ROBOFIL 240SL • 440SL / 440SL / 240cc• 240cc • 440cc/ 440cc / 380 380 • X90 X90
Options manual 140 000 392/E/07.2004
140 000 593/F/23.06.2004
Ver. H
1. Ta Tap per Exp Expert ert
2. Robot QC QCRw
3. e-ConnecT
4. Extens Extension ion for for taper taper angle angle up up to to 45° 45° with threading
5. Large Ree Reels
ROBOFIL 240SL•440SL 240cc•440cc 380•X90 Options manual
6. Auxi Auxilia liary ry M funct functio ions ns
7. Optio Option n for for mach machin ining ing with with wire Æ 0.10 mm
8. Exte Extern rnal al Robot Robot optio option n
9. Rota otary Tab Table
10.Worksh 10. Workshop op connection connection
11.Eject IMPRESSUM This document was conceived and written by Mr. J-M.Depraz, CTSA-Geneva. Technical data originate from our wire product line managed by J.Drouet, CTSA-Geneva. Typesetting and production by Edipresse Imprimeries Réunies s.a. / Renens. CHARMILLES 140 000 599/E/23.06.2004
12.Great height finishing
1. Ta Tap per Exp Expert ert
2. Robot QC QCRw
3. e-ConnecT
4. Extens Extension ion for for taper taper angle angle up up to to 45° 45° with threading
5. Large Ree Reels
ROBOFIL 240SL•440SL 240cc•440cc 380•X90 Options manual
6. Auxi Auxilia liary ry M funct functio ions ns
7. Optio Option n for for mach machin ining ing with with wire Æ 0.10 mm
8. Exte Extern rnal al Robot Robot optio option n
9. Rota otary Tab Table
10.Worksh 10. Workshop op connection connection
11.Eject IMPRESSUM This document was conceived and written by Mr. J-M.Depraz, CTSA-Geneva. Technical data originate from our wire product line managed by J.Drouet, CTSA-Geneva. Typesetting and production by Edipresse Imprimeries Réunies s.a. / Renens. CHARMILLES 140 000 599/E/23.06.2004
12.Great height finishing
Table of contents Introduction Availability of options Activation of options Macros for the options
0.6 0.6 0.7 0.7
Tapert Expert Introduction Contents of the kit Installation Conditions of application Wire to be used Prior measurements Positioning the part Programming Machining recommendations
3 3 3 5 5 6 8 9 10
Robot QCRw Introduction General description of mechanical components Principle of operation Robot operation Programming (M920 √ M921) Operational monitoring Restarting after power failure or incident Installation of the software option Recording of specific positions on W axis
3 4 7 9 11 13 14 15 18
CHARMILLES 140 000 599/E/23.06.2004
0.3
e-ConnecT Part 1: Utilization Introduction Principle of operation Instructions for use Example of utilization Routine maintenance of e-ConnecT
3 3 4 5 8 11
Part 2: Installation of the e-ConnecT option Important information Components used Installation of the option: general principles Installation of the option: procedure in detail Dealing with anomalies √ Action to be taken Change of Internet Service Provider (ISP) Change of e-mail/SMS converter
12 12 13 16 18 34 35 35
Extension for taper angle up to 45° with threading Introduction Contents of the option Assembling Example of utilization
3 3 3 4
Large Reels Introduction ROBOFIL 240•440 / 240cc•440cc ROBOFIL 390•690
3 4 5
Auxiliary M functions Introduction Description of functions
3 4
Option for machining with wire Æ 0.10 mm Introduction ROBOFIL 380•X90 Contents of the option Installation Checks before utilization ROBOFIL 240SL•440SL - ROBOFIL 240cc•440cc Contents of the option Mounting the option Manual positioning of the wire
0.4
Table of contents
3 5 5 6 8 9 9 10 13
CHARMILLES 140 000 599/E/23.06.2004
External Robot option Introduction Description of kit Connection principles Installation of the option Direct control of the interface (M instructions) Macro-instruction G912 Resumption in the event of power supply failure or an incident Use, upkeep, maintenance
3 3 4 4 5 6 7 7
Rotary Table Introduction Principles of operation Programming Resumption in the event of power failure or other incidents Installation of the software option
3 4 7 8 8
Workshop connection Introduction Principles of operation Conditions for commissioning Installation of the software option Configuration Management of Control mode Note concerning transfer of files
3 3 4 4 4 6 9
Eject Introduction Principles of operation Elementary conditions to be fulfilled Formation of the attachment Programming Error messages
3 3 6 7 7 8
Great height finishing Introduction Principle of operation Components of the option
3 3 3
CHARMILLES 140 000 599/E/23.06.2004
Table of contents
0.5
Introduction This document presents an overview of all options and accessories available for the various models of the ROBOFIL machines equipped with the CT-Millenium CNC. The table below shows the options availability for each model : X √
option available option not available
Le number, nature and application domain of options and accessories are subject to change along with the evolution of the ROBOFIL family. For that reason, the descriptive modules are not numbered sequentially like the chapters in the other manuals.
Availability of options 240SL•440SL
240cc•440cc
380•X90
Tapert Expert
X
X
X
Robot QCRw
X (WT)
X
-
e-ConnecT
X
X
X
Extension for taper angle up to 45° with threading
X
X
-
Large Reels
X
X
X
X
X
X
Option for machining with wire Æ 0.10 mm
X
X
X
External Robot option
X (WT)
X
-
Rotary Table
X (WT)
X
X (Special products)
Workshop Connection
X
X
X
Eject
-
-
X
-
-
X
Auxiliary M functions
Great height finishing
X
option available √ option not available (WT) the machine must be equipped with the chromium-plated steel table in order to accept the automation options.
0.6
Table of contents
CHARMILLES 140 000 599/E/23.06.2004
Activation of options The screen page Options is used for activating certain options via the code of options supplied by Charmilles.
6479
• •
•
Select EXE √ Service √ Config.Machine √ Options. Enter in the field ≈Code of Options∆ the 14-character code transmitted by Charmilles, in accordance with the options installed on the machine. Press the key Validate Options Code.
The activation indicator is updated in the boxes of the options selected. They are now ready for use.
Macros for the options Several software options make use of Macro-instructions. If the macros have not yet been loaded, carry out the macro loading procedure (screen page EXE Measuring √ Macros).
√
The macros of the options are to be found in the Service\Macro directory.
CHARMILLES 140 000 599/E/23.06.2004
Table of contents
0.7
Tapert Expert (ROBOFIL 240•440) (ROBOFIL 240cc•440cc) (ROBOFIL 380•X90) Introduction
3
Contents of the kit
3
Installation Activation of options .............................................................................. Mounting diagrams ...............................................................................
3 3 4
Conditions of application
5 5
Wire to be used Prior measurements Measurement of ZB ............................................................................... ≈Guides Set Up ∆ cycle ........................................................................... ≈Taper Expert∆ cycle ..............................................................................
6 6 6 6
Positioning the part
8
Programming Parameters TCO and TCG ..................................................................... User parameters TRE and UV .................................................................. Programming limitation ..........................................................................
9 9 9 9
Machining recommendations
CHARMILLES 140 000 397/E/04.05.2004
10
Table of contents
1
2
Table of contents
CHARMILLES 140 000 397/E/04.05.2004
Introduction The Taper Expert option has been developed for machining parts with a taper angle from 3 to 30°. The guides and nozzles supplied with the option provide optimum wire guidance even with a large inclination. As regards the software, activation of the option combines the following two effects: correction of offset according to the programmed taper angle (TCO = Taper Correction Offset) exact relative positioning between the guide and workpiece, on the basis of a table of values obtained by a special ≈Taper Expert∆ measuring cycle (TCG = Taper Correction Guides) •
•
Contents of the kit • • • • • •
Wire guides (upper : Æ 6, H6 √ lower : Æ 6, H4) Modified guide nuts Threading nozzle diam. 3.4 mm Large-taper nozzles Extended measuring eye support Options code
Installation •
• • •
Fit the upper and lower guides supplied for the option, paying attention as regards the direction of mounting Replace the threading nozzle Mounting the new guide nuts Screw on the large-taper nozzles
Activation of options Applying the procedure described in page 0.6.
CHARMILLES 140 000 397/E/04.05.2004
Tapert Expert
3
Mounting diagrams
ROBOFIL 240.440 and 240cc.440cc Upper head
Lower head
Guide Æ 6 x 4
Guide Æ 6 x 6
6419
6420
ROBOFIL 390.690 1st configuration Upper head
Lower head
Guide Æ 6 x 4
Guide Æ 6 x 6
6422» 6421
6422
ROBOFIL 390.690 2nd configuration Using the Extension option on the upper head. A description of this option and its utilization can be found in chapter 2 of the Technologies Manual.
6540
4
Tapert Expert
CHARMILLES 140 000 397/E/04.05.2004
Conditions of application The intersection of 2 segments in sharp corner mode or constant radius mode causes a resultant angle that is greater than the programmed angle.
656
The resultant angle can be determined by means of the equation: Tg θ = tg β / sin ( α/2) When clamping the workpiece, it will be thus necessary to choose a central position in the work area to allow room for a sufficient clearance of the UV axes. This will permit to reach the maximal inclination angles while avoiding the risk of reaching the UV travel limits.
Wire to be used Zinc-coated soft brass SR25 (Cobracut W) Rmax: 400 N/mm2 A: 30% •
The following tables are to be used:
Technology table
ROBOFIL
240cc•440cc
240•440
380•X90
Steel
(U)SR25A.TEC
(U)LS25A.TEC
(U)LS25A.TEC
Hard metal
(U)SR25W.TEC
(U)LS25W.TEC
(U)LS25W.TEC
Wire table
(U)SR25.WIR
(U)LS25.WIR
(U)LS25.WIR
These are to be activated in the standard manner, before performing the measurement cycles described below. •
It is also possible to use a half hard brass wire LS25 or zinc-coated half hard brass wire SS25 (Rmax 500N/mm2), with the appropriate Technology tables and Wire tables. In this case however, the goal for surface finish should not be set under CH21. The results obtained can be classified as follows:
CHARMILLES 140 000 397/E/04.05.2004
SR25 *** LS25 ** SS25 **
Tapert Expert
5
Prior measurements Measurement of ZB The Guides Set Up and Taper Expert cycles mentioned below are performed by means of the extended measuring eye supplied in the kit. Before carrying them out it is necessary to measure accurately the distance ZB between the mounting plane and the middle of the eye. First mount the eye on the clamping table, then measure Zb accurately using a comparator. 6416
Guides Set Up cycle
≈
∆
After mounting the option and measuring ZB, perform as a minimum a ≈Guides Set Up∆ cycle with the Taper parameter set at 3°. Precision in taper work depends to a large extent on the accuracy of this cycle, which determines the basi c parameters ZID and AXOZ for the inclination angle of 3°. The cycle is to be carried out with the Generator parameters in force: activate the table corresponding to the wire utilized set the value of User parameter MTOL (measurement tolerance) at 20 microns set the value of the Electrical Touch parameter at 0 (screen page EXE √ Service √ Generator Configuration) • • •
When using the extension with a ROBOFIL X90, it is necessary to modify the parameter PRTZ of the cycle as follows: With extension Without extension ROBOFIL 390 PRTZ = 211000 250000 ROBOFIL 690 PRTZ = 361000 400000 Activation: Select EXE - Measuring √ Adjust √ Guides Set Up (see Operating Guide).
Taper Expert cycle
≈
∆
The Taper Expert calibration cycle is executed after the Guides Set Up cycle performed with the inclination angle of 3°. It determines ZID and AXOZ adjustment values that will have to be applied for inclination angles 30°, 28°, 26°, 23°, 19°, 15°, 10° and 3°. So for these angles it repeats the Guides Set Up cycle operations. For a successful measurement with a 30° wire inclination, it is recommended to mount the centering eye not too close to the table edges (minimum distance : 70 mm), in order to allow room for a sufficient clearance of the UV axes. - The Taper Expert cycle is in the form of a Macro-instruction. If the macros have not yet been loaded, carry out the macro loading procedure (screen page EXE √ Measuring √ Macro). - The Taper Expert screen page has an interruption key that enables the cycle to be stopped if a problem arises during execution.
6
Tapert Expert
CHARMILLES 140 000 397/E/04.05.2004
- The Taper Expert cycle will be executed after the first installation of the guides of a Taper Expert kit. It will not be absolutely essential to repeat it each time units of the same kit are fitted, provided the machining conditions (type of wire, Technology tables and Wire tables, tension WB) remain identical. Only the guide setup will then be necessary. Activation: select EXE √ Service √ Maintenance √ Taper Expert
6417
The fields AXOZ, ZID, ZB, HCA, ZMA have the same meaning as in the case of the Guides Set Up cycle: AXOZ blocking of Z axis at zero (result of the Guides Set Up cycle) ZID distance between lower guide and mounting plane (result of the Guides Set Up cycle) ZB distance between mounting plane and middle of measuring eye (prior measurement). Approximately : 20 mm (X40) or 10 mm (X90) HCA distance between middle of measuring eye and upper guide for the measurement in low position ZMA distance between middle of measuring eye and upper guide for the measurement in high position
4622
TCO activation of offset correction according to the taper angle TCG activation of adjustments on ZID and AXOZ determined by the ≈Taper Expert∆ measuring cycle according to the taper angle. The following values can be allocated to HCA and ZMA :
CHARMILLES 140 000 397/E/04.05.2004
Tapert Expert
7
Execution of the cycle: •
•
•
•
•
Check the value of AXOZ, ZID, ZB, HCA and ZMA as per the instructions above Press the Prepare key TCO and TCG are disabled Press the Start button (green) Wait until the cycle has come to an end (duration approx. 30 minutes) (stoppage possible before the end by means of the interruption key) Press the Save key to store the measurement results Check that parameters TCO and TCG are activated at the end of the cycle ≈
≈
∆
∆
The Taper Expert option is now ready for use.
Positioning the part The workpiece must be ground with a defect of parallelism of the upper and lower faces less than 5 microns. Clamp the workpiece in a central position of the work area. After mounting, check the following: - using a comparator, check that the lower face coincides with the mounting plane (with an angle of 25°, a positioning error of 20 microns causes a difference of 10 microns on the side face) - using a comparator, check that the defect of parallelism between the upper face and mounting plane is less than 5 microns.
Mounting plane
Procedure for correcting defects that may be present: - carefully clean the workpiece and the area where it is mounted - reduce the clamping force - rearrange the fixing clamps if necessary.
8
Tapert Expert
6416
CHARMILLES 140 000 397/E/04.05.2004
Programming Parameters TCO and TCG No special programming is required as regards the ISO program when the Taper Expert option is used. Activation is obtained by means of the two parameters TCO and TCG, which can be accessed in the screen page EXE √ Service √ Maintenance Cycles √ Taper Expert. The current status of these parameters is also displayed in screen page EXE √ User parameters: TCO activation of offset correction according to the taper angle TCG activation of adjustments on ZID and AXOZ determined by the ≈Taper Expert∆ measuring cycle according to the taper angle.
6418
(the parameter TCO can be left active permanently).
User parameters TRE and UV RE and UV are also used for controlling machining with taper. Parameter TRE must be set at 1 so that the ISO taper machining instructions (G51, G52 and G50) are executed in a program. If TRE = 0, all ISO programs will be executed as a cylindrical shape (UV axes movements identical to XY movements) Parameter UV is used to allow 5-axes programming, i.e. the explicit controlling of the U and V axes by the ISO program, which also makes it possible to perform machining with taper or other more complex shapes.
The parameters TRE and UV are mutually exclusive.
Programming limitation In 4 axes mode (parameter UV enabled), it is not possible to use programming with circular interpolation (G02, G03).
CHARMILLES 140 000 397/E/04.05.2004
Tapert Expert
9
Machining recommendations •
•
•
It is recommended to use the sequences designed for maximum accuracy (i.e. those characterized by 3 or 4 stars in the Technologies Manual) With a taper angle greater than 5°, it is recommended to set the upper and lower minimum injections at 3.5 liters/minute In the roughing phase: reduce the Generator parameter FF according to the maximum taper angle of the part, i.e. 2 % per degree of taper angle In order to store this modification in a modified technology table, please note that an FF cannot be stored, but an equivalent effect of frequency reduction can be obtained by modifying Generator parameter B as per the following formula: 100 B Br = ------------------------------100 - 2 alpha where :
•
•
•
Br = new value of B (to be stored in the modified table) B = original value of B alpha = taper angle in degrees
set the wire tension WB at 1.5 daN for finishing passes. For the finishing setting E7: modify the value of the parameter Pm (material removal) as follows according to the taper angle: o Taper angle 5° 10° 20° 30° o Parameter Pm 40 45 50 60 Finishing passes with a ROBOFIL 240.440 or 240cc.440cc: the quality of sparking will be improved by raising the Z axis by 15 mm.
10
Tapert Expert
CHARMILLES 140 000 397/E/04.05.2004
Chapitre
Robot QCRw (ROBOFIL 240•440) (ROBOFIL 240cc•440cc) Introduction
3
General description of mechanical components Pallet .................................................................................................. Magazine ........................................................................................... Lift ..................................................................................................... Horizontal axis ..................................................................................... Vertical axis ......................................................................................... Automatic side door .............................................................................. Table chuck .........................................................................................
4 4 4 4 6 6 6 6
Principle of operation Pallet loading sequence ......................................................................... Pallet unloading sequence ......................................................................
7 7 8
Robot operation Automation Panel .................................................................................. Remote control .....................................................................................
9 9 10
Programming (M920 √ M921) Conditions for execution of sequences M920 and M921 ............................ Modularity of sequences M920 and M921 .............................................. Manual commands available to operator .................................................. Principle of use of instructions M920-M921 ...............................................
11 12 12 12 13
Operational monitoring
13
Restarting after power failure or incident
14
Installation of the software option Configuration ....................................................................................... Robot reference setting (W axis) ..............................................................
15 15 17
Recording of specific positions on W axis Execution of the sequence ...................................................................... Verification tests ....................................................................................
18 19 19
CHARMILLES 140 000 610/E/15.04.2004
Table of contents
1
2
Table of contents
CHARMILLES 140 000 610/E/15.04.2004
Introduction Option QCRw (Quick Change Robot / Wire) comprises a magazine capable of holding several pallets and a mechanism for loading/unloading the pallets into/from the ROBOFIL's working zone. Of a simple and robust design, QCRw can transfer loads of up to 100 kg (including pallet). Completely automatic loading/unloading cycles for several successive workpieces means that the machine can operate independently for extended periods, so allowing overnight or weekend working and thus increasing machine productivity and profitability.
6480
The overall working of the QCRw robot is controlled by the numerical control, closely synchronised with other machining operations.
CHARMILLES 140 000 610/E/15.04.2004
Robot QCRw
3
General description of mechanical components Pallet The pallet is a standard support onto which the workpiece to be machined will be clamped, and which will take up its position on the table chuck of the machine.
Magazine The magazine makes it possible to store 1 to 3 pallets (according to the tooling selected) on 2, 3 or 4 levels (levels 3 and 4 = options). Each level is equipped with a frame which can move in the horizontal plane and stop in one of the three following positions: 1. Mid-point resting position, in which no operation is carried out. 2. Manual loading position, in which the frame is detached from its piston-cylinder unit and pulled backwards manually by the operator in order to load/unload one or more pallets. 3. Transfer position: when one of its pallets is selected, the frame is pushed forwards by means of a pneumatic piston-cylinder unit. In this position, the pallet will be raised by the lift until it reaches an upper stop, where it can be gripped by the vertical axis gripper.
Horizontal axis (W axis)
Vertical axis Levels 4 Actuator 3 t f i L
2 1 Transfer (3)
(Front)
Rest (1)
Side view
Manual loading (2)
6471
(Rear)
Front view
Lift When a frame is in the transfer position, it is pushed upwards into upper positio n which allows the pallet to be gripped by the gripper. The operation is performed in reverse to return the frame to its starting position. Each pallet is allocated a unique address of the format (i, k) which allows it to be selected: - i: level number - k: pallet number
4
Robot QCRw
CHARMILLES 140 000 610/E/15.04.2004
i :
levels
2
1 D1
D2
k : pallets 1
2
3 6472
Magazine configuration • As standard, the magazine has 2 levels It is available in a version with 3 levels (option 1) and 4 levels (option 2). • Seven different kinds of tooling can be used. Depending upon the tooling selected, 1 or 2 pallets can be placed on one level. • The tooling includes not only the table fixing system, but also the corresponding gripper. • The total number of pallets can thus range between: - a minimum of 2 (2 levels x 1 pallet) and - a maximum of 8 (4 levels x 2 pallets). • The workpieces within a row can be different if they are compatible with the tooling used (D1 can be different from D2, but D1 and D2 remain identical for each level). Configuration examples: 2 levels (standard) with 1 pallet
3 levels (option 1) with 2 pallets
4 levels (option 2) with 2 pallets
6473
On request, a 5-level/3 pallets version can be produced (Special Products) making it possible to manage up to 15 pallets depending on the type of tooling.
CHARMILLES 140 000 610/E/15.04.2004
Robot QCRw
5
Horizontal axis
(also known as W axis or 6th axis) The horizontal axis consists of a rail accommodating a sliding carriage which allows the pallets to move between the magazine and the machine's worktable.
(11)
(3)
(7)
(6) (10)
(2)
(4)
(5)
(9)
(8)
(1) 6474
Vertical axis The carriage is equipped with a gripper which moves vertically to and fro to grip the selected pallet and then place it onto the worktable - bottom position: gripping/placing of pallet (at the frame or worktable level) - top position: conveying pallet along axis W
Automatic side door Opening the side door makes it possible to move the pallet. When machining in submerged mode, the door can only be opened once flushing has been stopped and the tank drained.
Table chuck The function of the chuck is to lock the pallet onto the worktable, and to guarantee the positioning accuracy. Flexibilityª option: By default, the operating mode of the robot is optimized to favor the speed of loading/unloading operations. This mode makes it possible to deal with parts of up to 80 mm height. For parts higher than 80mm, the Flexibility option can be chosen (screen page EXE √ Service √ Machine Configuration √ Options). In this case, when a pallet is changed, a movement of the W axis is only performed when all the racks of the magazine are in the rest position and the elevator in the low position. ∫
6
Robot QCRw
CHARMILLES 140 000 610/E/15.04.2004
Principle of operation Pallet loading sequence (see figure on page opposite) (1)
Movement of frame into transfer positio
(magazine)
(2)
Frame lifting
(lift)
(3)
Approach of gripper
(horizontal axis W)
(4)
Lowering of gripper Opening of gripper
(vertical axis)
(5)
Movement of gripper into gripping position Closure of gripper
(horizontal axis W)
(6)
Raising of pallet
(vertical axis)
(7)
Opening of the side door Transfer of pallet into working zone Opening of chuck
(horizontal axis W)
(8)
Lowering of pallet into working position Locking of chuck Test of presence Opening of gripper
(vertical axis)
(9)
Withdrawal of gripper
(horizontal axis W)
(10) Lifting of gripper
(vertical axis)
(11) Return of gripper to waiting position 2 Closing of the side door
(horizontal axis W)
Movements are carried out in accordance with two different principles: - Magazine, lift, vertical axis, gripper and chuck: ≈hard-wired∆ control sequences specific to the robot and pneumatic units (e.g. top position and bottom position of gripper on vertical axis) - Axis W: this axis is fitted with a servo motor, which means that movements can be software controlled, providing that the stopping points are stored in the numerical control's memory during an initial calibration stage, using the screen page Robot Teaching (see paragraph ≈Saving specific positions of the W axis∆). Specific features of the Erowa Unoset ™ tooling - this equipment can accept up to 3 pallets per level - the loading/unloading sequences will be slightly different due to the fact that the gripper does not require an approach/gripping movement
CHARMILLES 140 000 610/E/15.04.2004
Robot QCRw
7
Pallet unloading sequence (1)
Opening of the side door Movement of gripper from waiting position towards pallet
(horizontal axis W)
(2)
Lowering of gripper Opening of gripper
(vertical axis)
(3)
Movement of gripper into working position Closure of gripper, opening of chuck
(horizontal axis W)
(4)
Raising of pallet Closure of chuck
(vertical axis)
(5)
Return of pallet to magazine
(horizontal axis W)
(6)
Closing of the side door Lowering of pallet towards magazine Opening of gripper
(vertical axis)
(7)
Withdrawal of gripper
(horizontal axis W)
(8)
Lifting of gripper Closure of gripper
(vertical axis)
(9)
Return of carriage to initial resting position
(horizontal axis W)
(10) Lowering of frame to original height
(lift)
(11) Return of frame to resting position
(magazine)
On completion of the sequence, all components have returned to their resting positions.
(1) (9)
(8)
(5) (4)
(7)
(6)
(2)
(3)
(11)
(10) 6475
8
Robot QCRw
CHARMILLES 140 000 610/E/15.04.2004
Robot operation The robot can be manipulated by the operator for test purposes or for recording specific points on the W axes (see paragraph below). Two operating methods are available: - the Automation Panel page, Panel page, which contains a set of buttons and function keys which permit ope ration of the various robot components in manual mode - a spe speci cial al use use of of Remote control, control, which allows certain operations to be carried out accurately with the operator in front of the work booth. The user should note that he/she is solely responsible for any manual ma nual operation of the robot: he/she must ensure that any actions are mutually consistent (e.g. door opening before movement along W axis, observation of collision risks etc.).
Automation Panel EXE page √ Manual √ Au Automation Panel
(specific page)
Conventions for LEDs on keys: - illuminated illuminated in orange if in in transient transient state (action (action under way or interrupted interrupted during during execution) execution) - illuminated illuminated in green if selection selection made, made, or in position. position. List of operations W axis
Gripper
• Home: return of W axis to resting position • Jog W+/W-: W+/W-: movement movement of W axis • Speed/inc Speed/incremen rementt selection selection (mutually exclusive, also apply to 5 other axes) • Pallet Pallet selecti selection on (1, 2 or 3) • Vertical Vertical axis axis up/down up/down • Approach Approach/grip /gripping ping position position • Gr Gripper closure/opening
Magazine
• Li Lift • Leve Levell (1 to 4) 4)
Side door
• Door opening opening/clo /closure sure
Machine/Chuck
• Chuck locking locking/ope /opening ning • Approach/gripping Approach/gripping position (machine) • Presen Presence ce test test
CHARMILLES 140 000 610/E/15.04.2004
LED green if: Position (1) In use
Gripper closed
Lift up/down Move Move to to rest rest/t /tra ransf nsfer er posi positition on
Chuck locked Pallet present
Robot QCRw
9
Important information concerning the speed of movement and and position display of of the W axis. In order to achieve the shortest possible workpiece changing times, the spee d of movement along axis W is 30 m/min. This is achieved by using control increments of 2 microns. This convention also affects how position of the W axis is displayed, with one unit also representing 2 microns .
Remote control When the Automation Panel screen page is active, the remote control can be used to control the robot. • This special operating operating mode is indicated by rapid flashing of key 2. • Keys 1, 3, 4, 6 then perform the following following functions: 1, 3 => => Jog W+/WW+/W- Moveme Movement nt of of W axis axis 1, 4 => Gripper Opening/closing of gripper 1, 6 => Chuck Opening/locking of chuck
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
17
18
20
21
23 6476
10
Robot QCRw
CHARMILLES 140 000 610/E/15.04.2004
Programming (M920 √ M921) Two instructions M920 and M921 make it possible to control execution of robot operating cycles. These instructions must be incorporated logically into a control program. The corresponding workpiece programs are thus not modified by using the robot for placing the workpiece. Loading Examples:
M920 Ii Kk M920 M1 M920 I1 K3 This command selects pallet 3 of level 1 and brings it into the working position. The sequence is executed entirely automatically. The values specified for I, K are always stored as the subsequent return position for the pallet. M920 M1 In this case, loading will be carried out manually by the operator. The instruction carries out the preliminary phases (movement of Z-XYUV axes, draining, opening of the door), then passes into suspended mode. The operator selects and loads the selected pallet either by hand, or by means of the manipulation tools (MDI commands, Automation Panel, remote control). The operator indicates completion of these operations by pressing the Start key which will cause the automatic program to continue. Before restarting the workpiece program machining instructions, the prior machining conditions are reestablished, namely: - door door close closed, d, fill fillin ing. g.
Exchange
Unloading
Examples:
M920 Ii Kk M920 M1 If a pallet is already in the machine, instruction M920 results in an exchange, exchange, i.e. the above loading sequence will automatically be preceded by the unloading of the pallet present in the machine. M921 M921 Ii Kk M921 M1 M921 This command is normally issued on completion completio n of ROBOFIL processing of a pallet loaded by instruction M920 I, K. The instruction results in the pallet being removed and returned to its original position. M921 Ii Kk If parameters I, K are defined, the pallet in place will be extracted and directed towards the position defined by I, K. The programmer must check that this operation is feasible, is free at that time, since there is no preliminary check performed by the robot. M921 M1 In this case, unloading will be carried out manually by the operator. As in instruction M920, the preliminary phases of moving into suspended mode and then the continuation of machining after the Start key has been pressed will be carried out automatically.
CHARMILLES 140 000 610/E/15.04.2004
Robot QCRw
11
Conditions for execution of sequences M920 and M921 • A value must already have been assigned to the Secondary plan parameter on the screen EXE -- User parameters. • The parameter TRE on this same page will be set to 1 by M920 or M921. • Once execution of M920 or M921 is complete, vertical alignment of the UV axes relative to the XY axes is always reestablished. The instructions M920 and M921 are to be used only in G40 mode (no offset) and G50 mode (no taper) Users must insert in their application programs the appropriate instr uctions in order to: - cut the wire before loading/unloading - position the axes in relation to the newly loaded workpiece - rethread the wire.
Modularity of sequences M920 and M92 1 • By default, the execution sequences for instructions M920 and M921 carry out all the preparatory actions before changing and actions to restore the state prior to changing (draining/filling of tank, opening/closure of door, axis movements). • Nevertheless, the content of the sequences is modular and can be modified using the screen page Automation -- Authorised actions for the various execution modes (automatic, manual, simulation).
Manual commands available to operator ISO command (MDI mode) W axis (6th axis)
Remote control (2 flashes)
Jog W+ WHome Approach - pickup positions
1 => W+ 3 => W-
Gripper
Opening Closure
4 => Opening 4 => Closure
Table chuck
Opening Locking
6 => Opening 4 => Locking
Magazine
Lift movement Frame movement
Side door
G00 W
Command (Automation Panel)
M04 Opening M05 Closure
Opening Closure
M08 Draining + opening M09 Draining + wait + opening M12 Closure + filling M13 Closure + wait + opening
12
Robot QCRw
CHARMILLES 140 000 610/E/15.04.2004
Principle of use of instructions M920-M921 O100 º.
! Command program
M920 I3 K1
! Loading pallet 1 (level 3, pallet 1)
M98 P110 º..
! Workpiece program, pallet 1
M920 I3 K2
! Exchange: return pallet 1, ! load pallet 2 (level 3, pallet 2) ! Workpiece program, pallet 2
M98P120 º. M921 º.
! Pallet 2 return
M30
Operational monitoring INFO √ Monitor page
CHARMILLES 140 000 610/E/15.04.2004
(standard page)
Robot QCRw
13
Two fields are added to facilitate monitoring of robot operation: Pallet in gripper: Pallet in machine:
Number of pallet involved in a loading/unloading cycle. Number of pallet loaded in machine.
The displayed pallet number corresponds to the pallet's address in the magazine (level i, pallet k). This number may also be used in order to be able to return the pallet manually to its original position in the event of malfunction.
Restarting after power failure or incident • The Auto-Restart device manages option QCRw, which means that the robot is treated in the same way as the whole ROBOFIL unit in the event of power failure (automatic restart without interruption of machining). • Any malfunctioning of the robot will result in suspension of the current operation and issue of a standard error message. • Pressing F1 key automatically opens the electronic documentation and displays information related to the event. • Most malfunctions related to robot use may arise from jamming of mechanical components (door, axis, gripper etc.) or collisions. • After analysing the information and context, the operator must attempt to remedy the p roblem and normalise the situation, if necessary using the robot control tools (Automation Panel, remote control). • Before automatic operation can be resumed by pressing the Start button, the situation at the time of interruption must have been reproduced exactly. • In the event of desynchronisation or loss of control, the operator will return all robot components to their starting positions using the control tools and will restart the program from the non-executed instruction.
14
Robot QCRw
CHARMILLES 140 000 610/E/15.04.2004
Installation of the software option The option is managed through the numerical control's man-machine interface (MMI): the screen pages used are modified standard pages or new specific pages dedicated solely to controlling the robot.
Configuration The configuration phase is carried out using the following three screen pages: 1
Declaration of QCRw option
EXE page √ Service √ Machine configuration √ Options
(standard page)
This makes it possible to specify the presence of options related to using the robot: - type of robot - W axis, side door, table chuck - manual pallet (handling by screen and remote control) - flexibility mode (parts of height greater than 80 mm) - dry set (not yet available) Declaring the options has following effects : - modification of standard screen pages (e.g. display of absolute W axis position) - accessibility of robot-specific pages (e.g. Automation Panel page) - possibility of operating the robot by remote control
CHARMILLES 140 000 610/E/15.04.2004
Robot QCRw
15
2
Drain level for opening side door
EXE page √ Service √ Machine configuration √ Dielectric
(standard page)
Specifies the level of dielectric in the tank at which the side door can be opened.
3
Robot configuration
EXE page √ Service √ Automation
(specific page)
This page is for entering initial values for the characteristic parameters relating to robot operation: - permitted actions: makes it possible specify whether the following actions: • opening/closure of side door • movement of W axis • draining/filling of tank will be executed by instructions M920-M921 in the following operating modes: • simulation • automatic change • manual change - type of tooling used (to be chosen from a selection list) - magazine size • levels (number of levels) • rows (number of rows per level) (not used at present - set the value at 1) • pallets (number of pallets per row)
16
Robot QCRw
CHARMILLES 140 000 610/E/15.04.2004
- changing position for machine axes XYUVZ • for an automatic change • for a manual change • The operator must specify machine axis positions which permit loading/unloading of pallets without risk of collision with heads while, if possible, minimising movement distances in order to shorten cycle times. • These XYUVZ positions can be set by editing their respective fields. • They can also be set by recording a current position using the associated function keys (Mem. X, Mem. Y, etc.). • The All function key assigns the current position of the 5 axes to the two sets of automatic and manual values.
Robot reference setting (W axis) EXE page √ Manual √ References
(standard page)
This page is the same as for the XYUVZ axes. It allows the absolute zero of the W axis to be set. Referencing must be carried out if the red indicator light beside the position display is lit. • Position the carriage at its travel mid-point on the W axis, with the side door open. • Press the -W function key => the carriage moves to its original position => the reference position for W is set
CHARMILLES 140 000 610/E/15.04.2004
Robot QCRw
17
Recording of specific positions on W axis EXE page √ Service √ Robot configuration √ Teaching
(specific page)
Before it is possible to carry out automatic robot cycles, the following intermediate stopping positions must be recorded: Rest Robot magazine Approach
Pallet 1 Pallet 2 Pallet 3
(K=1) (K=2) (K=3)
Robot magazine Pickup
Pallet 1 Pallet 2 Pallet 3
(K=1) (K=2) (K=3)
Chuck / Machine Approach Chuck / Machine Pickup
Erowa Unoset ™: not used
Erowa Unoset ™: Gripping Erowa Unoset ™: Approach
Wait Configuration stages 1, 2 and 3 together with W axis reference setting must be carried out so that, among other things, it is possible: - to display the W axis position - to use remote control on the robot.
18
Robot QCRw
CHARMILLES 140 000 610/E/15.04.2004
Execution of the sequence Direct input • Place the machine»s XYUVZ axes in a position allowing free movement of the carriage on the W axis • Activate the screen page EXE √ Service √ Robot configuration - Teaching • Using the Jog keys W+/W- of the automation panel or the remote control, place the carriage at the desired Rest position • In the screen page Teaching, press the insertion key W => the LED lights up to indicate the mode inputted • Select the field Rest => the current W position is displayed in the field • To accept this value, press the key Validate Repeat the last two operations in an identical manner for each position to be inputted.
Input via keyboard The value of the positions to be stored can also be entered directly using the keyboard. To do this proceed as follows: • deselect Insert W • select the field of the position to be stored • enter the value with the keyboard, and end with Return • press the key Validate Repeat these operations in an identical manner for each position to be inputted.
Verification tests • Press the key Verify => a mode ≈Reduced speed∆ is activated on the W axis (green LED lit up) This mode makes it possible to test the result of the teaching at reduced speed before carrying out the first loadings in machining • Perform one or several loading/unloading dry runs, for example in MDI mode by means of the commands M920 Ii Kk and M921 (see next paragraph) • Once the tests have been completed, do not forget to restore the normal speed of movement of the W axis by pressing once again the key Verify (green LED off)
CHARMILLES 140 000 610/E/15.04.2004
Robot QCRw
19
Chapitre
e-ConnecT (ROBOFIL 240•440) (ROBOFIL 240cc•440cc) (ROBOFIL 380•X90)
Part 1: Utilization
3
Introduction
3
Principle of operation Immediate notification of events in the form of SMS messages ....................... Recording of Internet e-mail communications ..............................................
4 4 4
Instructions for use Modification of filtering of messages at overall level .................................... Passive monitoring ................................................................................ Active monitoring with modification of programs (instruction G13(ECN, ...) ..... Modification of messages filtering at single recipient level ............................ Temporary disconnection of a recipient ..................................................... Change of a recipient»s telephone number ................................................
5 5 6 6 6 7 7
Example of utilization Workpiece .......................................................................................... Passive monitoring: immediate notification ................................................. Active monitoring: immediate notification for manual cutting of an attachment ... Consultation at a later time: data on productivity ........................................
8 8 9 9 10
Routine maintenance of e-ConnecT Periodic purging of directories ................................................................. Back-up copies ....................................................................................
11 11 11
CHARMILLES 140 000 615/E/04.05.2004
Table of contents
1
Part 2: Installation of the e-ConnecT option
12
Important information
12
Components used Components included in the e-ConnecT option ........................................... Components provided by the customer ...................................................... Remarks concerning the choice of components ...........................................
13 14 14 15
Installation of the option: general principles Stage 1: Installation of the modem and its Driver ......................................... Stage 2: Dial-Up Network (DUN) module .................................................. Stage 3: Module e-ConnecT ................................................................... Stage 4: Mail Server module .................................................................. Stage 5: Windows Messaging / Address Book module ..............................
16 16 16 16 16 17
Installation of the option: procedure in detail Preliminary action .................................................................................. Procedure ............................................................................................
18 18 18
1. Installation of the modem and its Driver
19
2. Dial-Up Network (DUN) module
24
3. e-ConnecT module Activation of the option - Options code ..................................................... Utilization of the screen page e-ConnecT ...................................................
27 27 27
4. Mail Server module
28
5. Windows Messaging / Address Book module Test of operation ...................................................................................
30 33
Dealing with anomalies Action to be taken Follow-up of messages on the ROBOFIL machine ........................................ Follow-up of messages outside the ROBOFIL machine ..................................
34 34 34
Operational security: standby channel
35
Change of Internet Service Provider (ISP)
35
Change of e-mail/SMS converter
35
√
2
Table of contents
CHARMILLES 140 000 615/E/04.05.2004
Part 1: Utilization
Introduction The purpose of the e-ConnecT option is to perform remote monitoring of the operation of a ROBOFIL machine: the significant events of the machining process are automatically transmitted to one or several recipients, either by immediate notification using SMS messages on a mobile telephone (SMS = Short Message S ystem), or using e-mail on the Internet network. The following events are transmitted: - start / end of a machining program - programmed stoppages or stoppages on errors - specific messages inserted in the program The remote monitoring by e-ConnecT will be profitable for centralized supervision of a stock of machines, or for remote follow-up of programs started during weekends, and will enable the user to be kept informed and to take immediate action when an interruption of production occurs, instead of only discovering the problem on a Monday morning after the machine has been idle for several hours. All this results in an overall increase in productivity and profitability.
CHARMILLES 140 000 615/E/04.05.2004
e-ConnecT
3
Principle of operation The simplified diagrams below illustrate the overall principle of e-ConnecT:
Immediate notification of events in the form of SMS messages ROBOFIL Machine e-mail Internet e-mail conversion => SMS (SMS messages) Recipient 1 (mobile) ...... Recipient n (mobile) In this case, the recipient is instantaneously informed about the significant events of the machining operation.
Recording of Internet e-mail communications ROBOFIL Machine e-mail Internet Letterbox
Consultation by Internet
In this case, the Internet letterbox is considered as a virtual recipient. It keeps track of all the events, and its content can be consulted periodically and archived. e-ConnecT enables users to perform notification by SMS in parallel with the recording of Internet communications, and thus benefit from the advantages of both transmission modes. e-ConnecT does not give the ROBOFIL machine the capability of producing and sending e-mails written manually by the user!
4
e-ConnecT
CHARMILLES 140 000 615/E/04.05.2004
Instructions for use Modification of filtering of messages at overall level The screen page EXE √ Service √ Config.Machine √ e-ConnecT is used for selecting the types of event that will be taken into account by e-ConnecT. Tick the types of event for which notification is required.
Windows Messaging
6481
Please note that failing to tick one of the boxes will block notification of all the events of this type for all the users! (If this machine has only one user, this filtering method is naturally more suitable than the individual filtering described on page 7, which is the appropriate one to use if several users are involved with the same ROBOFIL machine.) The screen page e-ConnecT has two 2 buttons. The one on the right is for activating the screen page Windows Messaging /Address Book, which will be used in the modifications described on page 7: • Modification of message filtering at single recipient level • Temporary disconnection of a recipient • Change of a recipient»s telephone number
CHARMILLES 140 000 615/E/04.05.2004
e-ConnecT
5
Passive monitoring Users can take their programs as they stand and make use of e-ConnecT to perform monitoring that can be described as passive, this being obtained by ticking the first 4 types of event in the screen page e-ConnecT: Notification of PROGRAM START Notification of PROGRAM END Notification of STOP ON ERROR Notification of STOP ON MM0/MM1
(1st blocking error)
In the case of a Stop on Error, only the first blocking error is notified. At this moment users know that a problem has occurred, and that they must carry out a more thorough investigation on the machine.
Active monitoring with modification of programs (instruction G13(ECN, ...) To obtain active monitoring, i.e. to be informed about the execution of certain specific points of the machining, proceed as follows: - in the screen page e-ConnecT tick the fifth type of event: Notification of G13(ECN,message) - at the position of the points to be indicated, insert in the programs the following ISO instruction: G13(ECN, m e s s a g e ) • The maximum length of the message between the comma and the parenthesis is 12 characters.
Modification of messages filtering at single recipient level It can happen that several recipients are concerned by the pro gress of the machining job. If they all wish to receive the same type of message, the filtering can be done as explained above at overall level by means of the screen page e-ConnecT. If on the other hand the levels of interest are different, e-ConnecT allows individual parameterization. This is done as shown below: In the screen page e-ConnecT, press the right side button => the screen page Windows Messaging is displayed Click on the icon Address Book => the screen page Address Book is displayed with the list of current recipients Select (double click) the recipient concerned by the modification => the screen page Properties is displayed
6
e-ConnecT
CHARMILLES 140 000 615/E/04.05.2004
Click on the tab Notes => the window Notes displays the parameters that format the SMS messages
(Screen e ow given just as an examp e! Presentations vary depending on the SMS contract!)
Edit the parameters mid* as per the filtering desired. The rules are as follows: • mid1 selects the events of type 1 • mid2 selects the events of type 2 • etc º Example opposite: selection of events of type 1, 2 and 5 • mid0 cancels all selections! • all selects all 5 types of event • a line preceded by // is ignored Conclude the editing by OK, Then close the Address Book and the page Windows Messaging.
Temporary disconnection of a recipient The same procedure is used for disconnecting all notifications concerning a recipient during an absence. In this case, the following specification must be used: MessageType_id: mid0 No further SMS will henceforth be transmitted to this recipient. Reactivation is performed by restoring the specification of the values mid1, mid2 º that existed previously.
Change of a recipient»s telephone number An identical procedure is used for changing if necessary the telephone number of the recipient: - open, as above, the window Notes of the recipient concerned, - locate the old telephone number (under the heading Subject: or Body: depending on the format) - replace the old number by the new one. Depending on the SMS service contract subscribed, it is possible that the telephone number has been recorded not in the window Notes, but in the E-mail address field of the window SMTP-Address as in the screen opposite =>
(Screen e ow given just as an examp e! Presentations vary depending on the SMS contract!)
In this case -- click on the tab SMTP-Address, - locate the old telephone number, - replace the old number by the new one. Conclude the editing with OK, then close the Address Book and the page Windows Messaging.
CHARMILLES 140 000 615/E/04.05.2004
e-ConnecT
7
Example of utilization Workpiece The purpose of this chapter is to illustrate three possibilities for using e-ConnecT: - passive monitoring (immediate notification, without modification of program) - active monitoring (immediate notification, with modification of program) - consultation of e-mails at a later time. These examples are based on a program for machining a punch as given in the Training Manual, chapter 2 (you may refer to this document to obtain detailed explanations about this machining job and the corresponding part-program). • The profile to be machined is a punch as shown opposite, involving: - a roughing pass - a finishing pass - a surface finishing pass.
R1
R2
R2
• The same part-program (named O019.ISO) is used for the 3 passes • The punch is held during the finishing pass and the surface finishing pass by an attachment of 4 mm that will be cut off manually at the end of the job
R1 2
R 8
• The complete machining sequence is managed by the following command program (named O119.ISO): O119 G11 (WIR, LS25) G13 (TEC, LS25A) ; M31 G21 G92 X0. Y21. ; S2 G01 X-2. Y-16.5 M98 P019 ; S18 M98 P019 B1 ; S10 M98 P019 ; M30
8
e-ConnecT
6322
; ; ;
Start of command program O119 Selection of the Wire table Selection of the Technology Table
; ;
Setting of counters to zero Unit: millimeters
; ; ; ;
Setting: roughing Approach cut along X Approach cut along Y Calling up of sub-program O019 /roughing
; ; ; ;
Setting: finishing Calling up of sub-program O019 /finishing (B1=> reverse direction) Setting: surface finishing Calling up of sub-program O019 /surface finishing
;
End of command program O119
CHARMILLES 140 000 615/E/04.05.2004
Passive monitoring: immediate notification (without modification of program) Without modifying the existing programs, it is possible to obtain the notification of events of types 1 to 4 (Start/End of program, programmed stoppages or stoppages on error). Let us suppose that the ROBOFIL being used is controlled by a single operator. In this case we recommend the following: - accept all types of message as regards the user profile level defined in the Address Book, page Notes (i.e. MessageType_id: All) - make the selection on the screen page e-ConnecT For example, if the operator is only interested in notification of the end of programs, he will make the selection shown opposite => 6481
(he will then also receive notification of stoppages on error)
Active monitoring: immediate notification for manual cutting of an attachment (with modification of program) Let us assume that the user does not want to be bothered with notifications of all the starts/stops of programs, and only wishes to receive messages specifically concerned with the way machining is progressing. For example, in the case in hand, he wishes to beInformed about the moment he has to take action on the machine to cut the attachment at an end of a sequence, and start up the next machining operation. In this case he will perform the selection shown opposite => (he will then also receive notification of stoppages on error)
6481
He will also have to modify the command program by inserting the following notification instruction: - - - - - S10 ; Setting: surface finishing M98 P019 ; Calling up of sub-program/surface finishing ; G13(ECN,Attachment) ; Message of notification ; M30 ; End of command program O119
CHARMILLES 140 000 615/E/04.05.2004
e-ConnecT
9
Consultation at a later time: data on productivity Let us suppose that, in parallel with notification, the user wishes to establish a systematic record of events in a letterbox on an Internet site. This recording will function in practice as a second virtual recipient with its own address in the Address Book. Because of this the following must be done: - allow transit of all the messages on the screen page e-ConnecT with the parameterization opposite => - perform the selection parameterization for each recipient in the Address Book (page Notes)
6481
Profile for the user: (first recipient for notification) MessageType_id: mid3,mid5 Subject: Body:
(Stoppages on error, specific messages) as per specifications of the e-mail/SMS converter
Profile for the letterbox: (second virtual recipient for recording) MessageType_id: All (records all events) No specification of Subject: and Body:, because the destination is a letterbox, without e-mail/SMS conversion The command program will be modified as follows: ---------; S2 G01 X-2. Y-16.5 M98 P019 G13(ECN,End roughing) ; S18 M98 P019 B1 G13(ECN,End finishing) ; S10 M98 P019 G13(ECN,Attachment) ; M30
10
e-ConnecT
; ; ; ; ;
Setting: roughing Approach cut along X Approach cut along Y Calling up of sub-program/roughing Message of notification
; ; ;
Setting: finishing Calling up of sub-program/finishing, reverse direction Message of notification
; ; ;
Setting: surface finishing Calling up of sub-program/surface finishing Message of notification
;
End of command program O119
CHARMILLES 140 000 615/E/04.05.2004
Consultation of e-mails can be done by connection to Internet. At the end of the machining job, the screen page of the Internet Browser will show the following list: Machine ---------------------------FI921004 FI921004 FI921004 FI921004 FI921004
Time ----------------------------14:12:00 14:27:00 14:34:00 14:39:00 14:39:00
Message -----------------------------Start 119 End roughing End finishing Attachment End 119
Received ------------------------14:12:10 14:27:10 14:34:10 14:39:10 14:39:20
The interest of this list is twofold: - automatic production of the execution protocol - possibility of retrieving data on productivity: because each message includes the time the event occurred, it is possible to deduce the duration of each pass: Roughing: 15.0 min. Finishing 7.0 min. Surface finishing: 5.0 min.
(= 27:00 √ 12:00) (= 34:00 √ 27:00) (= 39:00 √ 34:00)
Routine maintenance of e-ConnecT Periodic purging of directories • All the messages transmitted by e-ConnecT are saved in the local directory Sent itemsª. To avoid overflow, it is necessary to purge the contents of this directory periodically, for example by eliminating all e-mails that have been there for over 2 weeks. ∫
Selection: Screen page e-ConnecT √ Selection button Windows messaging => Local folders => Sent items • Certain e-mail/SMS converters can send back to the mail account of the ISP server some messages acknowledging conversion. These acknowledgements will be recorded in the Inboxª (local directory) of the messaging. In this case, this Inbox directory must also be purged periodically. ∫
Back-up copies To facilitate restoration of the normal situation when a problem has occurred, it is recommended to make back-up copies of the 2 files below at regular intervals (for example once a week): C:\Program Files\WindowsNT\WindowsMessaging\eConnecT: mailbox.pst and mailbox.pab
CHARMILLES 140 000 615/E/04.05.2004
e-ConnecT
11
Part 2: Installation of the e-ConnecT option
Important information 1.
e-ConnecT is a software option whose installation requires knowledge of an Options code transmitted by Charmilles Technologies S.A.
2.
This description of the installation procedure only concerns those persons carrying out the initial installation of the option, or subsequent modifications to the configuration, such as: change of Internet Services Provider (ISP). This procedure does not concern the users (SMS recipients), so they do not need to consult this second part.
12
e-ConnecT
CHARMILLES 140 000 615/E/04.05.2004
Components used The transmission of the information goes through the following stages: - Following a significant event, the e-ConnecT application of the ROBOFIL machine generates a message - This message is transmitted by one or several Internet e-mails - Each e-mail is processed according to its type: - either: recording in a letterbox for consultation later - or: conversion into SMS format and notification to a recipient - or: recording and SMS message ROBOFIL machine
- 3 software modules - e-ConnecT - Mail Server - Windows Messaging
generation of messages to be notified establishment of the connection and sending of e-mails management of recipients and follow-up of e-mails
- output port (serial line) Modem e-mail Internet - telephone number - subscription contract - Internet e-mail address Conversion --> SMS - subscription contract - Internet e-mail address SMS Recipient - mobile telephone - telephone number The number and type of e-mails and the designation of recipients is entirely parameterized within e-ConnecT on the console of the ROBOFIL machine. This parameterization can be modified subsequently. The approach used makes use of well proven are widely distributed standard communication components (hardware and software). Some of these items are included in the e-ConnecT option, and others are to be provided by the customer according to the local context.
CHARMILLES 140 000 615/E/04.05.2004
e-ConnecT
13
Components included in the e-ConnecT option Among the items mentioned in the diagram of the previous page, the following are included in the Charmilles e-ConnecT option: - the three software modules - e-ConnecT application module developed by Charmilles. It establishes the relationship with the progress of machining so as to detect the significant events and to activate the generation of messages. It also records these events in an internal file (Log File). - Mail Server module whose purpose is to define and manage the Internet connection and send the e-mails. It uses among others the following 2 items, which will be parameterized when the option is placed in service: RAS = Remote Access Services: setting up of a connection via modem DUN = Dial-Up Network: parameterization of a connection to a provider of Internet access (ISP) via modem - Windows Messaging application of Windows NT™ used for managing e-mails, in particular for: - managing the list of recipients (Address Book) - parameterizing the processing of e-mails - local follow-up of the sending of e-mails (Outbox and Sent Items directories) - the communication port (asynchronous serial line)
Components provided by the customer To supplement the above, the user shall provide the other items required, namely: - Equipment: - a modem with connecting cables - a telephone line for local calls - Internet - subscription to an Internet access provider (Internet Services Provider, ISP) - e-mail service - e-mail/SMS conversion service - Mobile telephony - mobile phone set - SMS subscription
These items are not required if immediate notification by SMS is not desired!
The installation procedure below will ensure proper operation of the link.
14
e-ConnecT
CHARMILLES 140 000 615/E/04.05.2004
Remarks concerning the choice of components Analog modem -
External model V90 √ 56 Kbps Serial line cable: male sub D 9 female sub D 9 Telephone cable: RJ11 / RJ11 (with adaptor if necessary)
RJ11
Germany
Switzerland
France
Belgium
- Connectors: - 4-point connector RJ11: telephone line - Sub D 9 point connector: serial line - Male jack: external power supply
Internet access The subscription contracts will give the parameters required for the initial configuration of the link: Contract
Parameters
Access to the network
telephone number login password
e-mail service
name of SMTP server adress login password
e-mail/SMS converter
e-mail address format required for the e-mails
Important notes concerning the e-mail/SMS converter - Subscriptions to this service can be contracted with: - either an Internet access provider - or with another provider through a separate contract - The converter determines the format of the e-mails it receives for conversion! (see also Windows Messaging module page 9)
Mobile telephony Mobile phone set
CHARMILLES 140 000 615/E/04.05.2004
telephone number (recipient)
e-ConnecT
15
Installation of the option: general principles This installation procedure consists of 5 stages presented in broad outline hereunder, and described in detail on pages 18 to 33. Although the manipulations are not too complex, a certain familiarity with Windows NT™ is necessary.
Stage 1: Installation of the modem and its Driver
(see page 19)
Purpose: Setting up the output link - connection of the modem - removal of the existing Driver - replacement by the Driver corresponding to the modem selected - parameterization of the new Driver - incorporation of the new Driver by restarting Windows NT™
Stage 2: Dial-Up Network (DUN) module
(see page 24)
Purpose: Parameterization of the connection to the ISP Specify the connection: - name of the ISP (Internet Services Provider) - telephone number
Stage 3: Module e-ConnecT
(see page 27)
Purpose: Activation of the e-ConnecT option by the authorization code of 14 characters transmitted by Charmilles Initial selection, among the 5 types of events, of those that will be taken into consideration by the e-ConnecT application. This screen page also serves to activate the two following modules by means of two buttons: Mail Server and Windows Messaging
Stage 4: Mail Server module
(see page 28)
Purpose: Configuration of the link with the Internet server Fill out the data concerning the connection:
16
- for the ISP:
identification of the ISP and the telephone number (specified in DUN), the login/password
- for the Letterbox:
the name of the ROBOFIL machine, the Internet address, the login/password
e-ConnecT
CHARMILLES 140 000 615/E/04.05.2004
Stage 5: Windows Messaging / Address Book module
(see page 30)
Purpose: While stages 1 to 4 served to set up the means of transmission, stage 5 uses the Address Book to define the recipients, and the content and format of the communication: Recipients Display name: Recipient»s name in Address Book E-mail address: Internet address to reach the converter E-mail type: SMTP Content and format Type of messages accepted (1 to 5) Title of message - The entries of the Address Book are customized when the option is placed in service, and their content will be adjusted later in the light of needs (addition, modification, deletion) - The Address Book constitutes the true instrument for running e-ConnecT: - when an event occurs (e.g.: Program Start, type 1), the e-ConnecT application examines the parameters of all the recipients defined in the Address Book - For each recipient, the application checks whether this type of event is selected and it activates, according to the parameters specified, the process of sending the e-mails <- - - - - - - ROBOFIL machine - - - - - - - > 1 event --> e-ConnecT application + Address Book
CHARMILLES 140 000 615/E/04.05.2004
--->
< - tel. network ->
< - - Internet - - >
1 e-mail
Mailbox and / or SMS conversion --->
--->
< - Mobile - > 1 SMS or several SMS
e-ConnecT
17
Installation of the option: procedure in detail Preliminary action e-ConnecT is a software option whose right to be used is issued by Charmilles. Before starting the installation procedure, check that the authorization √ evidenced by a code of 14 characters √ has duly been acquired for the ROBOFIL machine in question. The installation is done during the startup procedure of the numerical control: • Implement the startup procedure (Logon) • When the screen page Windows-NT™ is displayed, interrupt the normal process by pressing the Shift key • The Logon procedure is stopped • Select the account Setupª to start the installation of e-ConnecT (stage 1) ∫
Procedure The pages that follow contain a detailed description of the operations to be carried out: •The left hand column (ACTIONS) gives the succession of instructions to be entered on the keyboard of the numerical control. •The right hand column (DISPLAY) presents the screen pages and windows displayed on the machine console as you go along. • The data that has to be entered by the user in the course of the dialog are shown in bold characters. (Most of this information comes from contracts regulating the Internet connection and the SMS service.) • LThe dialog is conducted entirely in english.
18
e-ConnecT
CHARMILLES 140 000 615/E/04.05.2004
1. Installation of the modem and its Driver Purpose: Establish the output link, replacing the existing Driver by the Driver of the modem chosen by the user. Verify the parameterization of the output port. Before doing this, connect the new modem (refer to the supplier»s instructions for use) ACTIONS
DISPLAY
From the Windows-NT™ office, select: Network neighbourhood, Keyboard key Expandª (at bottom right, to the left of the Ctrl key), ∫
then select: Properties =>
Network
Tab: Services Select: Remote Access Service then the button: Properties =>
Remote Accesss Setup
The driver currently installed is selected. To remove it:
button: Remove <= => button: Yes
The display of the old driver disappears. To install the new driver: button Add =>
Add RAS Device (next page)
CHARMILLES 140 000 615/E/04.05.2004
e-ConnecT
19
ACTIONS
DISPLAY
Button: Install Modem =>
Install New Modem (Wizard: start )
Tick the box ≈Don»t detect my modem º∆, then the button: Next =>
Install New Modem Manufacturers - Models
The files of the new modem are generally distributed on an installation disk Button: Have Disk =>
Install From Disk
Insert the installation disk supplied with the modem, specify the name of the support, for example F:\, then the button: Browse =>
Locate File (next page)
20
e-ConnecT
CHARMILLES 140 000 615/E/04.05.2004
ACTIONS
DISPLAY
Using the Browser, locate in the list displayed the directory corresponding to the Operating system (normally: Win95-98), then the button: Open =>
Locate File
Select the installation file for the modem selected, extension .inf , then the key: Open =>
Install From Disk
=>
Install New Modem Models
Button: OK
Select in the displayed list the name of the chosen model of modem, then the button: Next =>
Install New Modem (next page)
CHARMILLES 140 000 615/E/04.05.2004
e-ConnecT
21
ACTIONS
DISPLAY
Select the communication port: Choice: Selected ports Selection: COM2 then the button: Next =>
Install New Modem (Wizard: end )
The installation of the driver continues until the message end of sequence is displayed Button: Finish =>
Add RAS Device RAS Capable Device
Select in the box RAS Capable Device the correct modem allocated to port COM2, then the button: OK =>
Remote Access Setup Port Device Type √
√
Check that the new modem is displayed correctly in the box Port √ Device √ Type Button: Configure =>
Configure Port Usage (next page)
22
e-ConnecT
CHARMILLES 140 000 615/E/04.05.2004
ACTIONS
DISPLAY
Check: Dial out only (incoming calls not allowed!) then the button: OK =>
Remote Access Setup Port Device Type √
√
Button: Continue =>
Network
Button: Close
The link operations (bindings) of the new Driver are executed. The installation of the new Driver is now completed. Remove the installation disk. It is now necessary to restart so as to take the new Driver into account =>
Network Settings Change
Button: Yes
The system is now shut down automatically, and then restarted. As previously, interrupt the starting by means of the Shift key when the screen page of Windows-NT™ is displayed so as to execute stage 2 of the installation of e-ConnecT.
CHARMILLES 140 000 615/E/04.05.2004
e-ConnecT
23
2. Dial-Up Network (DUN) module Purpose: Parameterize the connection to the ISP by creating an entry in the Phonebook In this case, no change of account after the interruption! The rest of the installation is done under the Charmillesª account. ∫
ACTIONS
DISPLAY
From the Windows-NT™ office, select: Start Programs Accessories Dial-Up Networking =>
Dial-Up Networking
Button: New =>
New Phonebook Entry (Wizard: start )
If the Phonebook is empty º., Instead of the display of the screen Dial-Up Networking, the question above is asked. Answer: OK . =>
New Phonebook Entry
Specify the name of the ISP then the button: Next =>
24
Server
e-ConnecT
(next page)
CHARMILLES 140 000 615/E/04.05.2004
ACTIONS
DISPLAY
Tick the 2 boxes: I am calling the Internet Send my plain text password º then the button: Next =>
Phone Number
Enter the telephone number (local line) then the button: Next =>
New Phonebook Entry (Wizard: end )
Button: Finish =>
(1) Dial-Up Networking
CHARMILLES 140 000 615/E/04.05.2004
(next page)
e-ConnecT
25
ACTIONS
DISPLAY
- The button New is used for creating a new entry - The button More is used for editing the entry currently selected (Phonebook entry to dial) Button: More Selection: Edit Entry and Modem properties =>
Edit Phonebook Entry Basic
Specify in Dial Using the Communication port to be used (created in stage 1) then the tab: Security =>
Select:
Edit Phonebook Entry Security
Accept any authentication including clear text
Validate the selection with the button: OK =>
Dial-Up Networking (screen page above)
Button: Close =>
Windows NT™ Office
To complete the start procedure: - press Ctrl / Alt / Delete to display a selection grid - select Logoff , click on OK: normal starting continues.
26
e-ConnecT
CHARMILLES 140 000 615/E/04.05.2004
3. e-ConnecT module Activation of the option - Options code After execution of stage 2, the entire starting procedure is completed, and the numerical control is in its normal operational environment. Applying the procedure described in page 0.6. The activation indicator is displayed in the box e-ConnecT. The option can now be used.
6479
Utilization of the screen page e-ConnecT Purpose: Define from among the 5 types of events those to be taken into consideration by the e-ConnecT application • Select the screen page: EXE √ Service √ Config.Machine √ e-ConnecT This page contains the following elements: Selection of the types of event that are to be the subject of a notification. Tick the types of event to be transmitted. - Take due note of the fact that if a given box is not ticked, this will block notification of all the events of this type for all users! Connection bar: displays the status of the connection - Blank: no connection established. - Partly filled: connection now being established (duration 30 to 40 seconds). - Full: communication in progress.
Windows Messaging Mail server
6481
Activation buttons of the two modules for putting into service: - Mail server => stage 4 (page 28) - Windows Messaging => stage 5 (page 30)
CHARMILLES 140 000 615/E/04.05.2004
e-ConnecT
27
4. Mail Server module Purpose: Configure the link with the Internet Services Provider (ISP) and the mail service ACTIONS
=>
DISPLAY
e-ConnecT
Button: Mail Server =>
General Log Window
At the beginning, Log Window contains the starting time of the connection and the 4 timeout parameters that have been set Tab: Connection =>
Connection
In the field Connection, Select the ISP specified in DUN Complete the fields: Login Password
Login of the ISP Password of the ISP
Verify: Phone n°
telephone No. of the ISP
Enter in: Network Cards NdisWanAdapter tick the option:
Dun
then the button:
Record
Tabt: Mailbox =>
28
Mailbox
e-ConnecT
(next page)
CHARMILLES 140 000 615/E/04.05.2004
ACTIONS
DISPLAY
Complete the fields: UsualName Name of the ROBOFIL machine (for example: FI921004) Email e-mail address Login e-mail login Password e-mail password then the button: Record Tab: Server =>
Enter in Smtp Srv
Server
Name of the SMTP e-mail server
then the button: Record Tab: Smtp Logs =>
Smtp Logs
Verify the presentation of the local folders: FIXXXXXX Local folders
Return to the initial tab General, =>
General
then the button: Hide =>
e-ConnecT
CHARMILLES 140 000 615/E/04.05.2004
e-ConnecT
29
5. Windo Windows ws Mess Messag agin ing g / Addr Address ess Book Book mod modul ule e Purpose: Define by means means of the Address Book the Book the processing mode of the e-mails: - specifying specifying the the recipient recipientss - specifying specifying the operations operations to be performed performed (recording, format for SMS conversion and notification). ACTIONS =>
DISPLAY
e-ConnecT
Button: Windows Messaging =>
Windows Messaging
(Display of the local folders used for sending e-mails.) Click on the icon: Address Book =>
Address Book
At the start, all that exists are models of recipients, which do not react to any type type of event event (because MessageType_id = mid0 in Notes). It is recommended to create the contents of the Notes page of a new recipient by copying and customizing an existing model In the list proposed: Select the model with the greatest similarity then select the tab: Notes =>
Modelª Modelª Properties
∫
Select the entire text, then copy it copy it (Ctrl C) then the button: Cancel =>
Return to Address Book
Click on the icon: New Entry (1st on the left) =>
30
New Entry
e-ConnecT
(next page)
CHARMILLES 140 000 615/E/04.05.2004
ACTIONS
DISPLAY
Sele Select ct:: Entr Entryy type type = Oth Other er add addre ress ss Tic Tick:
In the Pers ersonal Addr ddress Boo Book then the button: OK =>
New Other Address Properties New Address
Complete the descriptive fields of the SMS recipient according to the format required by the e-mail/ SMS converter: - Disp Displa layy Nam Namee - E-ma E-mailil addr addres esss - E-ma E-mailil type type
Name of recipient e-mail address SMTP
Deselect the box: Always send to this recipient º then select the tab: Notes =>
New Other Address Properties Notes
Paste the Paste the contents of the model copied previously (Ctrl V)
This model will serve as the basis for the customizing that customizing that has to be done in compliance with the specifications of the chosen e-mail/SMS converter.
CHARMILLES 140 000 615/E/04.05.2004
e-ConnecT
31
Customizing the contents of the Notes tab The tab Notes contains a form made up of various parameters: - 3 keywords that keywords that will be interpreted by the e-ConnecT application for conditioning the processing of the e-mail: • MessageType_id: MessageType_id: filters the types of e-mail accepted mid1: mid2: mid3: mid4: mid5: id5: all: mid0: mid0:
event of type 1 Start program event of type 2 End program event of of type 3 Stop on on error (1 (1st bl blocking er error) event of type 4 Programmed stop (M00, M01) event ent ofe type 5 Pro Programm ammed notific ificat atiion (G13, G13,EECN º) events of all types no events events selec selected ted (addr (address ess inac inactiv tive) e)
• Subject: Subject: inserts a title. • Body: Body: passes on some information. - : : insertion by e-ConnecT of the content of the message to be notified - comments (starting comments (starting with //): will be ignored by e-ConnecT, but serve to describe the operating mode of the form Only the digits (0 (0 to 9), 9), the letters (a (a to z upper or lower case) case ) and _ are accepted ACTIONS
DISPLAY
Update the contents of Notes as per the characteristics of the e-mail/SMS conversion format. For example, in the case opposite: MessageType_id: mid1,mid3 selects events of type 1 and 3 will be found both in the title (Subject:) and in the body of the message (Body:) // A comment serves to explain the utilization of the content of Notes then the button: OK =>
Address Book
The Address Book is now supplemented with the newly created address. It is now no longer a model, but a real address!
32
e-ConnecT
CHARMILLES 140 000 615/E/04.05.2004
This marks the completion of the addition of a new recipient. Close Address Book =>
Windows Messaging
then close Windows Messaging =>
e-ConnecT
Comment on the use of data contained in Notes When a significant event of type x occurs, it is confronted with the following types of filtering: Overall definition of the screen page e-ConnecT - type x event deselected => event ignored by all recipients - type x event selected => e-ConnecT reviews each recipient defined in the Address Book. Keyword MessageType_id: in Notes - type x event unspecified => recipient ignored - type x event specified (midx) => the content of the entry is examined: an e-mail is sent to the Internet server Keyword Subject: and Body: in Notes - undefined => the e-mail is recorded in a letterbox (no SMS conversion and no notification) - defined => SMS conversion and notification (no recording of the e-mail) It is be possible to obtain a recording of the e-mail and SMS notification of one and the same event by creating two distinct recipients in the Address Book. The e-mail => SMS converters offer a wide variety of possibilities. By way of example, there are converters whose format makes it possible to record several users in a single address of the Address Book. In this case a single e-mail will, after conversion, result in the sending of several SMS messages.
Test of operation • Enter in mode MDI the ISO instruction for sending a message: G13(ECN,TesteConnecT) then press Start • Activate the screen page e-ConnecT Observe the execution of the connection • Using the button, activate le Mail Server, Observe in Log Window the connection activity • Check that the message ∫TesteConnecTª has been received on your mobile telephone
CHARMILLES 140 000 615/E/04.05.2004
e-ConnecT
33
Dealing with anomalies Action to be taken √
Follow-up of messages on the ROBOFIL machine As explained in the principle of operation, message sending relies on a chain of components, only some of which are located in the ROBOFIL machine, the others being selected by the user from the range of products and services linked to Internet. Because of this, in the event of non-transmission, the investigation must be directed to every link in the chain. The follow-up and investigation tools specific to e-ConnecT are as follows: - screen page e-ConnecT / connection bar Blank: Partly full: Full:
no connection established connection now being established (duration 30 to 40 seconds) communication in progress
When a part-program has been selected, the Service screen pages are no longer accessible. The screen e-ConnecT can then be activated directly from EXE, in particular so as to allow monitoring of the connection / disconnection activity. - screen page Mail Server General / indicators and Log Window √
there are 4 indicators: - number of events detected and not yet processed by e-ConnecT - number of e-mails prepared and due to be sent - display of the time remaining for executing the current operation - No: before 1st e-mail is sent Yes: as soon as 1st e-mail is sent
Here Outbox Timeout Delivery
Log Window contains at the beginning: - the time when the connection started - the 4 timeout parameters that have been set
- Start time - Timeouts
Log Window records all the communication activities as they take place. These instruments make it possible to trace everything that happens on the ROBOFIL machine, from the triggering event through to the sending of the corresponding e-mail.
Follow-up of messages outside the ROBOFIL machine The follow-up of the messages within the Internet network and the SMS service will be done within the framework of the contracts signed with the service providers concerned (ISP √ e-mail/SMS converter). If the e-mail/SMS converter that you are using sends messages of acknowledgement of conversion back to the e-mail account of the chosen ISP, the Inbox directory of this messaging must be periodically purged.
34
e-ConnecT
CHARMILLES 140 000 615/E/04.05.2004
Operational security: standby channel The flexibility of use of e-ConnecT and the exploiting of the standard distribution channels of Internet open up many possibilities of configuration and utilization. For example, in cases where high reliability of transmission is required, it is possible to prepare for a critical recipient a second standby channel. This backup channel will run via a different ISP, by means of another DUN interface and an inactive entry in the Address Book. This alternative channel can be activated in a few minutes if the main channel is interrupted, by editing the parameters of the screen page Notes of the Address Book, and by switching over to the second DUN channel.
Change of Internet Service Provider (ISP) In cases where the access provider changes, it will be necessary to specify the relevant data to the new provider and to the new Internet address, in other words go through stages 2 (Dial Up Network) and 4 (Mail Server) of the installation procedure. If the e-mail/SMS converter stays unchanged, there is no need to go through stage 5 (Address Book)
Change of e-mail/SMS converter In cases where the e-mail/SMS converter changes, it will be necessary to go through stage 5 (Windows Messaging / Address Book) of the installation procedure, i.e. redefine all the addresses of existing recipients in the new required format.
CHARMILLES 140 000 615/E/04.05.2004
e-ConnecT
35
Extension for taper angle up to 45° with threading (kit n° 135007673)
Ro o i 240•440 (Robofil 240cc•440cc)
Introduction
3
Contents of the option
3
Assembling Example of utilization
CHARMILLES 140 000 630/E/05.02.2003
3 4
Table of contents
1
2
Extension for taper angle up to 45° with threading
CHARMILLES 140 000 630/E/05.02.2003
Introduction This option makes it possible to produce parts having taper angles up to 45°, with automatic threading in the vertical position.
Contents of the option 135007673
This kit with the number contains 8 elements:
Upper head :
Reference :
(1) (2) (3) (4) (5) (6)
135007684 109410027 200542916 200542384 104490300 100447011
1 top nut 1 O-ring seal 1 extension tube 1 threading nozzle D 3.4mm 1 injection nozzle D 16mm 1 skirt nut
(2) (3) (1) (9) (4)
The upper guide of diameter 0.25 (9) supplied as standard with the machine is also used in the assembling.
6477a
Lower head (7) 1 injection nozzle (8) 1 wire guide assembly
135005189 204339850
large taper diameter 0.25
Assembling • Place the O-ring seal (2) in its housing on the top nut (1) • Place the threading nozzle (4), the wire guide (9) and the extension tube (3) in the top nut (1), then screw the nut onto the upper head • Fix the injection nozzle (5) by means of the skirt nut (6) • Mount the lower wire guide assembly (8) of the kit • Mount the lower nozzle (7) of the kit
space of 2 mm
(6) skirt nut (5)nozzle Æ 16 mm
space of 0.25 mm (7) lower nozzle (8) lower wire guide
• There must be a space of 2 mm between the upper skirt nut and the part
5363a
• There must be a space of 0.25 mm between the lower injection nozzle and the part
CHARMILLES 140 000 630/E/05.02.2003
Extension for taper angle up to 45° with threading
3
Example of utilization Part:
Wire:
Select:
Steel Height 40 mm
Soft brass Diameter 0.25 mm 400 N/mm2 A 35%
or
Zinc-coated soft brass Diameter 0.25 mm 420 N/mm2 A 30%
Technology: LR25A.TEC or ULR25A.TEC Setting: roughing only (no finishing or surface finishing) - ROBOFIL 240 √ 440:
setting E24 modified as follows: B = 12 WB = 0.5 FF = 70
- ROBOFIL 240cc √ 440cc:
setting E2 modified as follows: B = 12 WB = 0.5 FF = 50
Offset: carry out a test to measure the actual material removal and thus determine the offset to be used ZID: carry out the tests recommended in chapter 2 ≈Information on technologies and machining∆ for taper machining (angle >8°, without Taper Expert option). As indicated, note the results and modify the parameters ZID and AXOZ accordingly (screen page EXE √ Measuring √ Guides Set UP)
Result:
Dimension tolerance: 0.025 mm (on the radius) Surface finish: CH29 / Ra2.8
Note:
By setting parameter A at 0.6 it is possible to obtain a surface finish of CH27 / Ra2.2
4
Extension for taper angle up to 45° with threading
CHARMILLES 140 000 630/E/05.02.2003
Large Reels
(ROBOFIL 240•440) (ROBOFIL 240cc•440cc) (ROBOFIL 380•X90)
Introduction
3
ROBOFIL 240.440 / 240cc.440cc Presentation ......................................................................................... Placing the wire in position .....................................................................
4 4 4
ROBOFIL 390.690 Presentation ......................................................................................... Placing the wire in position ..................................................................... Adjusting the wire tension .......................................................................
6 6 6 6
CHARMILLES 140 000 402/E/04.05.2004
Table of contents
1
2
Table of contents
CHARMILLES 140 000 402/E/04.05.2004
Introduction The purpose of the Large Reels option is to increase the running time of a ROBOFIL machine thanks to high capacity reels : ROBOFIL 390.690 :
16 kg
ROBOFIL 240.440 / 240cc.440cc :
16 kg or 25 kg
In this case, instead of being mounted on the front panel, the reel is placed on an unspooling bracket fixed to the rear of the machine. The wire is brought to the front panel by means of a guidance system (tubes and return pulleys). For ROBOFIL X40 models there is a variant of the Large Reels option compatible with the QCRw, 3R and Erowa robots. This combination of options makes it possible to exploit to the full the capacity for long running times of the machine (large wire capacity, automatic changing of workpieces).
CHARMILLES 140 000 402/E/04.05.2004
Large Reels
3
ROBOFIL 240•440 / 240cc•440cc Presentation The Large Reels support is placed in a cabinet fixed on the left side at the rear of the machine.
135 005 387c
Placing the wire in position Cabinet: Follow the installation diagram on the bottom of the cabinet. Guidance system: - runs the wire from the unspooler to the front panel - includes an articulated arm made up of 2 telescopic guide tubes and 3 pulleys - the first part is fixed and linked to the unspooler, while the second part is mobile and associated with the movements of the axes. Wire entry : ferrule
Mobile pulley
Wire entry : nut
Return pulley Protection
Protection
Fast pulley
4
Large Reels
135 005 388e
CHARMILLES 140 000 402/E/04.05.2004
To pass the wire through the guidance system : • fix the end of the wire to Spring A supplied with the kit • put the spring into the outlet passageway B of the cabinet • push it until the wire appears at the other end.
6482
Front panel : The wire reaches a return pulley located at the position of the normal reel supports. From here onwards, follow the usual path indicated on the front panel.
CHARMILLES 140 000 402/E/04.05.2004
Large Reels
5
ROBOFIL 390•690 Presentation The option includes the following 2 elements : - Unspooling panel with rocker arm - Reel support. These 2 elements are fixed on the Y axis bracket inside the cabin. As a result of this the reel accompanies the movements of the heads along X and Y.
130 006 276
130 006 301
Placing the wire in position Mounting the reel : Unscrew the knurled fastening nut, put the reel onto the shaft and retighten the fastening nut. Wire path on the support : - reel - upper pulley - intermediate pulley - rocker arm pulley - return pulley towards front panel - guide tube Front panel : The wire reaches a return pulley located at the position of the normal reel supports. From here onwards, follow the usual path indicated on the front panel.
Adjusting the wire tension The tension of the wire coming off the reel is adjusted by means of the powder brake mounted on the same shaft as the reel. Using the knurled button at the end of the shaft, set the wire tension manually at a value of 400-500 g for a wire of Æ 0.25 mm (check by means of a tensionmeter). 130 006 301
6
Large Reels
CHARMILLES 140 000 402/E/04.05.2004
Auxiliary M functions
(ROBOFIL 240•440) (ROBOFIL 240cc•440cc) (ROBOFIL 380•X90)
Introduction
3
Description of functions
4
CHARMILLES 140 000 635/E/04.05.2004
Table of contents
1
2
Table of contents
CHARMILLES 140 000 635/E/04.05.2004
Introduction The extended M functions make it possible to run or synchronize simple external systems with the ROBOFIL machine. The interface consists of 8 binary input-output signals numbered 1 to 8 (for their location and electrical characteristics, refer to the Maintenance Manual). 6 types of function can be executed: - 0 SET of the output signal (setting to 1) - 1 RESET of the output signal (setting to 0) - 2 PULSE on the output signal - 3 ACK (acknowledge) of the output signal through wait for input signal - 4 WAIT for presence of input signal - 5 WAIT for absence of input signal The commands are performed through an ISO program by means of the M instructions according to the format M 1 x y (M101 to M158) where x represents the type of function (0 to 5) and y represents the signal number (1 to 8). Example:
M105 M115
SET RESET
CHARMILLES 140 000 635/E/04.05.2004
of signal No. 5 of signal No. 5
Auxiliary M functions
3
Description des fonctions SET
M101 to M108
Setting to 1 or maintaining at 1 of the outp ut signal.
or Output1
RESET
M111 to M118
Setting to 0 or maintaining at 0 of the outp ut signal.
or Output1
Execution of the program is resumed immediately after execution of the SET and RESET functions.
IMPULSION M121 to M128 Setting to 1 or maintaining at 1 of the output signal over a calibrated duration. By parameterization it is possible to: - set the pulse duration separately for each signal 1 to 8 (duration between 0 and 32767 ms). - specify a resumption of program: at the end of the pulse (fig. a) or immediately (fig. b).
4
Auxiliary M functions
Output1 Pulse duration
Pulse duration
Pulse duration
Pulse duration
Output1
CHARMILLES 140 000 635/E/04.05.2004
ACK M131 to M138 This instruction causes the output signal to be set to 1 or maintained at 1. On detection of the ACK on the input signal, the output signal is set to 0.
Output1 Input1 Maximum time check
Maximum time check
According to parameterization: - the program is resumed on the appearance or disappearance of the ACK signal. - It is possible to indicate as an anomaly (error message) the presence of the ACK signal while the instruction M13y is being issued. - the ACK signal can be a level or the detection of a positive edge. - it is possible to assign a maximum time check (adjusted separately for each signal 1 to 8 between 1 and 1500 s) beyond which an error message will be emitted. A duration 0 cancels this check.
WAIT for presence M141 to M148 - When an instruction M14y is issued, the ISO program is suspended until the presence (level 1) of the input signal y. WAIT for absence M151 to M158 - When an instruction M15y is issued, the ISO program is suspended until the absence (level 0) of the input signal y. For the two wait functions: - If the input signal is already at the expected level, the program resumes immediately. - It is possible to assign a maximum time check (adjusted separately for each signal 1 to 8 between 1 and 1500 s) beyond which an error message will be emitted.A duration 0 cancels this check. Parameterization can be used to adapt the behavior of the auxiliary M functions to specific needs, for example: - adjustment of the duration of pulses - adjustment of the duration of monitoring of the wait - type of ACK signal (continuous or positive edge) - switching of input-output signals to reverse logic - maintaining at 0 or setting to 0 of the outputs according to the machine status (RESET, Suspension, Energy Saving, Emergency stop, Alarm, etc.) - execution or ignoring of extended M functions in DRY RUN, RESTART, etc. An initial parameterization is done during installation by the Charmilles Technologies Maintenance Service. Subsequent modifications can be carried out with the help of the information contained in the Maintenance Manual.
CHARMILLES 140 000 635/E/04.05.2004
Auxiliary M functions
5
Option for machining (Robofil 380•X90) with wire Æ 0.10 mm (Robofil 240SL•440SL) (Robofil 240cc•440cc) Introduction
3
ROBOFIL 380 . X90
5
Contents of the option
5
Installation Checking the brake calibration ................................................................ Wire feed ........................................................................................... Upper head ......................................................................................... Lower head ......................................................................................... Installing the SW10A wire reel √ Threading the wire ...................................
6 6 6 6 7 8
Checks before utilization
8
ROBOFIL 240SL•440SL - ROBOFIL 240cc•440cc
9
Contents of the option
9
Mounting the option Unspooling belt .................................................................................... Configuration of the upper head .............................................................. Configuration of the lower head .............................................................. Evacuation zone ...................................................................................
10 10 10 11 12
Manual positioning of the wire Thermal cutting ..................................................................................... Passing the wire through the upper head ................................................... Threading in the lower head ...................................................................
13 13 13 14
CHARMILLES 140 000 640/E/23.06.2004
Table of contents
1
2
Table of contents
CHARMILLES 140 000 640/E/23.06.2004
Introduction Machining with a wire of 0.1. mm diameter requires a certain level of experience. A special adaptation kit has been created for different machines. The contents and commissi oning of this kit are described in the following pages :
Machine
Kit No.
Pages
ROBOFIL 380 . X90
130 006 478
5 to 8
ROBOFIL 240SL . 440SL ROBOFIL 240cc . 440cc
135 010 212 135 010 213
9 to 14 9 to 14
CHARMILLES 140 000 640/E/23.06.2004
Option for machining with wire Æ 0.10 mm
3
4
Option for machining with wire Æ 0.10 mm
CHARMILLES 140 000 640/E/23.06.2004
ROBOFIL 380 . X90 When using a wire of 0.1. mm for the first time, certain precautions are needed concerning adjustments to the lower head (parallelism of the traction roller shafts). It is therefore recommended to call in the assistance of the CHARMILLES Customer Service when installing the kit. The procedure is described in the following pages.
Contents of the option Kit number : 130 006 478 Number 0 421 185 0 431 958 0 446 063 0 446 880 0 447 506 4 443 460 130 003 359
Quantity 1 1 1 1 1 1 2 1
140 000 593 140 000 594 140 000 595 140 000 596 140 000 597
CHARMILLES 140 000 640/E/23.06.2004
Description Cardboard packaging Threading nozzle 0.80 mm Wire reel SW10A TYPE K100 (2kg) Belt 400 x 20 Belt VL640 x 20 x 0.5 Set of wire guides 0.10 mm Pressure rollers Options∆ document - (French) - (English) - (German) - (Italian) - (Spanish)
≈
Option for machining with wire Æ 0.10 mm
5
Installation Checking the brake calibration Before commencing the installation: • Check the brake calibration with a normal wire of Æ 0.25 (The tensionmeter must have been checked beforehand with a wire of Æ 0.1 and a weight of 500g). • Readjust if necessary. 1848a
Wire feed • Replace the unspooling belt and the belt of the brake assembly with those supplied with the option (these are reserved exclusively for the use of Æ 0.1 mm wire).
6484
Upper head • Carry out the usual maintenance operations of the upper head. • Install the Æ 0.10 mm upper wire guide with the Æ 0.8 mm threading nozzle.
6485
6
Option for machining with wire Æ 0.10 mm
CHARMILLES 140 000 640/E/23.06.2004
Lower head Items of the kit to be mounted in the lower head 130 003 359 Pressure rollers 130 003 261 Deflector 109 202 311 Washers 109 042 089 Screws M5 x 25
6486
• Take off the cover. • Remove the two centering shafts.
6487
• Replace the two existing pressure rollers with the new smooth rollers of the kit. • Replace the pinions by the deflector (clearance between deflector and rollers: 0.05 mm). • Fix the deflector by means of the two M5 x 25 screws and the 2 washers from the kit. This arrangement can be kept for the other wire types and diameters!
• Install the Æ 0.10 mm lower wire guide. 6488
CHARMILLES 140 000 640/E/23.06.2004
Option for machining with wire Æ 0.10 mm
7
Installing the SW10A wire reel Threading the wire √
On the front panel (2-4-8 kg) : Box for mounting longitudinally. 130 004 959 Box For all machines, the wire is passed through the tubes without annealing, with the end of the wire folded over. To pass the wire through the upper and lower heads, wire annealing is mandatory just as with the other wire diameters. 6489
• Check the good stability of wire unspooling and the wire tension for the values of 350 and 500 g (keep the brake curve for Æ 0.25 mm wire). Do not forget to carry out the usual guides set up and nozzle adjust cycles! The maximum Z threading position ZMA For this wire diameter is 100 mm.
1848a
Checks before utilization • Use the Æ 0.7 self-adapting lower and upper nozzles. • Adjust the minimum upper injection flow rate so as to obtain a gentle trickle of water without pressure (1 to 2 l/min). • When using automatic threading, adjust the jet position with the UV threading setting. When restoring the machine to standard configuration, execute all the above operations in reverse order, and above all : - take care to put back the grooved roller on the right side spindle (fixed spindle) - set the pressure of the rollers at the second mark (normal pressure) - set parameter ZMA at its previous value.
8
Option for machining with wire Æ 0.10 mm
CHARMILLES 140 000 640/E/23.06.2004
ROBOFIL 240SL•440SL - ROBOFIL 240cc•440cc Contents of the option Kit number : 130 010 212 / 213 Quantity 2 1 1 1 1 1 2 1 2 4 1 1 1
Description Connections and extensions, obstructor Short fixing screws Plexiglas cover Upper head flat nozzle Upper head diffuser Upper head guide/nut (short) 0.8 mm threading nozzle Upper and lower 0.1 mm guides 0.1 mm lower head guide/nut Nitrided rollers Elevating washers Tungsten contact without slot Deflector for recovery box Reel of 0.1 mm SW10 wire
CHARMILLES 140 000 640/E/23.06.2004
Option for machining with wire Æ 0.10 mm
9
Mounting the option Unspooling belt • Mount the belt with the smooth side on the outside.
6574
Configuration of the upper head The rethreading block is eliminated (for the time being: no automatic rethreading for wires of 0.1 mm diameter). For this reason, the connecting pipes are fitted with extensions making it possible to reach the distributor block. • Use the short screws. Fix the obstructor on the disconnected rethreading cable. • Set parameter ATH at 0 (screen page EXE √ User Parameters). The Plexiglas cover must be mounted in the high position to permit evacuation of the dielectric fluid and allow cooling away from the contact zone.
Extensions
Plexiglas cover
6575
10
Option for machining with wire Æ 0.10 mm
CHARMILLES 140 000 640/E/23.06.2004
The standard nozzle is replaced by the flat nozzle equipped with the diffuser. The upper guide extension is removed, and the long nut is replaced by the short nut from the kit. • Mount the 0.8 mm threading nozzle and the 0.1 mm wire guide. Standard version
0.1 mm version
Upper chamber
Upper chamber
Guide
Guide Threading nozzle
Extension Standard nozzle
Diffuser Short nut
Long nut Diffuser
6576
Configuration of the lower head • Install the contact without slot from the kit (the slot may cause wire vibrations).
Slot 6577
• Mount the 0.1 mm wire guide and the guide nut from the kit; the latter contains an entry cone that is more flared out so as to facilitate the threading of thin wires.
6578
CHARMILLES 140 000 640/E/23.06.2004
Option for machining with wire Æ 0.10 mm
11
• Replace the standard drive rollers by nitrided rollers from the kit mounted with the elevating washers. Rollers
Washers 6579
• Modify the tension of the spring (distance A approx. 24 mm instead of the normal value of 22 mm).
6580
Evacuation zone •Install the deflector in the recovery box so as to spread out the strands of cut wire and to avoid the formation of a column.
12
Option for machining with wire Æ 0.10 mm
CHARMILLES 140 000 640/E/23.06.2004
Manual positioning of the wire For small diameter wires, follow the procedure below :
Thermal cutting The length of the ≈prepared∆ wire (i.e. drawn out and annealed) must be as short as possible. To achieve this, the fingers of the left hand holding the wire must be positioned as close as possible to the left contact. Since the break takes place at the level of the right contact, the length prepared is thus virtua lly the same as the distance between the 2 contacts.
Correct
Correct 6581
Passing the wire through the upper head • Switch on
upper contact retraction, wire unspooling, threading jet.
• Insert the end of the wire above the upper head until it is sucked in by the threading jet. • Allow the wire to move until it reaches the top of the lower head. With a correct length of prepared wire, the end of the wire does not reach the drive rollers and runs no risk of becoming bent.
6582
CHARMILLES 140 000 640/E/23.06.2004
Option for machining with wire Æ 0.10 mm
13
Threading in the lower head • At this moment, switch on the automatic threading
.
Threading comes to an end automatically. The wire is slowly and steadily pushed by the unspooling system. It is guided by the threading jet and conveyed by the suction jet between the drive rollers through to the entry tube of the chopper.
Important remarks! - It is necessary to have the machine correctly set up and adjusted. In particular, it can be useful to run the following 2 cycles : - Calibration of the wire speed. - Calibration of the brake. If they have not been performed recently during a normal maintenance operation (weekly or monthly). - Before starting actual machining, use a tensionmeter to check the wire tension for the values that will be used with the 0.1 mm wire. - When restoring the machine to standard configuration for wires of diameter greater than 0.10 mm, do not forget to carry out all the reverse operations with respect to those listed above !
14
Option for machining with wire Æ 0.10 mm
CHARMILLES 140 000 640/E/23.06.2004
Chapitre
External Robot option (ROBOFIL 240•440) (ROBOFIL 240cc•440cc) Introduction
3
Description of kit
3
Connection principles
4
Installation of the option
4
Direct control of the interface (M instructions)
5
Macro-instruction G912 Examples ............................................................................................ Principle for use of macro-instruction G912 ................................................
6 6 7
Resumption in the event of power supply failure or an incident
7
Use, upkeep, maintenance
7
CHARMILLES 140 000 802/E/17.06.2003
Table of contents
1
2
Table of contents
CHARMILLES 140 000 802/E/17.06.2003
Introduction The external Robot option allows a ROBOFIL X40 / X40cc machine to be equipped with a robot which will automatically load / unload pallets in the work space. Automatic availability of several successive parts allows the machine to function autonomously for extended periods, also enabling night and weekend working. The result is an increase in productivity and an increase in profitability. The connected external robot includes its own operating logic, which responds with a dialogue appropriate to the ROBOFIL machine instructions (M functions) to carry out part changes which are synchronised with the machining operations.
Description of kit The kit comprises the following elements : -
Automatic side door option Interface card (8-bit parallel) to the robot Connecting cables (internal to ROBOFIL machine) Extended M functions (software)
CHARMILLES 140 000 802/E/17.06.2003
External Robot option
3
Connection principles Connection of two elements is governed by the following rules :
The ROBOFIL machine includes the following elements : 1. parallel interface (8-bit) for transmission of binary control signals 2. Burndy 12-pin connector for connection of the emergency Stop 3. adaptation to EC and ISO standards for automation (multi-channel emergency Stop) 4. provision for safety elements controlled by the robot (door lock, switch, etc.) 5. anti-intrusion protection to EC and ISO standards The external robot must be fitted with the corresponding elements : 1. control cable for the 8-bit parallel interface 2. 12-way connecting cable for connection of emergency Stop 3. pneumatic monitoring and control of chuck(s) 4. safety elements controlled by the robot (door lock, switch, etc. and their wiring from the robot) 5. mechanical anti-intrusion protection to EC and ISO standards : between the ROBOFIL machine and the robot, there must be a 33 cm minimum space to allow possible intervention to be carried out via the automatic door (adjustments, maintenance, repair). A movable safety barrier must be fixed in front of this space to prevent any accident. Furthermore, the robot must be designed for connection to an EDM machine (earthing, anti-interference protection, protection against EMI, etc.).
Installation of the option Declaration of the external Robot option Apply the procedure described on page 0.6 : EXE page √ Service √ Machine configuration √ Options Specify the presence of options linked to robot use : - side door - type of robot : external Robot.
4
External Robot option
CHARMILLES 140 000 802/E/17.06.2003
Direct control of the interface (M instructions) ISO standard instructions M04 Opening of side door M05 Closure of side door M08 M09 M12 M13
Emptying + door opening Emptying + door opening : waiting Door closure + filling Door closure + filling : waiting Use of these instructions in MDI mode allows the operator to control the side door directly for emptying and refilling the tank.
Extended M functions M102 to 108 : M112 to 118 :
Selection of pallet number, p, with the aid of interface signals 2 to 8 (signals set to 1) 7 selection signals set to zero (p = 0) (p can thus take a value from 0 to 127)
M131 :
if p = 0
if p = 1 to 127
Activation of robot If pallet in place
No pallet
Unloading : return pallet in place to origin position
No action
Exchange : return pallet in place to origin position then loading of pallet p
Example : selection of pallet no. 21 Weight Selection --------------------------M102 1 1 M113 2 0 M104 4 1 M115 8 0 M106 16 1 M117 32 0 M118 64 0
CHARMILLES 140 000 802/E/17.06.2003
=> => => => => => =>
Loading of pallet p
1 0 4 0 16 0 0 ----------Code : p = 21
(port 2) (port 3) (port 4) (port 5) (port 6) (port 7) (port 8)
External Robot option
5
Macro-instruction G912 - To simplify programming, a macro-instruction G912 is made available to control the global execution of the robot»s operation cycles (loading √ exchange √ unloading). Syntax : G912 Tn
n = pallet number n=0 T must always be specified.
loading, exchange unloading
- Macro-instruction G912 must logically be inserted in a control program. The corresponding part-programs are then not modified by the use of a robot for putting a part in place. - By default, the sequence for execution of instruction G912 performs all the preparation actions before loading and return to normal after loading (emptying / refilling of tank, opening / closure of door).
Examples : Loading
G912 T3 (case where no pallet is in place in the ROBOFIL machine) This command selects pallet 3 and brings it into work position. The value specified for T (3 here) is stored by the robot as the later return position for the pallet. Execution of the sequence is entirely automatic : before resumptio n of the part-program machining instructions, prior conditions of use (door closure, refilling) are restored.
Exchange
G912 T3 (case where a pallet is already in the machine) Instruction G912 T3 proceeds with an exchange : - unloading sequence (described later) for the pallet in place to its position of origin - loading sequence for pallet 3 (described above).
Unloading
G912 T0 This command will be issued at the end of processing, by the ROBOFIL machine, of the pallet loaded by the G912 T3 instruction. Its effect will be to pick up the pallet again to return it to its position of origin, 3, in the robot»s store. After unloading, the automatic door remains in the open position.
6
External Robot option
CHARMILLES 140 000 802/E/17.06.2003
Principle for use of macro-instruction G912 0100 º.. G912 T3 M98 P110 º.. G912 T2 M98 P120 º.. G912 T0 º.. M30
! Control program ! Loading pallet 3 ! Pallet 3 part-program ! Exchange : return pallet 3, loading pallet 2 ! Pallet 2 part-program ! Pallet 2 return
Resumption in the event of power supply failure or an incident - The Auto-Restart device is capable of taking charge of the robot, as long as the latter is equipped with an Auto-Restart system. This means that the robot is treated as the whole of the ROBOFIL machine when there is a supply failure (automatic restart without any interruption of machining). - Any operational problem in the robot causes interruption of the current operation and the issue of a standard error message. - Pressing the F1 key automatically opens the electronic documentation, with a display of information relating to what is happening. - The majority of faults related to robot operation can arise from blockage of mechanical devices (door, axis, gripper, etc.) or collisions. - After analysis of the information and the context, the operator must try to deal with the problem and get back to a normal situation. - To be able to resume automatic execution via the Start button, it is necessary for the situation at the moment of interruption to have been set up again exactly. - In the event of loss of synchronisation or loss of control, the operator will manually reset all elements of the robot to their start position using the robot controls.
Use, upkeep, maintenance Comply with the requirements and recommendations of the documentation provided by the external robot supplier.
CHARMILLES 140 000 802/E/17.06.2003
External Robot option
7
Rotary Table
(ROBOFIL 240•440) (ROBOFIL 240cc•440cc) (ROBOFIL 380•X90)
Introduction
3
Principles of operation Taking the rotary axis references (point zero) .............................................. Display of the W axis position ................................................................ Manipulation using the screen ................................................................. Manipulation using the remote control ......................................................
4 4 4 4 6
Programming
7
Resumption in the event of power failure or other incidents
8
Installation of the software option
8
CHARMILLES 140 000 962/E/05.05.2004
Table of contents
1
2
Table of contents
CHARMILLES 140 000 962/E/05.05.2004
Introduction Rotary Table is an option making it possible to command with a program a rotation movement of 360° of the part being machined.
A
It is mounted on the standard table of the ROBOFIL machine. Its position can be raised by means of spacing blocks.
B
1685a
- The rotation can be along a horizontal axis (parallel to the X axis of the machine √ type A) or vertical (parallel to the Y axis of the machine √ type B). - The rotation is controlled by the numerical control as a movement of an axis called W axis. A movement instruction is expressed in degrees, and the positioning accuracy is of the order of a few thousandths of an angular degree (depending on the model √ see detailed specifications). - The rotation movements to position the part must be done when no machining is in progress and with no movement of the other axes XYUVZ. - The rotary unit can be fitted with: an automatic chuck (optional) used for fixing the part a brake (optional) used for immobilizing the part Notes : The mechanical mounting and the electrical, hydraulic and pneumatic connections of the option are described in separate documents. The software installation procedure is described in the last paragraph of this document. - The Rotary Table option is not compatible with the QCRw Robot option. - If the chuck equipping the rotary unit is of manual type, the Chuck option must not be declared during configuration of the rotary table.
CHARMILLES 140 000 962/E/05.05.2004
Rotary Table
3
Principles of operation Taking the rotary axis references (point zero) The taking of references, i.e. determining the zero point of the angular coordinates, is done during the initial installation. It does not need to be repeated subsequently, apart from special circumstances such as: - Loading of a new software version - Disconnection/reconnection of the table - Desire to change the point Zero of the axis Perform at least one complete rotation of the W axis Place the W axis in the position desired for the point Zero Select: EXE √ Manual √ References Press the Reset W button Switch off and then restart the machine
Display of the W axis position When the Rotary Table option has been installed, the display of the sixth axis W in all the screens makes it possible to know its position at any time (expressed in degrees, independently from the metric/inch conversion).
Manipulation using the screen Select the page EXE √ Manual. Axis rotation command Jog buttons W+ (clockwise) W- (counter-clockwise) The choices of speed SPD and increment INC also apply to these 2 buttons.
4
Rotary Table
CHARMILLES 140 000 962/E/05.05.2004
Gripping of the part Press the Chuck key => the chuck opens Present the part, press the Chuck key => the chuck closes, the part is gripped => the LED of the Chuck key lights up To release the part: press the key again The chuck opens, the part is freed, the LED goes out
Testing for presence of the part Press the Test key => the presence of the part is checked by a compressed air sensor => if the presence is confirmed, the LED of the Test key lights up
Immobilization of the part Press the Brake key => the part is immobilized => the LED of the Brake key lights up To free the movement of the part: press the key again. The brake is released, the part can move or be freed, the LED goes out
Activation of the remote control Press the RC key (remote control) => the remote control is activated in Rotary Table mode => the LED of the RC key lights up => the green light of the remote control activation key flashes. To cancel the use of the remote control, press the key again. The LED goes out, and the remote control activation key green light stops flashing
CHARMILLES 140 000 962/E/05.05.2004
Rotary Table
5
Manipulation using the remote control When the green light of the activation key is flashing, the 5 buttons on the remote control shown below are specially allocated to the control of the rotary table. Key 1 (top left) Counter-clockwise W axis rotation Key 2 (top center) Flashing Key 3 (top right) Clockwise W axis rotation Key 4 (left, below 1) Chuck open/close (red light on/red light off) Key 6 (right, below 3) Brake on/brake off (red light on/red light off) The other buttons retain their normal utilization.
6
Rotary Table
CHARMILLES 140 000 962/E/05.05.2004
Programming
G00
Angular movement
Syntax
G00 Wnnn.nnn The value nnn.nnn represents the angular movement in degrees, and must respect the following conditions: - Positive or negative - Absolute value less than 360 - 3 digits after the decimal point The digits beyond the 3rd after the decimal point are ignored. The axis is defined in mono-rotation, that is to say: - If the absolute value of nnn.nnn is greater than 360 it will be reduced by 360 and the axis will only perform the movement exceeding 360. Example: if nnn.nnn = 380., the axis rotates 20° - If the absolute value of nnn.nnn is greater than 180 it will be reduced to the complement of 360, and the axis will only perform the shortest movement in the reverse direction. Example: if nnn.nnn = 270., the axis rotates √90°
G92
Part system of coordinates
Syntax
G92 Wnnn.nnn This command fixes for the W axis an origin for the part coordinates, i.e. introduces on W an initial offset that will affect all subsequent movement instructions on W.
M178 / 179 Syntax
M178 M179
Brake opening / closing Opening Closing
These ISO instructions can be used in the programs, or entered directly on the console in MDI mode for immediate execution.
CHARMILLES 140 000 962/E/05.05.2004
Rotary Table
7
Resumption in the event of power failure or other incidents Apart from the command and control features referred to above, the Rotary Table option does not incorporate any specific monitoring elements or error messages. In the event of a power failure, as regards the Rotary Table: - In the stopped position:
the axis remains in position the chuck remains closed (if present) the brake remains blocked (if present)
- During a movement of the W axis:
the axis will be dealt with like any other axis
Consequently, if the machine is equipped with an Autorestart system, machining can be resumed when power is restored.
Installation of the software option Open the screen page EXE √ Service √ Machine configuration √ Options In the Automation / Rotary axis zone, fill out the fields according to the configuration : - W axis Tick the box - Rotary axis Tick the box - Table chuck Tick the box if the chuck is present - Brake Tick the box if the brake is present
After this defining has been done, stop then restart the machine so as to load the pa rameters corresponding to the configuration choices carried out.
8
Rotary Table
CHARMILLES 140 000 962/E/05.05.2004
Workshop Connection (ROBOFIL 240•440) (ROBOFIL 240cc•440cc) (ROBOFIL 380•X90) Introduction
3
Principles of operation
3
Conditions for commissioning
4
Installation of the software option
4
Configuration
4
Management of Control mode Establishment of the connection ............................................................... Suspension / Resumption of the connection ............................................... Aborting the connection .........................................................................
6 6 8 9
Note concerning transfer of files
9
CHARMILLES 140 000 967/E/05.05.2004
Table of contents
1
2
Table of contents
CHARMILLES 140 000 967/E/05.05.2004
Introduction The purpose of the Workshop Connection option is to enable the activity of a ROBOFIL machine to be followed up remotely on a personal computer. The connection is via an in-house company network (ETHERNET type).
ROBOFIL Ethernet
PC
Principles of operation The remote follow-up can be performed in 3 different ways through 3 separate channels:
UDP (= User Datagram Protocol) channel: Limited supervision of several machines Each machine regularly transmits a summary status situation to a control computer. In this way a single operator can perform a centralized follow-up of a stock of several machines, while carrying out another activity in parallel. Supervision Point to point link, with no possibility of intervention - provision of information on the machining status (current program, status) - notification of significant events (start and end of programs, start and end of execution, alarms) This is a simple transmission of information to another system, which does not thereby acquire any capacity for intervention
Control Point to point link, with the possibility of limited intervention - possibility of running the machining operation by commands of selection, starting, interruption and resumption, stopping of programs - the transfers or resumptions of control are carried out at the Operator level This transfer of control is temporary, since it is authorized from the console of the ROBOFIL machine, and can be suspended or cancelled at any moment from this same console. It is partial, since only the operations concerning the activation of programs are involved: adjustment of the parameters is done without interruption and exclusively from the console of the ROBOFIL machine.
CHARMILLES 140 000 967/E/05.05.2004
Workshop Connection
3
Conditions for commissioning The Connection option commissioned on the ROBOFIL machine provides a platform including the integration into the software of the numerical control and the transmission of data on the ETHERNET network by the protocol TCP/IP. (this documentation concerns this part only) The connection of the receiving system via the local network must be the subject of a study and an integration project, comprising the development of the dialog protocol and an application device for presentation. Charmilles technical services can supply the information and documents required for this development.
Installation of the software option The Workshop Connection option requires the ROBOFIL machine to be connected to the company»s local in-house network. For the conditions regarding connection (hardware and software required), please consult the IT service of the company. - Activation of the Workshop Connection software option is executed when the machine is installed or at the time of an update. - It is possible to choose Supervision mode, Control mode or both modes simultaneously. - As soon as one of the 2 modes is selected, the UDP channel also becomes available. - For a description of the activation of the options, refer to the introduction chapter of this Options manual.
Configuration The Workshop Connection option communicates to the local network by means of 3 virtual channels: - UDP (User Datagram Protocol) channel (limited supervision of several machines) - Supervision channel (Supervision mode) - Control channel (Control mode) The 3 communication channels can be enabled or disabled individually by means of the screen page EXE √ Service √ Machine configuration √ Workshop connection. This operation is done at the Machine setter level. this screen is only accessible if at least one of the two modes of the Connection option (Supervision or Control) was enabled when the option was installed.
4
Workshop Connection
CHARMILLES 140 000 967/E/05.05.2004
Communication tick box: - this box is used for disabling the 3 communication channels en bloc without touching their configuration. - if this box is not ticked, the other functions below cannot be edited Port numbers : these 3 numbers are allocated internally in the software; they cannot be edited
Profile of authorization ------------------------------------------------Machine setter or above
Not accessible
UDP channel Disable box Permission box
Used for disabling the channel Authorizes the function
Machine setter or above All profiles
Canal de Supervision Disable box Permission box
Used for disabling the channel Authorizes the function
Machine setter or above All profiles
Used for disabling the channel
Machine setter or above Not accessible
Canal de Contrôle Disable box Permission box
Differences in the processing between Supervision mode and Control mode - enabling of Supervision mode is done by means of the 2 boxes above - enabling, suspension and stopping of the Control mode is managed dynamically by the operator via an additional screen page EXE √ Program Execution √ Remote Execution (see description below)
CHARMILLES 140 000 967/E/05.05.2004
Workshop Connection
5
Management of Control mode Management is performed at Operator level. Select the screen page EXE √ Program Execution If the following conditions are fulfilled: Workshop Connection option enabled Control mode declared Control channel enabled a function key Remote Mode is displayed, making it possible to open a new screen page to manage the Remote Control. If the Control channel has been disabled, the function key Remote Mode is displayed on a gray background, and cannot be used without prior re-enabling of the channel.
Establishment of the connection Pressing the key Establish Connection makes the transfer of control effective, i.e. it has the following effects:
on the remote station: (depending on what functional feature is included in the customer program) - possibility of connection, consultation, and commands linked to program execution (selection, starting, interruption, stopping) - possibility of emulating certain functions START (green), STOP (red) and ABORT (blue) on the machine console: - disabling of the START (green), STOP (red) and ABORT (blue) keys of the front panel - cancellation of commands linked to program execution (selection, starting, interruption, stopping) - possibility of taking action regarding optimization of machining (access to User Parameters and Generator Parameters maintained) Information on the level of remote control activity: - Indicator FULL REMOTE - Current Status window: displays the identity of a connected system (if the window is empty: no connection currently in progress) - Current Action window: displays the actions initiated on the remote system,with a bar graph to show their progress If the window is empty: no action currently in progress Connection management keys - Suspend Connection key - Abort Connection key
6
Workshop Connection
CHARMILLES 140 000 967/E/05.05.2004
Screen page EXE √ Program Execution in Remote Execution mode. The possibility of establishing a Connection is declared (≈Establish Connection∆ key).
Current status window A connection has been established.
Current Action window An action started by the remote system is in progress.
CHARMILLES 140 000 967/E/05.05.2004
Workshop Connection
7
Suspension / Resumption of the connection
Pressing the Suspend Connection key is used for a resumption of limited local control. i.e. it has the following effects: - on the remote station:
Notification of the interruption: no command or action whatsoever on the ROBOFIL is possible
- on the machine console:
Indication of the suspension in the Current Status window The indicator FULL REMOTE remains lit up If a program is being executed, it will be interrupted as soon as the connection is suspended Re-activation of Manual mode: the operator can perform interventions on the machine Activation of the Resume Connection key to return to the previous status of remote control
During the suspension it is not possible to resume or abort the interrupted program. The suspension ends logically through the restoring of the connection, subject however to restoring the machining conditions and coordinates that were current at the time of suspension. The program being executed at the time is then automatically continued.
8
Workshop Connection
CHARMILLES 140 000 967/E/05.05.2004
Aborting the connection The Abort Connection key can be pressed at any moment by the local operator. This completely cancels the transfer of control, i.e. it has the following effects: - on the remote station:
Notification of the aborting: no command or action whatsoever on the ROBOFIL is possible
- on the machine console:
Complete resumption of the control The indicator FULL REMOTE goes off A program being executed continues normally under the local control (console of the machine).
aborting the connection during a suspension This case corresponds to the sequence Establish Connection Remote program start Suspend Connection Abort Connection In this case, the program that is active at the time of suspension can either be continued or stopped from the console after the aborting of the connection and the complete resumption of the control.
Note concerning transfer of files The Workshop Connection application has not been designed for transferring files between the control computer and the ROBOFIL machine. On the other hand, if and when the two systems are both part of the same local network, all the facilities for sharing and exchanging files specific to the network can be used, for exam ple to transmit ISO programs from the control system to the ROBOFIL machine.
CHARMILLES 140 000 967/E/05.05.2004
Workshop Connection
9
Eject (ROBOFIL 380•X90) Introduction
3
Principles of operation Cutting of part with formation of attachment ............................................... Piston descent to break the attachment ......................................................
3 4 5
Elementary conditions to be fulfilled
6
Formation of the attachment
7
Programming
7
Error messages
8
CHARMILLES 140 000 977/E/05.05.2004
Table of contents
1
2
Table of contents
CHARMILLES 140 000 977/E/05.05.2004
Introduction The Eject option is used for automatically evacuating a slug. By eliminating the interruption of machining to await the intervention of an operator, it helps to increase the working time and the profitability of a ROBOFIL machine. To achieve this objective, the slug must be held in place by the formation of an attachment. The purpose of the Eject device is to break the attachment by the strike of a piston activated by compressed air. The slug will thus fall in a controlled manner, at a chosen place and time, without risk of jamming under the lower arm. Evacuation of the slug will take place: - either after roughing, for open finishing / surface finishing - or at the end of sequence, for finishing / surface finishing in the slot the Eject option cannot be used in conjunction with the Rotary Table or Robot options.
Principles of operation A sub-program O3333 supplied with the technical documentation of the option executes all the partial stages required for the evacuation of the slug: -
upward movement of the Z axis retraction of the Y axis to free the bottom of the part movement of the V axis to bring the ejector into position above the slug (fig.1) activation of the piston downward movement (fig.2) verification of the ≈out∆ position of the piston, confirming that the attachment has been broken return of the piston to the ≈in∆ position return of the axes to their position before the evacuation
The main program will thus include the following instructions: - M01 - M50 - G00Y0G50 - G86 - M98 P3333 - M60 º..
Stop before the attachment Cutting of the wire Cancellation of the taper Cancellation of the Hold Attachment mode Calling up of the sub-program for controlling Eject Rethreading Continuation of the main program
If at the end of the sub-program the operation is unsuccessful (piston failing to come out), the evacuation is declared a failure by an error message followed by stopping of the machine.
CHARMILLES 140 000 977/E/05.05.2004
Eject
3
Cutting of part with formation of attachment
3808
4
Eject
CHARMILLES 140 000 977/E/05.05.2004
Piston descent to break the attachment
V
Y
3809
CHARMILLES 140 000 977/E/05.05.2004
Eject
5
Elementary conditions to be fulfilled - The workpieces workpieces must be clamped with with sufficient sufficient support support to withstand withstand the vertical vertical effort exerted exerted during the ejection - In the case of clamping clamping in a vice, vice, provide a support support at the other other end of the workpiece workpiece by means of a Z stop - If the strike point point coincides with with the threading threading point, the diameter diameter of the threading threading hole must be less than the ejector diameter To ensure that the slug falls of its own accord after the attachment is broken: - it is prefera preferable ble to have have the slug»s slug»s cent center er of gravity within the surface of the slug (avoid a ≈crown∆ shape) - the attach attachmen mentt must be positio positioned ned as close close as possible to the center of gravity - the strike strike point point must must be positione positioned d at roughly roughly 0.85 times the distance between attachment and center of gravity starting from the attachment
Strike point
Attachment point
Center of gravity
195
Two blocks of 20 mm thickness (with the corresponding screws) make it possible to adjust the spacing of the Eject device thus facilitating the positioning of the strike point along the Y axis. Two supplementary ejectors of different lengths are also supplied in the kit, so as to take account of the different lengths of nozzles that can be used
If it is likely that the extraction of the slug could cause problems (because of its weight, shape or position), it is possible to cut several partial slugs before returning to the initial geometric shape for the finishing operations.
6
Eject
CHARMILLES 140 000 977/E/05.05.2004
Formation of the attachment The conditions governing the formation/cutting off of an attachment are defined by means of 2 parameters in the screen page EXE √ User Parameters √ Advanced Parameters, Slug management: - Type of slug attachment
(0, 1 or 2) 0 : cancel the Attachment function 1 : create a holding attachment 2 : cut off an existing attachment
- Length of the attachment
(in mm or inches)
Programming The conditions for forming the attachment can also be managed in an ISO program. Refer to : Programming manual, Chapter: ≈M Functions∆, Paragraph: ≈Attachment holding /cutting off∆ function.
G86, 87, 88 Syntax
G86 Cancellation of the Attachment function ≈Holding the slug with an attachment ∆ mode G87 G88 Cutting off the attachment∆ mode These commands are used for specifying the desired method for processing of the attachment, or for modifying by program the value expressed in the parameter ≈Type of attachment∆ of the screen page EXE √ User Parameters √ Advanced Parameters.
G89 Syntax
Definition of the attachment function
Length of the attachment G89 P _ (P is a whole number expressed without decimal point in microns or 1/100.000th inch) This command is used for specifying the desired length of the attachment, or for modifying by program the value expressed in the parameter ≈Length of attachment∆ of the screen page EXE √ User Parameters √ Advanced Parameters.
When G87 is defined, the attachment of length P will be formed before execution of the instruction M01 (Optional Stop).
CHARMILLES 140 000 977/E/05.05.2004
Eject
7
Sub-program O3333 Evacuation of the slug Called up by: M98 P3333 The sub-program automatically executes all of the partial stages required for the evacuation of the slug. The sub-program supplied can be edited and supplemented as follows: - determining exactly the initial clearance movements along Y, V, Z - adding information messages concerning execution of the sequence, for example : MSG Awaiting piston low position MSG Awaiting return to original position
Error messages The following 2 messages warn about a possible operating anomaly of the Eject option: Travel limit reached
A mechanical limit on the Y, V, or Z axis has been reached during the initial clearance movement.
Waiting time exceeded
The piston has not reached its low position or has not gone back to its original position within the set time limit.
8
Eject
CHARMILLES 140 000 977/E/05.05.2004
Great height finishing (ROBOFIL 380•X90) Introduction
3
Principle of operation
3
Components of the option
3
CHARMILLES 140 000 972/E/05.05.2004
Table of contents
1
2
Table of contents
CHARMILLES 140 000 972/E/05.05.2004
