RADAN COMPUTATIONAL LIMITED

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User Manual
2.0
04/04/02
gppdata\tl2530_sin840D.1 vfy/tl2530, tls

Machine Tools Covered: Trumpf lasers with Siemens sinumeric 840d control i.e.
TCL
TCL
TCL
TCL
TCL

2530
3030
3050
4030
6030

INDEX
INTRODUCTION
GUIDE TO USING THIS MANUAL
USER EDITABLE SYSTEM DATA
SUPPLIER EDITABLE SYSTEM DATA
QUESTIONS ASKED BY THE POST PROCESSOR
OPERATOR REQUIREMENTS
Controller parameter tables
SHEET LOAD/UNLOAD
Load position
PROGRAM INITIALISATION
Initial setup
Initialised values
PROFILE TOOLING
USING TAGS (MICROJOINTS)
RAISING HEAD BETWEEN PROFILES
TOOL CHANGE OPTIONS
PRE-PIERCING
FEED RATE CONTROL
Movement
Cutting
Acceleration
CORNER COOLING
CUTTING LARGE SHEETS IN HALF
HAZARD AVOIDANCE AND SPRINTLAS

SUBROUTINES
COMPILER ERROR MESSAGES
SYSTEM DATA REQUIREMENTS
VERIFIER GRAPHICS

INTRODUCTION
This document is intended to supplement the Radpunch &
Radprofile User Manual by describing key features of the
post processor for the machines listed below.
This manual does not cover the preparation of NC drawings
prior to running the post processor but does discuss how this
preparation will affect the NC program produced.
As a Radpunch/Radprofile user, your system will have been set
up in what was considered the most appropriate way for your
machine tool. You have a certain amount of control via the
system data editor if you wish to modify your configuration,
and on some post processors there are extra data items,
changeable by your system supplier, that further affect your
machining operations. This manual describes all the possible
configurations of your post processor, and guides you in
making any changes.
GUIDE TO USING THIS MANUAL
This manual covers all the aspect of the post processor
that can vary from job to job due to the way that you
answer post processor questions, tool the job or write the
order text. This manual does not attempt to discuss fixed
strategies used in the post processor over which there is
no control.
Some post processor capabilities are controlled, or switched
on or off, via system data. There are two types of system
data:
USER EDITABLE SYSTEM DATA
This type of system data can be changed by you now.
To change this type of system data you will need to be
the system administrator. The system administrator is any
user who has their read and write permissions set to 9.
When a system is installed, the only user with these
facilities is called 'sysman'. Others can be created by
'sysman'.
Log in as sysman and select "Edit System data" option of
Radpunch/Radprofile System Functions. References to this
type of system data will be in the following form, the
text in quotes is that which appears in the System Data

Editor.
User System Data: "Maximum Feedrate"
SUPPLIER EDITABLE SYSTEM DATA
This type of system data can be changed but needs the
assistance of your system supplier.
If you decided to edit this type of system data
yourselves, without seeking advice, your system supplier
can not be held responsible for the consequences.
References to this type of system data will be in the
following form:
Configuration System Data : m58 [y]
You can either be talked through editing such system data
on the phone or you can send us your current system data,
in the form of an embedded drawing, and we will make the
appropriate modifications and send it back.
View the "FREQUENTLY ASKED QUESTIONS" section if you have a
problem, you may well find an immediate solution.
QUESTIONS ASKED BY THE POST PROCESSOR
There are certain decisions that this post processor makes that will
affect the content of the NC program produced. It is often necessary
for you to 'have a say' in what NC blocks are created to cater for
your way of working, or for different machine tool requirements.
In order to give the post processor the flexibility to achieve this
it will ask the following questions.
* Enter Program Number
Usually the radan drawing name is scanned for a number, if this
is unsuccessful the postprocessor will ask the question.
* Enter laser positioning height
You should answer with the height you want the laser to be at
when positioning (TC_POS_LEVEL)
This question is optional and invoked by:
Configuration System Data : m84 [ASK_HEIGHT]
SHEET LOAD CYCLE PARAMETERS
* Alright to use default values (y/n)
If you have previously answered and saved values for
some or all of the following questions, you can
choose to use these answers again by answering y.
Answering n will allow you to edit the previously
saved values, and you also have the option of saving
the new answers by overwriting the old ones. Look

out for the question: 'Do you wish to save these new
values (y/n):'.
Radan staff will often refer to the saved answers to
such questions as the 'Cutting condition database',
because the questions usually refer to different
profile cutting options that affect quality of cut
for different sheet thicknesses and materials.
If your machine supports the Liftmaster option you will be
asked :
* Loading device (0 None, 1 Table Changer, 2 Liftmaster) :
[Default 2]
Otherwise you will be asked :
* Do you want to use table changer (y/n) :

[Default y]

* Sheet stop corner (1-4)

[Default 2]

* Do you want to use sheet measurement (y/n)

[Default n]

If the answer is "y" two further questions are asked

* What is the X measurement range (<x wrange mm)[Default 50]
* What is the Y measurement range (<y wrange mm)[Default 50]
* Do you want to calibrate height control (y/n) :[Default y]
* Do you wish to save these new values (y/n) ?
At the end of the series of questions, you are
asked whether or not you want to save these
values. If you respond "y", then the values that
you have entered will be saved into the database.
The next time the post processor is run the values
will be recalled and offered as default responses to
the questions. It is of course possible to override
the saved values, and to update the database with
new values if desired.
If the machine is fitted with the cat-eye option
Configuration System Data: m84 [CAT-EYE]
the following question will be asked:
* Do you wish to use the cat_eye? (y/n)
If you answer 'y' to this you will be asked:
* Detect (s)heet corner or (c)entres of 2 holes? (s/c)
These option correspond to methods 1 and 5
respectively.
Depending on which method is chosen you will

be asked some of the following questions.

These correspond to the parameters in the
description of TC_SHEET_MEASURE in the Trumpf
manual. The "s" method is the default. In all
cases the value entered for the programmed
co-ordinate will be used as the default answer
for the corresponding approximate co-ordinate.
For the "c" method:
* Enter programmed X co-ordinate of first hole
See Trumpf programming manual for explanation
* Enter approximate X co-ordinate of first hole
See Trumpf programming manual for explanation
* Enter programmed Y co-ordinate of first hole
* Enter approximate Y co-ordinate of first hole
* Enter diameter of first hole
* Enter programmed X co-ordinate of second hole
* Enter approximate X co-ordinate of second hole
* Enter programmed Y co-ordinate of second hole
* Enter approximate Y co-ordinate of second hole
* Enter diameter of second hole
For the "s" method (the default answers are
for the bottom left corner of the sheet):
* Enter programmed X position of corner
* Enter approximate X position of corner
* Enter programmed Y position of corner
* Enter approximate Y position of corner
* Enter length of X edge (-ve if a right hand corner)
* Enter length of Y edge (-ve if a top corner)
* Enter distance to re-measure the sheet
LASER CUTTING CONDITIONS
* Alright to use default values (y/n)
If you have previously answered and saved values for
some or all of the following questions, you can
choose to use these answers again by answering y.

Answering n will allow you to edit the previously

saved values, and you also have the option of saving
the new answers by overwriting the old ones. Look
out for the question: 'Do you wish to save these new
values (y/n):'.
Radan staff will often refer to the saved answers to
such questions as the 'Cutting condition database',
because the questions usually refer to different
profile cutting options that affect quality of cut
for different sheet thicknesses and materials.
* Enter tag type: Microjoint, Soft weld, Hard weld

(0/1/2):

* Maximum angle to use corner cooling (TC_WAIT) (0 - 180) :

Corner cooling is only required when the angle between
lasered features become significant. Enter the angle,
between features, at which corner cooling will be used.
For example enter 90 if all corners at 90 or sharper
require corner cooling. When corner cooling is needed a
TC_WAIT block will appear in the NC program.
To turn corner cooling completely off enter 0.
* Enter cooling wait time (0.1 - 9.9 secs) or 0 to use LTT :
When corner cooling is enabled you will be asked to
enter the wait time. This time is output in the TC_WAIT
command. If you enter 0, the time in the machine tool's
controller table will be used instead.
* Enter laser technology table
The technology table name to use for TC_LASER_ON.
Up to 5 (10 for later systems) different laser cutting
conditions are allowed in a job. For each cutting condition
("tool") used the following questions are asked. You can refer
to the Trumpf programming manual or Trumpf technology tables
for the appropriate entries:
Cutting Condition nnn with master tool number mmm
* Enter laser method (1-12)
The laser method number for TC_LASER_ON
* Pierce mode
Enter the pierce mode for TC_LASER_ON. Ensure this is
set to zero for cut-only methods. If you use 'change on
the way' or 'Common Line Cutting' then the post
processor will automatically adjust this value when no
pierce is needed.
* Cutting mode
The cutting mode to use in TC_LASER_ON. This will
change the laser power, accelerations and feed rates

depending on how your technology table is set up.

Ensure that this is set to zero for pierce-only
methods (e.g. in pre-piercing)
N.B.
Laser technology tables must be compatible in nozzle
id, setting height and focus position otherwise an "Unable to
select program" error message may result on the controller.
* Do you wish to save these new values (y/n) ?
At the end of the series of questions, you are
asked whether or not you want to save these
values. If you respond "y", then the values that
you have entered will be saved into the database.
The next time the post processor is run the values
will be recalled and offered as default responses to
the questions. It is of course possible to override
the saved values, and to update the database with
new values if desired.
OPERATOR REQUIREMENTS
The operator will maintain the technology tables and canned cycles
resident on the controller.
SHEET LOAD
The sheet will be loaded on the bed in accordance with the SHEET_LOAD
table in the program.
Cat-eye
If the machine is fitted with the cat-eye option
Configuration System Data: m84 [CAT-EYE]
a SHEET_MEASURE table and TC_SHEET_MEASURE command
will be output in the blocks if you chose to use it
(see QUESTIONS ASKED BY THE POST PROCESSOR above).
PROGRAM INITIALISATION
Initial setup
The system has been set up as a ten station machine. Each
station corresponds to a different application of the tool.
There are five cutting conditions that can be applied using
tool centre point programming or offset programming.
The tool descriptions need to be entered in the Master Tool
File, all are laser tools. A tool will be needed for each
cutting condition used in a job . Tool diameter will be used
for tool centre point programming so this should be chosen
with care.
A standard tool file should be set up such that the first
five stations represent tool centre point programming and the
latter five represent offset/kerf programming. The cutting
conditions for the first five stations are repeated for the

second. Thus the choice of tool will dictate the station and
thereby the cutting condition and offset type.
Initialised Values
Header Table Parameters.
The L2530 expects a large amount of tables in the header
information of the program. Many of the parameters are constant
from job to job, others rely on system data or cutting
conditions.
The Machine Datum
The L2530 having established the position of the BLHC of the
sheet using the SHEET LOAD table parameters uses this as the
datum for the job.
PROFILE TOOLING
CUTTING CONDITION QUESTIONS
There are compilation time questions to control the profiling
method, technology table, piercing, and cutting.
Refer to "QUESTIONS ASKED BY THE POST PROCESSOR" section above.
USING TAGS (MICRO-JOINTS)
The the user will be prompted if microjoints are to be
modified to soft or hard welding.
The welding operation is performed on linear "tool centre
point" programmed profiles by modification of a microjoint.
The profile is cut 7mm beyond the microjoint start, turned off
in weld mode, moved back to the microjoint point, a weld
executed, a move of 5.5mm along the profile path and the laser
switched on to resume cutting.
The microjoint must be placed outside of 7mm from the start or
end of a linear centre line programmed profile. Neither must
leadins or leadouts be placed at the microjoint or the system
will revert to a microjoint at that point.
RAISING HEAD BETWEEN PROFILES
The height above the sheet that the head is raised to between
profiles can be set by:
User System Data: "Rapid traverse Z axis height"
The distance below which the head should be kept down when
moving between profiles can be set by:
User System Data: "Max move with plas down"
Otherwise height is controlled by the technology tables on the
controller, and the parameters in the laser call routines.

TOOL CHANGE OPTIONS

Laser tool changes invoke a change of cutting conditions and can
be made "on the way" in laser methods 5, 6, 11 & 12.
PRE-PIERCING
Pre-piercing can be effected by laying down single tool
symbols. Be sure to answer the cutting condition questions
appropriately, setting the tools to pierce-only or cut-only as
required.
FEED RATE CONTROL
Movement
All movement between lasering will be done at the feed rate
specified by the machine system data.
The FEED command values in ORDER mode can be used to override
this. They work on a percentage basis.
Eg FEED 100 is equivalent to the value specified in the machine
system data.
Cutting
The laser feed rate can not be altered directly by the post
processor. The L2530 maintains technology tables of cutting
conditions which specify feed rates. By switching laser tool in
the drawing the cutting condition is changed. The L2530
controller will then set the feed rate to the feed rate for the
cutting condition.
Acceleration
The acceleration to the required feed rates is a parameter of
the laser technology table (max 2m/s/s).
CORNER COOLING
On corners containing acute angles it may be desirable to add a few
seconds delay to avoid localised overheating. This blockmaker supports
the TC_WAIT command, which can be output automatically for linear and
arcuate slots which subtend an angle less than a user definable maximum
angle. This angle and the length of the delay are set via the
blockmaker questions.
CUTTING LARGE SHEETS IN HALF
A special facility exists for cutting sheets in half. To do this,
create a profile that has the following rules.
* Add a lead-in that starts off the sheet (see 1 below), and
ends on the sheet (see 2 below).
* Add a lead-out that starts on the sheet (see 3 below), and
ends off the sheet (see 4 below).
_____________________________________________________
/

|
|
|
|
|
|
1 | 2
3 | 4
!-|-+-------------------------------------------------+-|-!
|\
\
/|
| \
\
/ |
| Lead In
Main Profile
Lead Out |
|
|
|
|
\_____________________________________________________/
When this whole profile is cut. The head moves to the end of the lead
in (2) and measures the sheet thickness. Then it moves to the start of
the lead in (1) and turns on the laser using fixed height control.
After cutting the lead in (2) Height control is turned on, if required.
At the end of the main cut (3) the height control is turned off again
before the lead out is cut.
WARNING when cutting from off the sheet :
* This effect is not limited to cutting the sheet in half. The
same process will happen with any profile that starts off the
sheet and ends on the sheet.
* If the end of the lead in is over a hole, cut profile, etc.,
then measuring the sheet thickness at this point is impossible
and the whole profile will be cut with the original cutting
condition.
SPRINTLAS MODE
When the laser is activated in Sprintlas mode (i.e. using methods 9,
10, 11 & 12) it is possible to reduce the laser power to 1% instead of
switching it off when moving from one profile to the next:
TC_LASER_OFF(1)
TC_LASER_OFF(2)
TC_LASER_OFF(3)
TC_LASER_OFF(4)

Laser
Laser
Laser
Laser

OFF, Z axis to positioning height

OFF, Z axis to home height
at 1% power, Z axis at positioning height
at 1% power, Z axis at cutting height with
height regulation ON

Thus, when combined with performing moves with the head down (with
height sensing), considerable time savings can be achieved.
Sprintlas mode is best used in conjunction with hazard avoidance
(refer to:'USING HAZARD AVOIDANCE WITH SPRINTLAS MODE') to reduce the
risk of damaging the laser head on tipped part or allowing it to go
down a hole. Otherwise it is advised to set:
User System Data: "Max move with plasma down"
to a low value so that the head is raised for all but the shortest
moves.
The head will be raised to the positioning height if a move exceeds
this value or if a STOP or PICK command is encountered.
The following table summarises the behaviour of this post processor,
i.e. the LASER_OFF code and whether the head is kept down, when hazard

avoidance is switched OFF:

DESCRIPTION

SPRINTLAS

NON-SPRINTLAS

Order mode MOVE

< Max dist
> Max dist

Yes (4)
No (3)

No (1)
No (1)

Move to a feature
< Max dist
> Max dist

Yes (4)
No (3)

No (1)
No (1)

USING HAZARD AVOIDANCE WITH SPRINTLAS MODE

For information on how to use hazard avoidance, please refer to the
Radpunch and Radprofile user manual.
This post processor understands that, when hazard avoidance can't find
a safe route to the next feature, it can take avoiding action by
lifting the profile head prior to it's next move. This will
avoid running into a form or falling down a hole because cutting head
height sensing is on.
When hazard avoidance
decides will take too
lift the head and 'go
following distance to

selects a route that this post processor

long to travel down, the post processor will
straight there'. The post processor uses the
determine if the route is too long:

User System Data: "Max move with plasma down"

If the total hazard avoidance distance is shorter, the head will remain
down, if it is farther away, the head will be raised.
The following table summarises the behaviour of this post processor
when hazard avoidance is switched ON (i.e. whether the head is kept
down and the LASER_OFF code used):
DESCRIPTION

SPRINTLAS
MODE

NON-SPRINTLAS
MODE

Order mode MOVE

< Max dist
> Max dist

Yes (4)
No (3)

No (1)
No (1)

Hazard avoidance move

< Max dist
> Max dist

Yes (4)
No (3)

No (1)
No (1)

Move to a feature
< Max dist
> Max dist

Yes (4)
No (3)

No (1)
No (1)

SUBROUTINES
User subroutines are supported by individual calls for each ocurrance.
The subroutine identity is made up of three parts. The first character
is an identifying "L" followed by two characters that represent the
unique subroutine number. The following six characters are taken from

the Job Name in Order Mode, telescoped to remove invalid characters.

For example, for
Job Name : Machine Frame Component 1234
Then the thirteenth subroutine identity would be :
L13Machin
COMPILER ERROR MESSAGES
"Trying to offset circular cut without prior linear lead-in". A G01
positioning move is needed to introduce the offset before cutting an
arc. Ensure a linear lead in.
"Incompatible laser methods for "Change on the way""
Only methods 5,6,11 & 12 allow "Change on the way"
"glb_mat_squery failure"
There has been a problem with the database - if escape was pressed to
exit this is ok otherwise contact the help desk.
"SHEET_LOAD table too large. Too many loads." - there has been a
problem with this table - contact the help desk.
"WARNING: Microweld conditions not met - reverting to microjoints.
See manual"
You have requested microwelding which contravenes the conditions microjoints will be implemented. Change the situation if microwelds
are necessary.
"ERROR: Zero pierce code entered for pre-piercing tool"
The pierce code for a pre-pierce tool needs to be non-zero. Check that
the cutting condition questions have been answered appropriately.
Any other error messages should be reported to the help desk.

SYSTEM DATA REQUIREMENTS

This post processor uses the following system data items :u24 Max machine feed rate
m87 Z height in rapid traverse
(not used if question asked - ie "ASK_HEIGHT" in m84)
cus_name from psys_conf
m1 x working range
m2 y working range
m65 sheet loader type
This should be set if the machine is equiped with a
Liftmaster.
Valid entries for this system data are :

1
2
3
4

=
=
=
=

L2530
L3030
L4030
L6030

Currently only the L3030 Liftmaster is supported.

m84 Software level
MULTI_TABLES
When compiling the program, we only ask for 'Laser
Technology Table' once however in some circumstances
you may wish to use a different table for each tool.
This can be enabled by using the 'MULTI_TABLES' option.
VERIFIER GRAPHICS
The verifier distinguishes a microweld from a normal pierce by
displaying a 'ships wheel' symbol.