC Function 1) Use or to select a register from the above list. Press Enter to confirm the selection. 2) For example, if we want to monitor the current values of G register, we can press F4. The values of all G registers will be displayed: Figure 9.4 Monitoring Register 3) Then there are three kinds of digital forms to display the value F5[BIN]: display the register value in binary F6[DEC]: display the register value in decimal F7[HEX]: display the register value in hex 103

10 Parameters 10. Parameters User can check or modify the parameters. Users are divided into three groups. Different group are allowed to access different parameters. The three groups are: CNC vendor, Machine tool s vendor and machining operator. The group is identified by the password. Users from different group have different password. From Main menu, press F10[EXTEND MENU], enter into extend menu. Then press F3[PARA], parameter function menu will be displayed. Figure 10.1 Parameter Menu 1) F1[PARAM. INDEX]: Parameter Index 2) F2[PASSW. CHANGE]: Password Change 3) F3[Password input]: For user to input the password. 4) F5[LOAD DEFAULT]: Load default value for parameters. 5) F6[BACKTO LAST]: Set the parameter value at last time. 6) F7[BACKUP PARAM.]: Make a backup file for the current parameters. 7) F8[LOAD PARAM.]: Load the parameters value from a back up file. 104

10.1 F1: Parameter Index 10. Parameters There are different sorts of parameters. User can choose the specified sort of parameters to check or modify from this index. For the CNC s vendor and the machine tool s vendor, password should be provided first to access parameters belonged to his own authority. A parameter list would pop up when press F1 [PARAM. INDEX]: Figure 10.2 Parameter List 1) F1: Machine parameters 2) F2: Axis parameters 3) F3: Servo parameters 4) F4: Compensation parameters 5) F5: PMC user parameters 105

10.1.1Machine Parameters 10. Parameters Turret direction(0/1) 0: positive direction of X axes in graphic display is downward. 1: positive direction of X axes in graphic display is upward. Diameter/Radius at X(1/0) 0: dimension along X axes is given as radius 1: dimension along X axes is given as diameter Metric/Inches(1/0) 0: unit of dimension is thousandth of an inch 1: unit of dimension is thousandth of a mini-meter Power-off protection(1/0) 0: data protection in case of power off is disabled 1: data protection in case of power off is enabled Tool Comp. Type(0:Abs. 1:Rel.) 0: compensate the tool nose radius in absolute coordinates 1: compensate the tool nose radius relative to standard tool Pulse type(0:uni-dir,1:bi-dir,2:ab) 0: pulse is uni-direction 1: pulse is bi-direction 2: pulse is AB phase Spindle encoder direction(32:+,33:-) 32: direction of encoder on spindle is positive 33: direction of encoder on spindle is negative Spindle encoder part number Part number of the spindle encoder. 106

10.1.2Axis Parameters 10. Parameters Pulse/um(um) Movement distance of the axis per revolution of the motor. The unit is um for linear axis, a thousandth of 1 for rotational axis. Pulse/um(pulse) Encode counter per revolution of the motor. Note: this two numbers can be commonly divided into prime numbers. Software limits positive(um) Positive position of this axis s software limit in M.C.S Software limits negative(um) Negative position of this axis s software limit in M.C.S Reference approach mode(1:+-,2:+-) Method to approach the reference point of this axis. 1: Move forward to find the encoder s zero position after the reference switch is reached. 2: Moving backward to find the encoder s zero position after the reference switch is reached, Reference approach direction( +, - ) Rapid traverse direction during reference point approaching. +: positive direction. Use this option if the tool is at the minus side of the reference switch -: negative direction. Use this option if the tool is at the negative side of the reference switch Reference point position(um) Coordinates value of the reference point in the M.C.S 107

Reference point offset(um) Offset distance after the encoder s zero position is found. 10. Parameters Rapid traverse speed for reference approach Speed before the reference switch is reached. Slow speed for reference approach(mm/m) Speed used to find the encoder s zero position after the reference switch is reached. Deceleration distance for G60 Distance between the deceleration point and the command position while G60 is used to do uni-direction position. Rapid traverse rate(mm/min) Speed for rapid traverse. G00 use this speed. Maximum feedrate(mm/min) Maximum feed rate for this axis. Acc. time constant for rapid traverse(mm/min) Acceleration time to get a speed increase of 1000mm/min during rapid traverse motion. Jerk time constant for rapid traverse(ms) Jerk time to get an acceleration increase of 1000mm/sec during rapid traverse motion Acc. time constant for feeding(mm/min) Acceleration time to get a speed increase of 1000mm/min during machining feeding. Jerk time constant for feeding(ms) Jerk time to get an acceleration increase of 1000mm/sec during machining feeding. Track tolerance: Maximum tracking error. 108

10.1.3Servo Parameters 10. Parameters Feedback to NC(45:YES,46:NO) 45: Encoder counter feedback to NC. This is always true if servo driver is used. 46: No encoder or no position feedback to NC. This is always true if step motor is used. Servo part number. first one. Part number of the servo driver. Value is from 1~31. 1 means none and zero is the Position loop gain(open-loop) Gain coefficient of the position loop. For open loop control. The bigger this value, the better rigidity the system can reach. But if the value is too high, the system may become unstable and vibration may occur. The value ranges from 1~10000. The unit is 0.01sec -1. Default value is 3000. Position loop feedforward coefficient(kf) The value ranges from 0~65535. Default value is 0. Velocity loop proportion coefficient(kp) Ranges from 0~65535. Default value is 2000. 3000~7000 is recommended. Velocity loop integral(ki) Ranges from 0~65535. Default value is 100. 20~50 is recommended. Maximum torque Ranges from 0~255. Default value is 150. Only effective for HSV-11. Rated torque Ranges from 0~255. Default value is 100. Only effective for HSV-11. 109

10. Parameters Tracking error Tracking error threshold. Alarm will be displayed if the actual tracking supersede this value. Pulse per revolution Pulse counter value the NC get per revolution of the motor. 10.1.4Compensation Parameters Backlash(um) This value should be calibrated by measurement instrument. The unit is 0.001mm. It should be set as 0 if bi-directional pitch compensation is used. Pitch err. comp. type(1:uni-dir,2:bi-dir) Pitch error compensation type. 1: Compensate the pitch error in uni-direction. 2: Compensation the pitch error in bi-directions. Compensation points number: Range from 0~127. Can be extended to 5000. The maximum measure point is 128 if uni-direction compensation type is used. The maximum measure point is 64 if bi-direction compensation type is used. Index of reference point. Index of the compensation point in the compensation table. Compensation gap Distance between two adjacent compensation points. 110

10.1.5PMC User Parameters 10. Parameters 111

10.2 F2: Password Change 10. Parameters This function is to change a password. This function is only enabled when the user enter his password. The following steps are to change a password: 1) Enter the old password first. 2) Enter the new password. Figure 10.3 Inputting an old password Figure 10.4 Inputting a new password 112

10.3 F3: Password Input 10. Parameters This function is to input the password. 10.4 F5: Load Default Figure 10.5 Inputting the password This function is to set the parameters as the default value. 10.5 F6: Back to Last This function is to set the parameter values at last time. 113

10.6 F7: Backup 10. Parameters This function is to make a backup file for the current parameters. 1) Press Y if you want to backup the current parameters 2) Type the backup file name. Figure 10.6 Backup the parameter values Figure 10.7 Typing a backup file name 3) Press Enter, the current file will be backup in the file. 114

10.7 F8: Load 10. Parameters This function is to load the parameters value from a back up file. 1) Use or to select the backup file source among CF, DNC or Floppy disk. Figure 10.8 Backup file List 2) Use or to select the backup file from the file list. 3) Press Enter to confirm. Figure 10.9 Confirming to load a backup file 115