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NCdrive Manual

NCdrive

Manual

NCdrive Manual
NCdrive Manual

Software Lizenzvertrag

Nachfolgend sind die Vertragsbestimmungen für die Benutzung von MegaTECH/4CAM GmbH-Software durch Sie, den Endverbraucher (im Folgenden auch: "Lizenznehmer"), aufgeführt. Durch Installieren der Software erklären Sie sich mit diesen Vertragsbedingungen einverstanden.

VERTRAGSBEDINGUNGEN

1. Gegenstand des Vertrages

Gegenstand des Vertrages ist das auf dem Datenträger oder aus dem Internet erhaltene Computerprogramm, die Programmbeschreibung und Bedienungsanleitung, sowie sonstiges zugehöriges Material. Sie werden im Folgenden auch als "Software" bezeichnet. MegaTECH/4CAM GmbH macht darauf aufmerksam, dass es nach dem Stand der Technik nicht möglich ist, Computersoftware so zu erstellen, dass sie in allen Anwendungen und Kombinationen fehlerfrei arbeitet. Gegenstand des Vertrages ist daher nur eine Software, die im Sinne der Programmbeschreibung und der Bedienungsanleitung grundsätzlich brauchbar ist.

2. Umfang der Benutzung

MegaTECH/4CAM GmbH gewährt Ihnen für die Dauer dieses Vertrages das einfache nichtausschließliche und persönliche Recht (im Folgenden auch als "Lizenz" bezeichnet), die beiliegende Kopie der MegaTECH/4CAM GmbH-Software auf einem einzelnen Computer (d. h. mit einer einzigen Zentraleinheit (CPU), und nur an einem Ort zu benutzen. Ist dieser einzelne Computer ein Mehrbenutzersystem, so gilt dieses Benutzungsrecht für alle Benutzer dieses einen Systems. Als Lizenznehmer dürfen Sie Software in körperlicher Form (d. h. auf einem Datenträger abgespeichert) von einem Computer auf einen anderen Computer übertragen, vorausgesetzt, dass sie zu irgendeinem Zeitpunkt auf immer nur einem einzelnen Computer genutzt wird. Eine weitergehende Nutzung ist nicht zulässig.

3. Besondere Beschränkungen

Die Software und das zugehörige Schriftmaterial sind urheberrechtlich geschützt. Soweit die Software nicht mit einem Kopierschutz versehen ist, ist Ihnen das Anfertigen einer einzigen Reservekopie nur zu Sicherungszwecken erlaubt.

Dem Lizenznehmer ist untersagt,

- ohne vorherige schriftliche Einwilligung von MegaTECH/4CAM GmbH die Software oder das zugehörige schriftliche Material an einen Dritten zu

übergeben oder einem Dritten sonst wie zugänglich zu machen.

- ohne vorherige schriftliche Einwilligung von MegaTECH/4CAM GmbH die Software abzuändern, zu übersetzen, zurückzuentwickeln, zu entkompilieren oder zu entassemblieren,

- von der Software abgeleitete Werke zu erstellen oder das schriftliche Material zu vervielfältigen,

- es zu übersetzen oder abzuändern oder vom schriftlichen Material abgeleitete Werke zu erstellen,

- die Software zu verschenken, vermieten oder zu verleihen.

4. Inhaberschaft an Rechten

Sie erhalten mit dem Erwerb des Produktes nur Eigentum an dem körperlichen Datenträger, auf dem die Software aufgezeichnet ist. Ein Erwerb von Rechten an der Software selbst ist damit nicht verbunden. MegaTECH/4CAM GmbH behält sich insbesondere alle Veröffentlichungs-, Vervielfältigungs-, Bearbeitungs- und Verwertungsrechte an der Software vor.

5. Dauer des Vertrages

Der Vertrag läuft auf unbestimmte Zeit. Das Recht des Lizenznehmers zur Benutzung der Software erlischt automatisch ohne Kündigung, wenn er eine Bedingung dieses Vertrages verletzt. Bei Beendigung des Nutzungsrechtes ist er verpflichtet, die Originaldiskette wie alle Kopien der Software einschl. etwaiger abgeänderter Exemplare, sowie das schriftliche Material zu vernichten.

6. Haftung und Gewährleistung

Das Produkt ist erprobt und auf seine Funktionstüchtigkeit bei sachgemäßer Anwendung unter Verwendung der Handbücher/Onlinehilfe überprüft. Für die jeweilige Verwendungsmöglichkeit des Lizenznehmers wird keine Garantie übernommen. Aufgetretene Mängel sind dem Vertragshändler unverzüglich, spätestens innerhalb von 8 Werktagen seit Lieferung bei offenen Mängeln, seit Entdeckung bei verdeckten Mängeln durch für den Vertragshändler kostenfreie Rücksendung des Produktes anzuzeigen. Die Gewährleistung erfolgt durch Nachbesserung bzw. Ersatzlieferung. Ein Anspruch auf Wandlung oder Minderung besteht nur bei Fehlschlagen der Nachbesserung bzw. Ersatzlieferung und unter der Voraussetzung, dass dem Vertragshändler erfolglos eine Nachfrist von mindestens 14 Tagen gesetzt worden ist. Weitergehende Gewährleistungs-, oder Ersatzansprüche, insbesondere Schadensersatzansprüche wegen positiver Vertragsverletzung, entgangenem Gewinn, Betriebsunterbrechung, Verlust von Informationen usw. sind ausgeschlossen, es sei denn, dem Vertragshändler wird vorsätzliches oder grob fahrlässiges Handeln nachgewiesen. Eine Haftung für mittelbare Schäden ist in jedem Fall ausgeschlossen. Sämtliche Gewährleistungsansprüche erlöschen in jedem Fall 24 Monate, gewerbliche Endabnehmer 12 Monate, nach Lieferung.

7. Sonstiges

Es gilt das Recht der Bundesrepublik Deutschland. Sämtliche Rechte und Pflichten aus diesem Vertrag sind ohne Zustimmung des Vertragspartners weder übertragbar noch abtretbar, sofern sich aus diesem Vertrag nichts anderes ergibt. Sämtliche Vereinbarungen auch Änderungen oder Ergänzungen dieses Vertrages, bedürfen zu ihrer Wirksamkeit der Schriftform. Sollten einzelne Bestimmungen dieses Vertrages unwirksam sein, berührt das die Wirksamkeit der übrigen Bestimmungen nicht. Unwirksame Bestimmungen sind durch Regelungen zu ersetzen, deren wirtschaftlicher Erfolg dem der unwirksamen soweit wie möglich entspricht.

4CAM GmbH

Hauptstr. 18

86756 Reimlingen

info@4cam.de

www.4cam.de

Tel: 09081-805067-0

Fax: 09081-805067-67

August 2007

© 2007 4CAM GmbH

NCdrive

3

Directory

I Softwareinstallation

9

II

Before the Implementing

13

1 Equipment

protection

13

2 Safety

instructions

and industrial safety

13

3 and

Maintenance

care

13

4 Guarantee

13

5 Security

advise

14

6 Field

of

application

14

7 Technical

data

14

8 System

prerequisites

15

III Implementing

19

1 Connect

NCdrive

with the PC

19

2 Connect

NCdrive

with the machine

20

Connector

pin

assignment NCdrive V1.1

22

Connector

pin

assignment NCdrive V1.2

23

State-LED`s

24

Mounting

guidelines

NCdrive for Isel C142

24

Tips

for

users of Optimum amplifiers

25

Tips

for

users of HSE Amplifiers

26

Tips

for

users of SMC Amplifiers

26

Firmware-Update

 

27

IV Program interface in details

31

1 AUTO

MODE

31

2 MANUAL

HANDLING

33

3 Coordinate

display

33

4 Control

panel

34

Keys

to

move the axis

 

34

Reference

trip

36

Stop

Movement

 

37

Zero-points

37

Functions

tool

and work piece changing

38

Switch

an

control of machines functions

38

Special

functions

in the automatic mode

39

Functions

for

the control the program execution

39

5 Register

and

Status

40

6 Functions

for

positioning

40

7 The

hand

cycles

41

Technology

area

- Description of the Input fields

42

Geometry

area

- description of the different forms

43

Example

basic

type circle

44

Example

basic

type double circle

46

Example

basic

type threefold circle

47

Example

basic

type rectangle

48

4

NCdrive

 
 

Example

basic

type angle

49

Example

basic

type trapezium

50

 

Geometry

pattern

51

V

NCdrive Settings

55

1

Interfaces

 

55

2

M-functions

1

59

3

M-functions

2

60

4

Tool

changer

 

62

5

NC

programm

63

6

Axis

1-3

 

64

7

Axis

4

70

8

Hotkey

configuration

 

71

VI

Error Messages

75

VII

NCdrive diagnosis

79

VIII

Frimware Update

83

IX

Basics of the NC-programming

89

1

Coordinates

 

89

2

Arrangement

of

the axis

89

3

Programming

of

NCdrive

90

4

Construction

of

a NC-Program

90

5

Plane

Selection

 

94

X

Command reference for NCdrive, like DIN 66025

99

1

Motions

 

99

 

G00

- Fast movement

 

99

G01

- Straight with feed

100

G02

- Circular arc/helix clockwise

101

G03

- Circular arc/Against clockwise

102

2

Options

103

 

G04-

Holding

Time

 

103

G05

-

Exact stop

103

G25/26

-

Loop

103

G40/41/42

-

Tool radius correction

104

G53-G60

Zero

points

105

3

Coordinates

 

105

 

G70

- dimensions in Inch

 

105

G71

- dimensions in Millimeter

105

G74

- referece position in X/Y

105

G75

- reference position in Z

106

G90

- absolute coordinates

106

G91

- inkremental coordinates

106

G92

- setting actual coordinates

106

G98

- Tool lengths correction

106

G99

- Delete tool correction

106

4

Feed

Speed

 

107

NCdrive

5

G94

- Speed settingsin mm/min

107

G95

- Speed settings in mm/rev

107

5 Drilling

cycle

and milling machine cycle

108

G84

- Drilling / Deep drilling

108

G85

- Drilling a hole circle

109

G86

- Rectangle pocket

110

G87

- Circle pocket

111

G88

- Slot

112

G89

- Planar surface

113

6 Machines

functions

114

M00

- Absolute stop

114

M01

- Alternative stop

114

M02

- Stop and program end

114

M30

- Stop, program end and backtracking

114

M03

- Spindle in clockwise

114

M04

- Spindle counter clockwise

114

M05

- Spindle off

114

M06

- Tool change

114

M07

- Coolant Nr. 2 on

115

M08

- Coolant Nr. 1 on

115

M09

- Coolant off

115

M10

- Clamp tool

115

M11

- Solve tool

115

M12

- Measure tool length

115

M48

- Override effectiv

115

M49

- Override ineffective

115

M60

- Workpiece change

115

In-/output,

special

machines functions

115

7 Special

signs

118

%

program

beginning

118

/ -

selectively

sentence suppression

118

;-

main

clause

118

*

-

Comment line

118

()

Comments

118

8

Tool

definition

and raw part definition

119

TOOL

119

PART

119

9 Execution

sequence

XI NCdrive connection plan (externally)

120

123

1 Connection

of

the axes

123

2 the reference switches and the emergency stop

Connection

of

123

3 Connections

of

the outputs 1 and 2

124

of

4 the outputs 3 to 6

Connection

124

5 Connection

of

the inputs 1 to 8

124

of

6 the analog-output

Connection

124

XII EG-Konformitätserklärung

129

Index

131

Chapter I

Chapter I Softwareinstallation

Softwareinstallation

Chapter I Softwareinstallation

Softwareinstallation

9

Softwareinstallation 9

1

Softwareinstallation

The NCdrive-Software is offered in two different specifications. So there are differences in the installation:

1. MegaNC and NCdrive as a bundle

No installation is necessary. The NCdrive-software is a component of MegaNC.

2. NCdrive without MegaNC

Here you get the software on a CD or by download. It will be installed by a setup-routine. While running the

setup you'll have to decide where to install the software. A new icon will appear on the desktop and a menu-entry is created.

Please note that the software on the PC and the firmware of the controller must have the same version to work correctly. Therefore we would advise you to a firmware update of the NCdrive-controller. For this you find help in the chapter "firmwareupdate".

Chapter II

Chapter II Before the Implementing

Before the Implementing

Chapter II Before the Implementing

Before the Implementing

13

Before the Implementing 13

2 Before the Implementing

Incorrect handling may cause damages! Follow therefore always the following hints.

2.1 Equipment protection

The voltage used in your electricity network must be the same like the statements on the controller. Hardware marked with 230 V can also run with 220 V. Protect the hardware against humidity. Avoid direct solar irradiation. Inflated temperatures damages the electronic control unit. Touch the workpiece only with running milling machine. In danger press the EMERGENCY-STOP-button at the machine or PAUSE-key on the keyboard of the pc.

2.2 Safety instructions and industrial safety

Before every use please control connectors and cables, in case of a damage let it repair by an expert. Control the correct connection of the EMERGENCY-STOP-switch at your machine. Insert the connector only during switched off machine. Clamp the work piece hardly enough. While positioning with fast movement with clamped tool please keep in mind not to crash with the milling table, clamp devices or work piece. Before starting to work look that there are no tools left in the workspace. Remove the cover of the milling spindle only for cleaning.

2.3 Maintenance and care

The device can be cleaned with a damp cleaning cloth. Take care that no strange objects (for example: Metal swarf, dust) get into the device or into the plug connector.

2.4 Guarantee

Damaged deliveries get replaced if you assert your guarantee claims in the time of 10 days. For the NCdrive, the guarantee time period amounts 24 months from the day of delivery (certificate by bill). Should during the guarantee time product lacks appear, which are based on material mistake, we will remove this after our choice through repairing or exchange. Appropriate application and use is a precondition for warranty. A liability for damages, especially through misemployment, overcharge outside of the technical specifications, variation and modification, caused of faulty or diverted applications as soon as for consequentional damages which did not accrue at the NC-drive itself, is barred. A liability after the product liability act as well as unauthorised action remains untouched.

Complaints can only be accepted if you send the device unopened to your dealer or directly to the manufacturer.

14

NCdrive

2.5 Security advise

Even though milling the work piece with the simulation program was successful, there is no absolute guarantee that there is no problem (crash) while milling and drilling with the NCdrive.

problem (crash) while milling and drilling with the NCdrive. For that there are following reasons: For

For that there are following reasons:

For the simulation, the software gets information about the the specification and the dimensions of the work piece, about the tools used and the location of the clamping tools. It's your responsibility to make sure that these data are the same on the real machine. An examination by a program is not possible. Mind that the values registered in the NC-program and NCdrive for the tool, the clamping, the work piece and the point of origin will correspond in reality. Using on your machine e.g. a tool with different dimensions, damage may occur, although simulation was correct. To avoid damages it's advisable - also when simulation is correct - to make a dry run first. You can do this by starting the milling process without a work piece or without turning the tool. Mind that the clamping tension of the work piece remains also during the milling.

2.6 Field of application

The NCdrive-controller and its software is a PC based CNC controller for stepping motors by an output of pulse and direction signals for up to 4 axes with unlimited look ahead. For special amplifier cards (e. g. SMC 800/1500) there is a special firmware.

For this reason we can use modern operating systems and PCs without with the restrictions of the real time capacity of windows.

The modular construction of the NCdrive-software allows to use different ways for the operation of the available machine. The band width passes of an extensive hand operation with integrated preparation macro and DIN-program-import and -interpretation to the complete 2D/3D-CAD/CAM suite. Through the extensive settings features, you can adapt the software to almost all 3- or 4-axes-machines. Moreover an integrated software-SPS (storage programmable control) permits also to manage movements, input- and output-signals e. g. a tool changer.

The modern architecture of the software and the controller is supported by the use of windows 2000/XP.

2.7 Technical data

Max. number of axes: 4 (simultaneous interpolating) Max. stepping frequency: 31,250 Hz Outputs for stepping motors: 4 x pulse /direction, boost, current reduction (TTL), also for SMC 1500 available additional outputs: 4 x Reed-Relay additional inputs: 8 x Optokoppler (5 V AC/DC, bidirectional) PC-Interface: RS-232, 38.400 Baud (USB by adapter)

Power supply 6 – 12 VDC (over connector network component, min. 250 mA)

Available software-interfaces Program according to DIN 66025, MegaNC

Before the Implementing

15

Before the Implementing 15

2.8 System prerequisites

Intel or AMD-CPU from ca. 800MHz Windows 2000/XP serial interface at the PC (RS232) or USB-Adapter (optional)

Chapter III

Chapter III Implementing

Implementing

Chapter III Implementing

Implementing

19

Implementing 19

3

Implementing

Before the initial electric operation of NCdrive, you should guarantee, that the standard pin assignments correspond with the ones of your machine. Otherwise damages of the machine or unexpected movements of the milling machine may occur. Therefore special precautions are to be taken with first start-up:

27
27

Selection of the appropriate firmware, see also "firmware update" Inspect the pin-assignment of the 25-pol.-plug connector to machine Disconnect the head drive and further aggregates that represent a security risk Follow the safety instructions in chapter "Before implementing"

13

3.1 Connect NCdrive with the PC

Connect NCdrive to the pc by the included connection cable (9 pol. D-Sub). Notebooks often need an USB-to-serial connector, because often there are no more serial interfaces available. After connecting NCdrive with the PC and the power supply, you can start the software. By default the COM1-Interface is pre-selected in the configuration. Using another COM-port the following error message may appear:

another COM-port the following error message may appear: You can confirm to this message by pressing

You can confirm to this message by pressing the OK-button and entering the basic configurations with CONTROL-SETTINGS you can select the corresponding COM-interface. OK saves the changes and closes the menu.

COM-interface. OK saves the changes and closes the menu. The default value is COM1, in exceptional

The default value is COM1, in exceptional cases, for example using an USB-serial-adapter it also may be COM5. All available interfaces are indicated in the list.

20

NCdrive

3.2 Connect NCdrive with the machine

Connect the 25 pol. interface with the machine. It is obligatory that the pin-assignment of your machine agrees with that of NCdrive. For some machine manufacturers we have adapters as an accessory. In the appendix you find the pin allocations to configure your own cable. Test the emergency stop at the connected machine. The controller can evaluate the status of the machine using the data lines 10-15 and reacts correspondingly.

using the data lines 10-15 and reacts correspondingly. Interrupt the power supply to the milling spindlet

Interrupt the power supply to the milling spindlet to prevent a starting of the tool. Start NCdrive-Software. Connection to the controller should be built up automatically the and green light should flash at the same time. If this should not be the case, then you find information to the error tracing in the appendix. Test with the diagnosis-tool of NCdrive the configuration of the inputs and outputs and save the settings into the configuration. Special attention should be dedicated to the reference switches to guarantee a first save working with the machine

switches to guarantee a first save working with the machine Pressing the limit switches the check

Pressing the limit switches the check marks should appear for the corresponding axis. In case of marked boxes without contact to the switches the inputs have to be inverted (see above). The output check boxes also can be pressed manually to test the function of spindle or coolant control. Define what kind of machine type you use. NCdrive supports milling machines and lathes. Regarding to the very different way to work you have to choose the machine typ in control -> settings -> NC program.

Implementing

21

Implementing 21
Implementing 21 Now the values for each axes have to be undertaken.The setup of the single

Now the values for each axes have to be undertaken.The setup of the single axes is very extensive and

freely adjustable, because we can realize with our controller the cooperation with a lot of machines of various manufacturers and also machines types. Hereby some technical knowledge and some data of the machine to be configured is necessary. If you should not be entirely certain, you find frequently the necessary statements in the technical documentation of your machine or by inquiries at your dealer. Inaccurate data can lead to damaging the machine components or dimensional deviations! Therefore these settings are to be undertaken only with the necessary background knowledge. You find more about this

under "Axes-Setup

64

".

First the section and the steps/section must be registered. The section corresponds normally with the spindle thread. For rotation axis, it would be 360 (° instead of mm).

In a stepping motor with a solution of 200 steps, there are the following possibilites for steps/section:

Fullstep: 200

Halfstep: 400

Quarterstep: 800

Eighthstep: 1600

The software-limit switches for the first tests of positioning should be for example -500 and +500. With this the range of the axes is limited.

-500 and +500. With this the range of the axes is limited. In order to go

In order to go back to hand control leave the dialogue and connect NCdrive again with the machine. You get this by: CONTROL – CONNECTING or by the Hotkey ¦v. With the hand control, the axes are driven now one after another. Use the arrow buttons in the menue or on your keyboard (in combinaton with the Shift-key). If necessary change the direction in the axes configuration. Should one of the axes run into the false direction, you can change its direction under CONTROL - SETTINGS-1.-4. AXIS with the checkbox "direction inverted". First perform referencing. Find out the maximum range for the axes

22

NCdrive

3.2.1 Connector pin assignment NCdrive V1.1

22 NCdrive 3.2.1 Connector pin assignment NCdrive V1.1 Connector pin assignment of the NCdrive-Controllers V1.1

Connector pin assignment of the NCdrive-Controllers V1.1 (black rubber seal):

Firmware:

NCdrive.bin

NCdriveHSE.bin NCdriveOptimum.bin

NCdriveSMC.bin

25-pol. D-Sub:

1

Main spindle

Direction X/Y/Z

Strobe

2

Direction X

3

Cycle X

Cycle A

I11

4

Direction Y

Output 1

PH1

5

Cycle Y

Output 2

I20

6

Direction Z

I21

7

Cycle Z

PH2

8

Direction 4. Axis

Sel 0

9

Cycle 4. Axis

Sel 1

10

emergency stop

Reference switch X

11

Reference switch Z

emergency stop

Home

12

Reference switch Y

Reference switch Y

13

Reference switch X

Reference switch Z

14

Coolant

Cycle X

15

Reference switch 4. Axis

Reference switch 4. Axis

16

Boost

Cycle Y

17

Current reduction

Cycle Z

18-25 GND

15-pol. D-Sub

1

Output 3 (Relais)

2

Output 4 (Relais)

3

Output 5 (Relais)

4

Output 6 (Relais)

5

Base Relais 3-6

6

Input 1

7

Input 2

8

Input 3

9

Input 4

10

Input 5

11

Input 6

12

Input 7

13

Input 8

14

Base Inputs 1-5

15

Analog output 0-5 V

Implementing

23

Implementing 23

3.2.2 Connector pin assignment NCdrive V1.2

23 3.2.2 Connector pin assignment NCdrive V1.2 Connector pin assignment of the NCdrive-Controllers V1.2

Connector pin assignment of the NCdrive-Controllers V1.2 (green rubber seal):

Firmware:

NCdrive.bin

NCdriveHSE.bin NCdriveOptimum.bin

NCdriveSMC.bin

25-pol. D-Sub:

1

Main spindle

Direction X/Y/Z

Strobe

2

Direction X

3

Cycle X

Cycle A

I11

4

Direction Y

Output 1

PH1

5

Cycle Y

Output 2

I20

6

Direction Z

I21

7

Cycle Z

PH2

8

Direction 4. Axis

Sel 0

9

Cycle 4. Axis

Sel 1

10

emergency stop

Reference switch X

11

Reference switch Z

emergency stop

Home

12

Reference switch Y

Reference switch Y

13

Reference switch X

Reference switch Z

14

Coolant

Cycle X

15

Reference switch 4. Axis

Reference switch 4. Axis

16

Boost

Cycle Y

17

Current reduction

Cycle Z

18

Analog output 0-5 V

Analog output 0-5 V

Analog output 0-5 V

19-25 GND

 

15-pol. D-Sub

1

Output 3 (Relais)

2

Output 4 (Relais)

3

Output 5 (Relais)

4

Output 6 (Relais)

5

Base Relais 3-6

6

Input 1

7

Input 2

8

Input 3

9

Input 4

10

Input 5

11

Input 6

12

Input 7

13

Input 8

14

Base Inputs 1-5

15

+ 5V

24

NCdrive

3.2.3 State-LED`s green: signalyzes readiness and flares while getting data, shines from the first connection between PC and NCdrive yellow: Blinks while the movement of the axes red: Shines with emergency stop together with the green led. In case of transmission error to the controller, only the red LED shines

3.2.4 Mounting guidelines NCdrive for Isel C142

new version C142 (emergency stop on the right side):

disconnect interfaces cables to the PC and dismount interface group UI4.C also dismount next front panel on the left side (blind one) mount NCdrive-controller in place of the removed interface card on both free connector strips, so that that 10-pole plug connector of NCdrive is on the upper side. attach plug connector of the ribbon cable at the NCdrive-front panel to the 10-pole connector, so that the marked side of the cable is to the right. screw NCdrive front panel to the case mount again the blind panel connect NCdrive-Interface cable with the PC Install and configure NCdrive-software

old version C142 (emergency stop on the left side):

disconnect interfaces cables to the PC and dismount interface group UI4.C remove all three power amplifier plug the rear jumper on the power amplifier (next to the fuse) to the upper position (marked with "H") and be sure that the front jumper is in the lower position. dismount the backside front panel behind the power amplifiers guarantee that the three with "V/H" ("full step/half step") marked jumpers on the bus board (accessible now by the back side) are in the position "H" (use a new jumper, if necessary) mount again the front panel of the backside mount NCdrive-controller in place of the removed interface card on both free connector strips, so that that 10-pole plug connector of NCdrive is on the upper side. attach plug connector of the ribbon cable at the NCdrive-front panel to the 10-pole connector, so that the marked side of the cable is to the right screw NCdrive front panel to the case mount all three power amplifiers again. Connect NCdrive-Interface cable with the PC Install and configure NCdrive-software

References to the software configuration The configuration of the pin assignment of the interface cable ("Input for switches" and "Output for controls" in the menu Control - Settings) is out of function because it is not necessary for the Isel-variant of the NCdrive-controller. The Emergency Stop pin is not used; instead of this the Emergency Stop of the C142-Steuerung interrupts the power supply to the NCdrive-controller. The analog output is not used the ouptputs 1 to 6 and the inputs 1 to 8 correspond exactly to the ones of the interface groups replaced by NCdrive an available, electromagnetic brake of the Z-axis must not be configured and is automatically released while the NCdrive-controller is running under NCdrive-software

Special References If the C142-Controller is equipped with a plug connector on the back for RS-232-wire to the PC (special equipment or reconstruction) it can be used furtheron, (do not use the10-pole plug connector of the NCdrive-controller, further mount a blind panel at the place of the NCdrive-front panel and use the original ribbon cable instead of the one of NCdrive.) After the reconstruction with NCdrive the 0-point may have changed because of differences in the reference switch query. In this case values for correction can be set in the NCdrive configuration with Control -> Settings - Axis 1-4 -> Reference offset.

Implementing

25

Implementing 25

3.2.5 Tips for users of Optimum amplifiers Following types of amplifiers are supported directly by the firmware

CNC Controller III und VI, Version 1

You can recognize the controller box by the marking on the front panel

the controller box by the marking on the front panel For this series use the firmware

For this series use the firmware "NCdriveOptimum.bin".

CNC Controller III und VI, Version 2 You can recognize the controller box by the marking (V2) on the front panel.

the controller box by the marking (V2) on the front panel. For this series use the

For this series use the firmware "NCdrive.bin".

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NCdrive

3.2.6 Tips for users of HSE Amplifiers Following types are supported directly with the corresponding firmware:

STEP4020, STEP5040, STEP8060 in connection with the firmware NCdriveHSE.bin microSTEP400 in connection with the firmware file NCdriveMicroSTEP.bin

Depending on the selected firmware the pin assignment adapts to the HSE standards.

3.2.7 Tips for users of SMC Amplifiers Following types are supported directly with the corresponding firmware:

SMC800 and SMC1500 in connection with the firmware NCdriveSMC.bin SMC1500 (with SMC1500Z), SMC1500S and SMC3000 in connection with the firmware NCdrive.bin The models SMC3000i and ISMIF are not supported.

Depending on the selected firmware the pin assignment adapts to the SMC standards

Implementing

27

Implementing 27

3.2.8

Firmware-Update There are two advantages having the possibility to update the firmware of NCdrive:

1. also future software-solutions can be integrated easily into the functional range ov NCdrive

2. NCdrive is suited nearly universal for different controllers

Procedure for the firmware update

In the installation folder of NCdrive, you find in the subdirectory /firmware the program `NCdriveUpdate.exe'

subdirectory /firmware the program `NCdriveUpdate.exe' Select the favorured *.bin-file in the path. /firmware Using

Select the favorured *.bin-file in the path. /firmware

Select the favorured *.bin-file in the path. /firmware Using a PCNC-compatible controller, select ncdrive.bin,

Using a PCNC-compatible controller, select ncdrive.bin, otherwise corresponding firmware version.

Select the correct COM-Port in the dropdown filed Interface.

Be sure that NCdrive is in starting mode, because otherwise the new firmware cannot be sent to the controller. You get this by disconnecting the power plug and making NCdrive currentless for a moment. Then connect the box again to the power supply.

With 'Execute' you start the transmission of the firmware to NCdrive. The correct transmission is confirmed:

you start the transmission of the firmware to NCdrive. The correct transmission is confirmed: © 2007

Chapter IV

Chapter IV Program interface in details
Chapter IV Program interface in details

Program interface in details

Program interface in details

31

Program interface in details 31

4 Program interface in details

To switch over to the different operating modes and program part following functions are used:

AUTO MODE With this you can get all functions, that are necessary to execute an existing program.modes and program part following functions are used: MANUAL MODE In this area, extensive cycles are

MANUAL MODE In this area, extensive cycles are available you for the milling of simple geometries. The work piece is processed with the help of predefined cycles.that are necessary to execute an existing program. EMERGENCY-STOP-SWITCH In combination with NCpowerdrive, you

EMERGENCY-STOP-SWITCH In combination with NCpowerdrive, you can reset the emergency stop status. Herewith the amplifier is re-activated.work piece is processed with the help of predefined cycles. PROGRAM CHANGING With this button, you

PROGRAM CHANGING With this button, you can change the existing program. Herewith the Windows editor is opened by default.stop status. Herewith the amplifier is re-activated. NClyzer With the NClyzer, you can simulate the processing

NClyzer With the NClyzer, you can simulate the processing of the G-Code program with the used tools and the defined work piece.program. Herewith the Windows editor is opened by default. 4.1 AUTO MODE This is the standard

4.1 AUTO MODE

This is the standard surface that is active with the program start. NCdrive is in automatic mode, whereby all possibilities for setup and adjusting are available. According to type of the machine, a corresponding surface is represented.

Milling:

are available. According to type of the machine, a corresponding surface is represented. Milling: © 2007

32

NCdrive

Lathe:

32 NCdrive Lathe: If there is no definition for the tool changer, clamping and length control

If there is no definition for the tool changer, clamping and length control in the M-command configuration, the icons for these functions are not shown in the menu.

In this mode you can load a G-code program or it will be procured by MegaNC. Herewith the active zero-point and the tool selection is to be noted.

Program interface in details

33

Program interface in details 33

4.2 MANUAL HANDLING

In the manual handling, you have the possibility to work with simple hand cycles instead of the NC-program.

to work with simple hand cycles instead of the NC-program. 4.3 Coordinate display The display indicates

4.3 Coordinate display

The display indicates the current position of the tool in real time. According to the configuration, the three linear axes and the 4th axis are available. The coordinate values can change according to the selected reference position (G53-G58).

are available. The coordinate values can change according to the selected reference position (G53-G58). © 2007

34

NCdrive

4.4 Control panel

These buttons are active after a successful connection to the controller. (Hotkey Alt-v)

a successful connection to the controller. (Hotkey Alt-v) According to configuration of the M-commands, the buttons

According to configuration of the M-commands, the buttons for tool and work piece change, length measurement and operation of the collet are visibly or invisible.

In the emergency stop condition, all buttons for moving the axes are inactive.

condition, all buttons for moving the axes are inactive. 4.4.1 Keys to move the axis With

4.4.1 Keys to move the axis With the arrow buttons X, Y and Z the machine is controlled in hand mode in the three-dimensional working room. Each dimension is designated with a so-called axis character. The arrows on the keys indicate the direction, in which the tool is moved on the axis. Because the tool can be moved on each axis in two directions, there are two control keys for each axis.

in two directions, there are two control keys for each axis. The buttons for that 4.

The buttons for that 4. axis are only indicated if this was configured in the Setup and an axis character was selected.

Program interface in details

35

Program interface in details 35

Among the keys, there are two buttons with special functions:

Set zero-point Sets the zero-point at the current position for G54-58the keys, there are two buttons with special functions: Radius correction on/out Here the radius of

Radius correction on/out Here the radius of the tool is considered when „scratching“ the work pieceSets the zero-point at the current position for G54-58 With the following modes for movements, the

With the following modes for movements, the axis can be driven:

Continuously: Axis proceeds with the speed „hand 1“ or with „hand 2“ in actuated § -key as long as the button or the Hotkey is pressed. §-key as long as the button or the Hotkey is pressed.

Positioning coarsely: The actuated axix proceeds in 1 or 10 mm steps (STRG-key)§ -key as long as the button or the Hotkey is pressed. Positioning medium: The actuated

Positioning medium: The actuated axis proceeds in O.1 or 1 mm steps (STRG-key)The actuated axix proceeds in 1 or 10 mm steps (STRG-key) Positioning finely: The actuated axis

Positioning finely: The actuated axis proceeds in 0.01 or 0.1 mm steps (STRG-key)The actuated axis proceeds in O.1 or 1 mm steps (STRG-key) In connection with the buttons

In connection with the buttons for the movement modes, the axis can be driven:

Move tool on the X-axis to the left, X-the buttons for the movement modes, the axis can be driven: Move tool on the X-axis

Move tool on the X-axis to the right, X+axis can be driven: Move tool on the X-axis to the left, X- Move tool on

Move tool on the Y-axis back, Y-to the left, X- Move tool on the X-axis to the right, X+ Move tool on

Move tool on the Y-axis forward, Y+the X-axis to the right, X+ Move tool on the Y-axis back, Y- Move tool on

Move tool on the Z-axis after below, Z-on the Y-axis back, Y- Move tool on the Y-axis forward, Y+ Move tool on the

Move tool on the Z-axis towards the top, Z+Y-axis forward, Y+ Move tool on the Z-axis after below, Z- IMPORTANT: The direction of the

IMPORTANT: The direction of the axis defines the movement of the tool, not the one of the proceeded component!

36

NCdrive

Important Hotkey`s for he manual procedure of the axis:

The default configuration needs the simultaneous pressing of the direction key and ® the Shift-key for a movement of one of the axis. For safety reasons moving the machine is only possibly by pressing two keys. You can avoid this e. g. for rigging tasks by pressing the Scroll Lock key.

§ Increases the values tenfold for the positioning keys coarsely/medium/fine

¨ This key enables the procedure the axis in two hand mode with the cursor keys.

£

¥¢¤

³

´

²

Hotkey`s for the procedure of the axis

The keys for the procedure of the 4th axes are „Home“ and „End“.

4.4.2 Reference trip After the turning on of the machine the current position of the tool is not known. Therefore you have to run a reference trip to start the task on a definite position. Use convenient end switches for this or if this is not possible drive every axis by hand against an end block.

not possible drive every axis by hand against an end block. Start of referencing Machine WITH

Start of referencing

Machine WITH end switches:

It's important to use correct values in the axis setup and the inputs to get a reliable referencing. Herewith the axis run one after another against the end switches until a signal is sent to the controler. Then the registered values in the axis-setup will be set for the reference position to define the zero point für G53 (zero point of the machine).

define the zero point für G53 (zero point of the machine). Machine WITHOUT end switches: In

Machine WITHOUT end switches:

In order to get an exact position on a machine without end switches drive all axis by hand into a defined end position and press the key for the reference trip. Then the registered values in the axis-setup will be set for the reference position to define the zero point für G53 (zero point of the machine).

Program interface in details

37

Program interface in details 37

4.4.3 Stop Movement

Program interface in details 37 4.4.3 Stop Movement Do you want to stop all movements of

Do you want to stop all movements of the machine, press this button.

system wide HOTKEY: ¯

Please note however, that this is no emergency stop (power-off), because - depending on the integration in the complete system - we can not influence the security circuits, e. g. an externally connected spindle.

4.4.4 Zero-points

With these buttons the zero-points can be selected or stored.

these buttons the zero-points can be selected or stored. The storage of G53 is not changeable

The storage of G53 is not changeable and shows the machine coordinate.

With these options you can adjust for example different positions for milling and recall them.

IMPORTANT: In cooperation with MegaNC you must have in mind, that the transfer concerns the program file and the zero point G54. If you want to define your own zero point, do not use G54, because this one interacts with your drawing and will be redefined with every modification of the drawing.

Using a well-defined master drawing in MegaNC be sure to use G54 to work with the designated zero point.

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NCdrive

4.4.5 Functions tool and work piece changing With the NCdrive-Software you have the possibility to change tools manually or with an automatic tool changer. The automatic tool change however demands specific conditions in the mechanics and settings in the Setup as well as the tool changer configuration.

Collet / Clamping disassociate With this option a manual change possibility is available, too. E.

Collet / Clamping disassociate With this option a manual change possibility is available, too. E. g. for tools that are too large for the changer

Tool lengths measurement

Tool lengths measurement

A

device for length measurement must be available and configured

Tool change

Tool change

Work piece change The spindle goes to the registered work piece change position

Work piece change The spindle goes to the registered work piece change position

Depending on automation rate of a lathe, these functions can be used. The buttons become activated if the associated M-configurations are registered.

Work piece clamping

Work piece clamping

Tool measuring

Tool measuring

A

tool measuring device must be available and configured

Tool change

Tool change

Work piece change The tool goes to the registered work piece change position

Work piece change The tool goes to the registered work piece change position

4.4.6 Switch an control of machines functions

According to the equipment of the machine, the controller can turn on and turn off the spindle or can control

revolution also by the analog output. converter).

This functions however only with suitable hardware (relay, frequency

Main spindle on / out

(M3/M5)

Reduce feed / increase

Enables changing the feed rate while working in the area of 0-150%.

changing the feed rate while working in the area of 0-150%. Cooling on / out (

Cooling on / out

(M8/M9)

Reduce revolution / increase

Enables changing the revolution while working in the area of 0-150%.

Program interface in details

39

Program interface in details 39

4.4.7 Special functions in the automatic mode In the automatic mode different functions are available during the program execution.

Deactivated:: Do not interrupt program execution in sentences with M01 Activated: Interrupt Program execution in : Do not interrupt program execution in sentences with M01 Activated: Interrupt Program execution in sentences with M01

Selective Stop

NCdrive interrupts the program execution in sentences in which a M01 is programmed

(Sentence selectively is ignored ) Sentences marked in the programming with a "'/"-sign, can be skipped during program executionprogram execution in sentences in which a M01 is programmed Selective sentence suppression Leap to the

Selective sentence suppression

Leap to the program beginningduring program execution Selective sentence suppression After an interrupt, you can continue the program execution

After an interrupt, you can continue the program execution with this key.Selective sentence suppression Leap to the program beginning Continue program execution The tool however must be

Continue program execution

The tool however must be driven out of the material to avoid a collision.

4.4.8 Functions for the control the program execution

In the mode Program execution single sentence one sentence is executed after another. Continuing work is possible by Program execution single sentence one sentence is executed after another. Continuing work is possible by a click on the same or another button for program execution.

In the mode Program execution block only a complete string or loop is executed. Continuing work is possible Program execution block only a complete string or loop is executed. Continuing work is possible by a click on the same or another button for program execution.

In the mode Program execution continuous the program is executed continuously to the program-end or up to an Program execution continuous the program is executed continuously to the program-end or up to an interruption.

With the function Stop Program the running process (string, loop) is executed and then stopped. Stop Program the running process (string, loop) is executed and then stopped.

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NCdrive

4.5 Register and Status

Here you see the current condition of the single indices like way conditions G, machines functions M, feed F, revolutions S and tool number T.

functions M, feed F, revolutions S and tool number T. In the status window the current

In the status window the current values are indicated for the feed and revolutions with override. Moreover the diameter D and tool protruding L (length from collet to tip) and the place P in the tool changer for the current tool T.

4.6 Functions for positioning

In manual mode up to 4 positions can be stored and addressed later. In addition different possibilities to find specific positions are available, e. g.an edge or the center of 2 or 3 points.

are available, e. g.an edge or the center of 2 or 3 points. With the buttons

With the buttons on the left side The current X/Y-position is discarded and stored in the chart. With the right buttons you can move the tool to the stored position. Herewith also the Z-axis moves to the position, stored in the field 'Retreat height'.

Program interface in details

41

Program interface in details 41

4.7 The hand cycles

The hand cycle in manual mode enables you to use manifold geometries without input of DIN-code. Also the generation of a drawing is not necessary. The 'millman'-functions make this possible.

Basically the hand mode area is divided in 6 single areas:

Technology area

Input of all data necessary for milling

Geometry area

Choice of the geometry by mouse click

Input area for geometry data

Data, that define form and size of the geometry

Arrange a geometry pattern

Selection of a pattern by mouse clicks

Input Data for geometry pattern

Define the values for a pattern and fixing the reference point

Preview area

Show a preview for geometry and geometry patterns with indication of the reference point

and geometry patterns with indication of the reference point Technology area Geometry area Input area for

Technology area

Geometry area

Input area for Geometry data

Arrange a geometry pattern

Input Data for geometry pattern

Preview area

42

NCdrive

4.7.1 Technology area - Description of the Input fields

4.7.1 Technology area - Description of the Input fields Input of the tool diameter in mm
4.7.1 Technology area - Description of the Input fields Input of the tool diameter in mm
4.7.1 Technology area - Description of the Input fields Input of the tool diameter in mm
4.7.1 Technology area - Description of the Input fields Input of the tool diameter in mm
4.7.1 Technology area - Description of the Input fields Input of the tool diameter in mm
4.7.1 Technology area - Description of the Input fields Input of the tool diameter in mm
4.7.1 Technology area - Description of the Input fields Input of the tool diameter in mm

Input of the tool diameter in mm

Input of the safety distance for Z in mm

(Distance between current position of the tools to the work piece surface)

Input of the feed for the X- and Y-Axis in mm/min

Input of the feed for the Z-Axis in mm/min

Input of the milling depth in mm

Input of the cutter offset in the pockets processing in

mm

This input field ist only active, if the option pocket is

activated

Input of the steps in Z-direction in mm

In our example the complete depth is 5 mm. It is processed in 3 steps up to the depth Z. First 2 mm, then once again 2 mm and at the end 1mm. Therefore a total depth is reached of 5 mm

Program interface in details

43

Program interface in details 43
Program interface in details 43 Input of the allowance in mm The input field is only
Program interface in details 43 Input of the allowance in mm The input field is only

Input of the allowance in mm

The input field is only active, if the option field pocket is activated. Further if option contour in combination with inner or outer ist activated.

Select the technology: Contour or Pocket

Using the option Contour the additional options Center, inner or outer can be selected. In this case radius correction will be included. Using the option pocket, do not forget to chose a value for Step X/Y.

4.7.2 Geometry area - description of the different forms The geometry area allows you to select a pre-defined geometry. There are 6 different possibilities for the selection. Depending on selection different data fields are offered for an input. Varying the values, the appearance of the geometry will be adapted.

the values, the appearance of the geometry will be adapted. In the following specifications the generation

In the following specifications the generation of the basic forms is described. A specification of each variant inside the basic form would explode the scale of this handbook. Therefore only the most important variants are described. After selecting the basic geometry change simply the values in the input fields and look at the same time at the changes of the geometry in the preview-window.

A geometry only is indicated in the preview-window if all options are conclusive. An update of the preview takes place after leaving the field of the last option.

44

NCdrive

Example basic type circle

geometry area with Input area for geometry data

type circle geometry area with Input area for geometry data Circle with a outer diameter of

Circle with a outer diameter of 50 mm Cutter diameter 6 mm Option Contour Option interior

of 50 mm Cutter diameter 6 mm Option Contour Option interior Circle with a outer diameter

Circle with a outer diameter of 50 mm and an inner diameter of 30 mm Cutter diameter 6 mm Option Contour Option inner

of 30 mm Cutter diameter 6 mm Option Contour Option inner Circle with a outer diameter

Circle with a outer diameter of 50 mm Cutter diameter 6 mm Option Pocket Step XY 3 mm

of 50 mm Cutter diameter 6 mm Option Pocket Step XY 3 mm Segment of a

Segment of a circle with a outer diameter of 50 mm and a inner diameter of 25 mm, start angle 270 °, end angle 45°, corner radius 3 mm, cutter diameter 6 mm, option pocket Step XY 3 mm, allowance XY 1 mm

preview

45°, corner radius 3 mm, cutter diameter 6 mm, option pocket Step XY 3 mm, allowance
45°, corner radius 3 mm, cutter diameter 6 mm, option pocket Step XY 3 mm, allowance
45°, corner radius 3 mm, cutter diameter 6 mm, option pocket Step XY 3 mm, allowance
45°, corner radius 3 mm, cutter diameter 6 mm, option pocket Step XY 3 mm, allowance

Program interface in details

45

Program interface in details 45

46

NCdrive

Example basic type double circle

geometry area with input area for geometry data

circle geometry area with input area for geometry data radius left 10 mm – radius right

radius left 10 mm – radius right 10 mm distance 20 mm cutter diameter 6 mm option contour – option inner

20 mm cutter diameter 6 mm option contour – option inner radius left 10 mm –

radius left 10 mm – radius right 10 mm distance 30 mm – angel of rotation 45° cutter diameter 6 mm option pocket

angel of rotation 45° cutter diameter 6 mm option pocket radius left 20 mm – radius

radius left 20 mm – radius right 10 mm distance 30 mm – angel of rotation 0° cutter diameter 6 mm option pocket

preview

radius right 10 mm distance 30 mm – angel of rotation 0° cutter diameter 6 mm

Program interface in details

47

Program interface in details 47

Example basic type threefold circle

geometry area with input area for geometry data

circle geometry area with input area for geometry data radius left 15 mm – radius center

radius left 15 mm – radius center 30 mm radius right 15 mm – distance left 30 mm distance right 30 mm – angel of rotation 0° option pocket – step XY 3 mm cutter diameter 6 mm

0° option pocket – step XY 3 mm cutter diameter 6 mm radius left 20 mm

radius left 20 mm – radius center 30 mm radius right 15 mm – distance left 40 mm distance right 20 mm – angel of rotation 0° option contour – middle cutter diameter 6 mm

preview

0° option contour – middle cutter diameter 6 mm preview In all these examples to the
0° option contour – middle cutter diameter 6 mm preview In all these examples to the

In all these examples to the threefold circle, like in the previous form examples, a lots of different geometries can be produced only by varying the values. You get ydditional variations by selecting contour or pocket

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NCdrive

Example basic type rectangle

Geometry area with input area for geometry data

rectangle Geometry area with input area for geometry data Width 30 mm – height 20 mm

Width 30 mm – height 20 mm option pocket – step XY 3 mm cutter diameter 6 mm

20 mm option pocket – step XY 3 mm cutter diameter 6 mm Width 30 mm

Width 30 mm – height 20 mm – top edge radius 6 mm bottom edge radius 6 mm – angel of rotation 60° option pocket – step XY 3 mm cutter diameter 6 mm

60° option pocket – step XY 3 mm cutter diameter 6 mm Width 30 mm –

Width 30 mm – height 30 mm – top edge radius 12 mm bottom edge radius 6 mm – angel of rotation 0° option pocket – step XY 3 mm cutter diameter 6 mm

preview

edge radius 6 mm – angel of rotation 0° option pocket – step XY 3 mm
edge radius 6 mm – angel of rotation 0° option pocket – step XY 3 mm

Program interface in details

49

Program interface in details 49

Example basic type angle

Geometry area with input area for geometry data

in details 49 Example basic type angle Geometry area with input area for geometry data preview
in details 49 Example basic type angle Geometry area with input area for geometry data preview
in details 49 Example basic type angle Geometry area with input area for geometry data preview
in details 49 Example basic type angle Geometry area with input area for geometry data preview

preview

in details 49 Example basic type angle Geometry area with input area for geometry data preview

50

NCdrive

Example basic type trapezium

Geometry area with input area for geometry data

50 NCdrive Example basic type trapezium Geometry area with input area for geometry data preview ©
50 NCdrive Example basic type trapezium Geometry area with input area for geometry data preview ©
50 NCdrive Example basic type trapezium Geometry area with input area for geometry data preview ©

preview

50 NCdrive Example basic type trapezium Geometry area with input area for geometry data preview ©

Program interface in details

51

Program interface in details 51

4.7.3 Geometry pattern In the area „geometry pattern“ you define a pattern for the geometry. There are 6 different geometry patterns for the selection:

single process single process, then transfer matrix pattern rectangular repeated process circular repeated process circular repeated process, align with the circle

process circular repeated process, align with the circle According to the selected geometry pattern, different input

According to the selected geometry pattern, different input fields appear to set the values for the arrangement of the geometry. Moreover the amount of the geometry is set.

The location of the reference point is very important. Working in hand mode it is always the starting point for the milling. All x- and y-values depend on this point.

Chapter V

Chapter V NCdrive Settings

NCdrive Settings

Chapter V NCdrive Settings

NCdrive Settings

55

NCdrive Settings 55

5 NCdrive Settings

The concept of NCdrive is very flexible and constructed multifunctional. For this reason there are various settings in order to bind optimally the used hardware. On the next pages, all points of the setup options are described.

In the past, manufacturer of machines and controllers have developed very different concepts to which we have adapted. So there is an internal solution for the manufacturers ISEL and Max-Computer (KOSY) and for amplifiers of the manufacturers OPTIMUM, EMIS and HSE (Pc-dreh) there are special firmware versions for NCdrive. With NCpowerdrive (by 4CAM) a further controller is available that is integrated into this software concept.

Depending on the firmware and NCdrive version selected, setup options are available or completely pre- defined in the software. So don't worry about these specific characteristics of these controllers.

To make the adjustments transferable or to switch among different configurations, use the functions Open and Save. Changes of the configuration are executed immediately.

Save. Changes of the configuration are executed immediately. You find the configuration actually used in the

You find the configuration actually used in the file ncdrive.ini in the program path.

5.1

Interfaces

In this area you find basic options for a correct connection between PC – NCdrive and the machine.

In this area you find basic options for a correct connection between PC – NCdrive and

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NCdrive

PC In the folder INTERFACES you must select the serial Interface of your computer. Normally it is COM1, COM2 or by USB-Adapter COM5 til COM7.

No entry in this field allows you to work with the NCdrive software without connecting to the box in an offline mode.

software without connecting to the box in an offline mode. If you use hardware components that

If you use hardware components that often change the number of your COM-port (sometimes bluetooth adapters may disturb the windows settings) a software crash may occur while starting NCdrive software. In this case the computers tries to start connection to NCdrive using the COM port defined in the file ncdrive.ini. If this port doesn't exist no more, the software has no chance to work properly. Please open the file ncdrive.ini in an editor and change the number of the COM port manually.

Switch inputs To interpret the feedback signals of the machine with concerning the status of reference and emergency stop, they have to be correctly defined. For the external NCdrive these pin assignments exist for the 25 pole SUB-D-Plug. You see the numbers of the pins on the plug.

SUB-D-Plug. You see the numbers of the pins on the plug. NCdrive is able to recognize

NCdrive is able to recognize an emergency stop condition of the machine if the electronic of the machine is suitable for this. In this case the pin over that the signal arrrives can be defined. By default this wire uses 5V to recognize a defective element (switch, cable, etc.). Otherwise, if voltage is active in ON state, the signal can be inverted. In the case that no emergency stop signal is delivered by the controller, you can erase the check mark in the pin assignment or invert the signal.

Inverted means that all signals are understood in the other sense. (OUT becomes ON)

Advice If the matrix is inactive, these settings are pre defined by the manufacturer and can not be changed.

Output signals In this area, functions for driving the stepping motor amplifiers are defined. The functions inhibit (current reduction) and boost (current raising) are important to enable an addressing of the motors.

NCdrive Settings

57

NCdrive Settings 57
NCdrive Settings 57 Analog output By this output, you get the possibility to address a frequency

Analog output By this output, you get the possibility to address a frequency inverter for a fast frequency- or rotary frequency spindle in the range of 0 to 5 V (NCpowerdrive 0-10 V). Here you can define the allocation of the voltage and the resulting spindle speed.

allocation of the voltage and the resulting spindle speed. Data files Here you can indicate the

Data files Here you can indicate the scheme for your standard tools (text file with TOOL-assignments) and the paths to the NClyzer as well as an NC-editor.

and the paths to the NClyzer as well as an NC-editor. Timing output The period of

Timing output The period of the impulse can be adjusted in three steps by 64, 32 and 16 µs.

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NCdrive

58 NCdrive Mention the following limiting values for the configuration: The correct function of the amplifier

Mention the following limiting values for the configuration:

The correct function of the amplifier depends on the period of the step impulse. If they are too short, they are not recognized at all or only partially by the amplifier and errors in positioning may occur. Therefore you should a choose a long period for the impulses. As the length of the impulse is dependent on the step frequency, a slighter one must be selected if the impulse period is not enough. The maximum speed of an axis is limited by the torque of the motor, the resonance point of the drive and other characteristics of the mechanics.Try to approach nearest to this mechanic limit. It only can be detected by experiment. The (theoretical) maximum speed is determined also by the maximum step frequency (together with the step precision). This can be calculated in simple manner and has not to be determined (or rather should) experimentally.

Hereby has to be noted: An increase of the maximum step frequency increases the theoretical maximum speed, however it causes sometimes problems with the length of the signals, that decrease. A lower maximum step frequency removes problems with to short step impulses, reduces however the attainable maximum speed. Often you find the maximum allowed frequency in the technical data of the amplifier or directly with the manufacturer.

Keyboard A security feature is the immediate stopping of all movements by any keystroke on the keyboard. This can be canceled at your own risk, to work with other programs. In this case, the PAUSE-key is used for stopping. This also functions if you just work in another program.

This also functions if you just work in another program. Under the term "altern. movement keys"

Under the term "altern. movement keys" we understand the possibility to drive an axis in five speed steps.

Specially while customizing the milling project on the machine this is a facilitation. The range of feed is adjusted with the values in "hand 1" and" hand 2" in the axis setup.

.

NCdrive Settings

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NCdrive Settings 59

5.2 M-functions 1

The M-functions manage different machine functions and can release actions of the machine by defined commands .

and can release actions of the machine by defined commands . Spindle The main spindle is

Spindle The main spindle is swithed on in the program by the command M3 (spindle on, to the right) and is switched off with M5. Because however every manufacturer addresses his relays on any input, a SPS-command is assigned in the background to get the real command for switching on and off.

Example: The main spindle is connected to the relay 6 of the NCdrive. The command for switching on a relay would be M11x and for turning off M10x whereby the x corresponds to the output. So M116 means to switch on, M106 to switch off relay 6

In the command fields also several commands sequentially can be registered. The complete amount of commands is available.See also the file 'NCdrive DIN.rtf' in the program path .\meganc.

Coolant The same commands are used.

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NCdrive

5.3 M-functions 2

Here you find the commands for tool change and work piece change.

you find the commands for tool change and work piece change. IMPORTANT: For an optimal interaction

IMPORTANT: For an optimal interaction of MegaNC and NCdrive and for a successful tool change, it is important, that the left front edge of the working area of the machine is known by NCdrive as the zero point (0, 0, 0).

Depending on the length definition (for example TOOL T1 P1 D4 L28) of the tool, different methods of tool changing are practiced:

Lengths value without prefix: no length measurement Length value with negativ prefix (-20): a manual measurement is undertaken, for example: scratching to the raw part Lengths value with positiv omen (+20): an automatic length measurement is undertaken with a measuring system

Some values are written BOLD in the following tables. These must be reviewed and adapted on your requests, to guarantee safe working.

NCdrive Settings

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NCdrive Settings 61

Tool change manual

Example configuration M6 (pick tool):

G53

Zero point referenced to G53 – machine coordinates

G71

Dimensions in millimeter

G75

relieve Z-axis – pullback up to reference position Z

G00 X0 Y0 M00 (TOOL INSERTION)

Fast feed to the desired tool change position in X and Y Wait with a message

G60

Re-select the last zero point again

Example configuration M6 (drop tool):

G53

Zero point referenced to G53 – machine coordinates

G71

Dimension data in millimeter

G75

Z-axis relieve – pullback up to reference position Z

G00 X0 Y0 M00 (TOOL TAKE OUT)

Fast feed to the desired tool change position in X and Y Wait with a message

G99

Delete storage of tool correction

G60

Re-select the last zero point again

Example configuration M12 (Lengths measurement):

G53

Zero point referenced to G53 – machine coordinates

G71

Dimension data in millimeter

G75

Z-axis relieve - pullback up to reference position Z

G60

Re-select the last zero point again

G00 X0 Y0

Fast feed to the desired tool change position in X and Y (depending

G00 Z2 M00 (TOOL LENGTH) G98 Z0

on zero point) Fast feed to 2mm above activated zero point (raw part) Wait with a message Correction of tool lengths

G75

relieve up toreference position Z

Tool change automatic

Example M6 (pick tool):

G53

Zero point referenced to G53 – machine coordinates

G71

Dimension data in millimeter

G75

Z-axis relieve - pullback up to reference position Z

G99

Delete storage of tool correction

G00 X110 Y0

Fast feed in front of the tool changer

M600

Go to position of tool changer (by NCdrive)

G00 Z50

Fast feed of Z-axis in a distance position above the position

M112

Collet open (for example connected to output 2)

G01 Z40 F500

Slowly pick up tool

M102

Collet close

G04 Q0.5 G01 Z50 F500

Wait 0.5 sec to guarantee safe clamping Take tool out of the magazine

G75

Z-axis relieve - pullback up to reference position Z

G60

Re-select the last zero point again

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NCdrive

Example configuration M6 (drop tool):

G53

Zero point referenced to G53 – machine coordinates

G71

Dimension data in millimeter

G75

Z-axis relieve - pullback up to reference position Z

G99

Delete storage of tool correction

G00 X110 Y0

Fast feed in front of the tool changer

M600

Go to position of tool changer (by NCdrive)

G00 Z50 G01 Z40 F500

Fast feed of Z-axis in a distance position above the position Slowly drop tool

M112

Collet open ( for example output 2)

G04 Q0.5 G01 Z50 F500

Wait 0.5 sec to guarantee safe deposition Retract Z-axis and deposit tool

M102

Collet close

G75

Z-axis relieve - pullback up to reference position Z

G60

Re-select the last zero point again

Example configuration M12 (Lengths measurement):

G53

Zero point referenced to G53 – machine coordinates

G71

Dimension data in milimeter

G75

Z-axis relieve - pullback up to reference position Z

G99

Delete storage of tool correction

G00 X30 Y338 G00 Z40

Fast feed in position above the device for length mesurement Fast feed of Z-axis considering the longest tool possible

M336

Move down axis 3 (Z-axis) until a change of status of input 6

G98 Z10

Correction of tool lengths depending on height of the device

G75

Z-axis relieve - pullback up to reference position Z

G60

Re-select the last zero point again

5.4 Tool changer

NCdrive supports tool changers with linear axis or rotation axis.

supports tool changers with linear axis or rotation axis. For this NCdrive needs some details, given

For this NCdrive needs some details, given in this mask. The number of tool positions are requested, but also

NCdrive Settings

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NCdrive Settings 63

information about the options of the tool changer.

The layout of the system on the machine is freely selectable, however the changer must be set along a main axis, that is for example in a layout along the Y-axis the X-coordinate of the first position is identical with the one of the last. If the 4th axis is selected and this determined as a rotational axis, the distance (rotation angle) must be indicated in degrees.

NCdrive stores the length of each tool, so that it not will be measured again next time. However, it can be to useful to measure the tool before every operation, if it can not be guaranteed that the length is always the same. In this case activate the function "always measure" the length".

5.5 NC programm

"always measure" the length". 5.5 NC programm Presettings These settings determine the standard values

Presettings These settings determine the standard values for the indicated parameters if in the loaded NC-program nothing is defined.

Machine With the NCdrive-Software and the controller also working with lathe is possible. Because herewith basic changes in the axis layout and further parameters are following, the corresponding machine type has to be selected.

Fast movement Fast feed movements in the hand control (customizing machine) are carried out with the adjusted speed under fast feed manual mode. For fast movements in the automatic-mode, an own value can be used under fast feed automatic mode.

Interpolation circle/track A basic feature of the controller is the look ahead. This means that a number of following parts of a milling track are taken as one path, that can be driven with constant feed. This is only achievable, if the single paths are set up to a certain angle to the next one. This so-called limiting angle allows to combine several parts to one piece. If the angle between two parts is bigger, feed must be reduced to minimum starting feed or the

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NCdrive

axis must stop completely.

At the beginning and end of a path may be an acceleration ramp and brake ramp.

With the parameters I,J and K the center point of a cycle is set in the functions G02/03. These can stand according to the CAM-System or own preferences as an absolute or relative coordinate in the program. For a correct interpretation of the coordinates by the controller this selection is very important.

With the option „ Allow full circles „ a further setting is available for interpreting of cycle functions. Because it's possible in the combination with 3D-CAM-systems that cycle segments beneath the accuracy of the controller may be produced, start- and final points would be set equal. This leads however, that instead of a short arch a complete circle is processed. To avoid this no full circles are carried out by default.

As a basis for the calculation of the positioning, and also for the limiting angle, only straight lines are used. For this reason circles and arches must be interpolated. In this process, points are calculated on the circular path. The amount and the accuracy are controllable by the value of "Tolerance of circles". As a basic value the half of the resolution of the machine can be used.

Pre processor With this option the integration of an NC-program-converter will be available in the future.

5.6 Axis 1-3

In order to be able to adapt the axial controller to different machines and requirements extensive setting possibilities for many parameters of the single axis were implemented. Please note, that the included standard values are not directly suited for all machines types. In cases of doubt, you should talk to your machine manufacturer or consult us.

you should talk to your machine manufacturer or consult us. Axis The terms for the axis

Axis The terms for the axis X/Y/Z are fixed. Only the 4th axis can get following terms: A,B,C,U,V,X or own terms

NCdrive Settings

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NCdrive Settings 65

Way measurement Step motors are driven with a corresponding impulse. To get the distance according to a turning movement of the motor, one has to know the transmission. For this you have to know the section, that is usually the pitch of the ball screw im mm or 360° with a rotational axis. In the input field Steps/Section the number of the necessary steps is given for the section registered above. A lot of step motors have an angle of rotation of 1,8° per step and require therefore 200 steps for a complete turning. That's only correct for the full-step procedure. Frequently however also the half-step procedure (400) or higher solutions are in use. Which solution your machine uses, you can find out in the hand book to the step motor of your machine supplier. With the Reverse tolerance mechanical deficits in the machine's components can be minimized. This can only be a „second-best solution“, because herewith the possibilities of the look ahead are reduced. Therefore you first should try to reduce the reverse tolerance to a minimum. Giving a number of digits for the Display resolution, you can influence the indicator of coordinates for the axis. In case of a movements into the incorrect direction, you can use the invert option for an opposite turning of the motors.

Software-limit switch To protect the machine against mechanical damages it is recommended to limit the procedure way already in the controller software.

Velocities With these parameters, the behavior of the axis can be influenced in acceleration, procedure and deceleration. The maximum speeds protect in connection with the acceleration and deceleration values in procedure movement against step losses. For example driving several axis simultaneously, the effective speed will be higher than the maximum speed of a single axis, we can even get higher fast movement speeds.

Following chart should clarify this:

fast movement speeds. Following chart should clarify this: With a maximum speed of the axis X

With a maximum speed of the axis X and Y of 3000 mm/min an effective fast movement speed of 4242 mm/min is achieved moving both axis. With a simultaneous processing of the Z-axis speed would already be 5196 mm/min.

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NCdrive

If the feed of one axis should be higher than the minimum speed, an acceleration ramp is used to get the set

value. Values below are proceeded without ramp. This value depends on the capability (torque) of the motor and the mass to be accelerated.

(torque) of the motor and the mass to be accelerated. With the values of acceleration and

With the values of acceleration and deceleration the gradient of the ramp is determined. Higher values produce a steep and short ramp.

A too steep ramp can lead to step losses. A too long ramp on the other hand may also cause the danger of

step losses because of resonance. In numerous attempts on different hardware, we made the experience that

a relatively low minimum speed and steep ramps obtained the best results.

Referencing To take all advantages of NCdrive, referencing is necessary. You can also work without referencing, but of various reasons ,

Step losses by excessive load, Small range of security in the values of the axis setup Manual moving of the axis in the turned off condition

there may be differences in the nominal/actual position. Therefore a reference trip against appropriate switches should be proceeded at the beginning of each handling. Preferably reference switches should be used as an electric opener with good accuracy because herewith also damages in the wires can be recognized. The switches are to be mounted preferably at the negative side of every axis, however this can be also configured by software.

NCdrive Settings

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NCdrive Settings 67
NCdrive Settings 67 All settings for the referencing have to be done for each axis individually.

All settings for the referencing have to be done for each axis individually. The sequence of the referencing is important for a save relieving of the tool in every position. So referencing should be done with a milling machine first at the Z-axis (1) after that at both axes X (2) and Y (3).

In case of cooperation of NCdrive and MegaNC or if you would like to allocate the reference position to a certain coordinate, you get this by the value Reference position. After the reference trip, these values are assigned to the corresponding axis. Normally the reference position would be at the same time machines zero point. But working with MegaNC we relate all programs to the left corner at the front end of the machine table, to use some comfortable advantages, it is useful to relate the machine zero point on the machine table.

Herewith the values must individually be found out for each axis while it means for X and Y the distance of the reference position (center of the tool) to the front and left corner of the table and for Z the distance from table surface to bottom edge of the collet.

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NCdrive

68 NCdrive So after referencing and a command to go to the position X0/Y/Z0 the collet
68 NCdrive So after referencing and a command to go to the position X0/Y/Z0 the collet

So after referencing and a command to go to the position X0/Y/Z0 the collet should touch the table. If you clamp a tool and register its length (from bottom edge of the collet to the tool tip) it will be mentioned in calculation and the tool should touch the table surface. Considering the values for the raw block and the ones for G54, the block is included in calculation, too.

Different from the input of the reference position the Reference offset allows to proceed the axis to the given coordinate and then to accept the value of the reference position. Herewith the axis is proceeded.

A reference trip is necessary for all CNC-machines, so that the controller knows the current position of the tool. Using a step motor contoller, there are some well-known procedures for doing this first movement. It is possible to skip this 'looking for the current position, but it can cause problems in the further handling. For the controller can recognize, where each axis is, it is proceeded normally in negative direction on suitable end-switches. This switch should be an opener because then damages of the wire can easily be found and mechanical damages by a collision of machine parts can be avoided. Using NOCs (normally open contacts), these can be defined by reversing the input for the respective switch.

The settings for Search track, Retract track and Reference track are the basics for the procedure of the referencing. Search track means the direction and the length of the 'search distance' to the switch. A positiv value proceeds the axis in positiv direction. The selected track should be a little longer than the actual distance for a safe arrival if step losses may occur. With Retract track contact is secured, because it means the additional distance from the first contact. Reference track is responsible for the removing from the switch. Within this distance the controller looks for the switching point and stops the procedure.

NCdrive Settings

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NCdrive Settings 69
NCdrive Settings 69 In combination with NCdrive Pro or NCpowerdrive there is additionally the possibility to

In combination with NCdrive Pro or NCpowerdrive there is additionally the possibility to use over-travel switches or in case of servo motors the index label.

If no reference trip has to be carried out, the reference switches have to be deactivated in all axis.

The input fields for Approach speed, Search-/Retract speed and Reference speed are responsible for the named procedure ways and should be selected corresponding to the mechanical and dynamic characteristics of the machine.

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NCdrive

5.7 Axis 4

The 4th axis can either be used as a further linear axis (U,V,W) or as a turning axis (A,B,C).

In the use as a turning axis, the registered values for the way measurement, velocities and reference trips are interpreted as °/min. The range of the axis is unlimited (both software limit switch deactivated) and after every movement the indicated or current coordinates are set on the range of 0 to 360° again. Moreover in case of an interpolation of several axis the procedure speed of the turning axis is interpreted separately, if the path speed (vector sum of the single speeds) is calculated. Herewith the linear axes are regarded as leading axis. This means in practice, that in combination with one or several linear axis the feed F always means values im mm/min on and only then, when the turning axis works exclusively, F indicates the angular speed in °/min.

NCdrive Settings

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NCdrive Settings 71

5.8 Hotkey configuration

Many functions are accessible on a direct way by the keyboard or external sensors, so called hotkey`s. These can be adapted however by the file hotkey.txt according to your own wishes. For this you must accept following syntax:

;<Function> <key> [N|S|C|A[<input1>[<input2>]]] [;<Comment>]

Whereby it may be used for <key> keys out of the area: „A“ - „Z“, „0“ - „9“ ,"F1" - „F12“, „+“, „-„, „*“ or „/“

and for

(S/C/A) the combination keys „S“ = Shift, „“C“ = Ctrl (Strg), „A“ = Alt

Standard setup:

XA

F1 A ;Automatic handling

DF - C

;reducing feed (-10%)

XM

F2 A ;manual handling

DS - A

;reducing rotation speed (-10%)

XR

F3 A ;Reset emergency stop

UF + C

;increase feed (+10%)

XE

F4 A ;Program changing

US + A

;increase rotation speed (+10%)

XN

F5 A ;NClyzer

 

53

M C

;G53 (machines coordinate)

P1 F1 C ;start position 1

54

4 C

;G54 (zero point 1)

P2 F2 C ;start position 2

55

5 C

;G55 (zero point 2)

P3 F3 C ;start position 3

56

6 C

;G56 (zero point 3)

P4 F4 C ;start posiiton 4

57

7 C

;G57 (zero point 4)

P5 F5 C ;start position with X of 1 and Y of 2

58

8 C

;G58 (zero point 5)

P6 F6 C ;start position with X of 1 and X of 2 P7 F7 C ;start midpoint between pos.1 and 2 P8 F8 C ;start cycle midpoint out of position 1, 2 and 3

MR

R C

;consider tool diameter

R1 F1 S ;store position 1

MN

N C

;set zero point

R2 F2 S ;strore position 2

M0

0 C

;positioning continuously

R3 F3 S ;store position 3

M1

1 C

;positioning raw (1/10mm)

R4 F4 S ;store position 4

M2

2 C

;positioning middle (0,1/1mm)

M3

3 C

;positioning fine (0,1/0,1mm) (0,01/0,1 mm)

MH

H C

;reference trip

F1 F1

;process circle

ME

E C

;stop movement

F2 F2

;process double circle

MK

K C

;tool clamping /tool piece clamping

F3 F3

;process threefold circle

ML

L C

;tool lengths measurement/tool piece measurement

F4 F4

;process rectangle

MT

T C

tool change

F5 F5

;process elbow

MW W C tool piece change

F6 F6

;process trapez

MS

S C

;main spindle

F7 F7

;process individually

MC

C C

;Coolant

F8 F8

;process individually, then transfer

 

F9 F9

;transfer

repeatedly

process

AH

H A

;selective Stop

FA F10 ;rectangular repeatedly process

AU

U A

selective senctence suppression

FB F11 ;circular repeatedly process

AN

N A

;program start

FC F12 ;circular repeatedly process

AW

W A ;start again

A1

1 A

;program execution single block

A2

2 A

;program execution justification

A3

3 A

;program execution continuous

A0

0 A

;program stop

Chapter VI

Chapter VI Error Messages

Error Messages

Chapter VI Error Messages

Error Messages

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Error Messages 75

6 Error Messages

„No connection to the control unit“

The serial interface (COM-Port) cannot be opened.

1. Interface not available (incorrect COM-Port configured)

2. Interface already used by another program

3. Problem with the interface-driver (for example by USB-adapters)

"Error while sending data to control unit“

While sending data of the PC to the controller, an error occured

1. serial interface of the PCs out of order

2. PC problem with the interface driver

"Error while receiving data from control unit“

After processing a command of the PC, the NCdrive controller delivered within a certain time no or incomplete answer data.

1. RS-232- connection disturbed

2. serial cable or connector defective

3. NC drive power supply out of order

4. MAX-232 interface in the NCdrive controller defective

5. NCdrive processor out of order or disturbed

6. serial interface of the PC defective

"The control unit sent an undefined answer“

While the first connecting between PC and NCdrive controller, the PC did not receive the expected answer data.

1. after "Error while receiving data from control unit“ the PC again tried to connect without turning off and on of the NCdrive-controller.

2. at that configured COM-interface another device as the NCdrive controller is connected.

"Wrong firmware version“

While connecting, the firmware of the NCdrive-controller did not deliver the correct version of the software-release (NCdrive.exe and firmware don't fit).

1. incorrect firmware release installed

2. incorrect PC-software version (NCdrive.exe) started

"The control unit was switched off meanwhile“

The PC sends another command to the NCdrive controller than the initial wake-up, while NCdrive is in starting mode (green LED out).

1. The NCdrive controller was switched off and on while the PC was connected without proceeding a 'Disconnect' and following 'Connect by the PC.

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NCdrive

2. NCdrive processor made a reset, activated by the „Brown-Out-Identification"; disturbed power supply (power supply defective, variations in voltage).

3. heavy EMV-interferences released a reset of the NCdrive-processor

"Target position out of moving area“

The target position is outside of the defined moving area of one of the 4 axes.

1. Target coordinate cannot be reached because of the actual software switches.

"Undefined line format“

1. In the command line, incorrect characters or syntax were entered

Chapter VII

Chapter VII NCdrive diagnosis

NCdrive diagnosis

Chapter VII NCdrive diagnosis

NCdrive diagnosis

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NCdrive diagnosis 79

7 NCdrive diagnosis

With this check-out tool you can

* supervise the status of the inputs

* operate the outputs manually

* adjust the range of the voltage for the analogous output

* and test the axis.

of the voltage for the analogous output * and test the axis. According to the model

According to the model of the NCdrive-controller, the connections are at the controller itself (external variant) or the available connections are used in the amplifier box. The active inputs are signaled by a green check. The exits can be turned by clicking on them.

Axis test For a safe operation without problems in the movement of the axis caused by too high values for acceleration or feed rates, you should test the dynamic lim