i-console

VERTICAL TYPE MACHINING CENTER

AWEA I Console Operation Manual

Machine typeA+/BM/AF/AV/FM ControllerFANUC 18iMB VersionAAEUFI00 Date2009/01/01

AWEA MECHANTRONIC CO.,LTD. 629, Suezhetou Section, Kwanpu Rd., Hsinpu Town, Hsinchu County, Taiwan 305 TEL: 886-3-5885191 FAX: 886-3-5885194

CONTENTS

C O N T E N T S1. OPERATION MANUAL OF ICONSOLE.................................................................................. 1-1 1.1 OPERATION PROCEDURES OF ICONSOLE ................................................................................. 1-1 1.2 OPERATING INSTRUCTIONS OF I CONSOLE .............................................................................. 1-1 MAIN SCREEN .......................................................................................................................... 2-2 2.1 SOFT KEYS OF MAIN SCREEN .................................................................................................. 2-2 2.2 ITEMS ON MAIN SCREEN ......................................................................................................... 2-3 TOOL LIST ................................................................................................................................. 3-5 3.1 SOFT KEYS OF TOOL LIST ........................................................................................................ 3-5 3.2 ITEMS ON TOOL LIST SCREEN .................................................................................................. 3-6 3.3 OPERATION ............................................................................................................................ 3-6 3.3.1 Select pocket ................................................................................................................. 3-7 3.3.2 Change tool number in magazine pockets .................................................................... 3-7 3.3.3 Change tool number on spindle .................................................................................... 3-7 3.3.4 Re-initializing tool table ............................................................................................... 3-7 WORKPIECE COORDINATE ................................................................................................... 4-8 4.1 SOFT KEYS OF WORKPIECE COORDINATE ................................................................................ 4-8 4.2 SIMPLE WORKPIECE COORDINATE MEASUREMENT .................................................................. 4-9 4.3 SOFTKEYS OF SIMPLE WORKPIECE COORDINATE MEASUREMENT .......................................... 4-10 4.4 ITEMS ON SIMPLE WORKPIECE COORDINATE MEASUREMENT SCREEN ....................................4-11 4.5 PROCEDURES OF WORKPIECE COORDINATE SETTING..............................................................4-11 4.6 ADVANCED WORKPIECE COORDINATE MEASUREMENT ......................................................... 4-12 4.7 SOFTKEYS OF ADVANCED WORKPIECE MEASUREMENT ......................................................... 4-13 4.8 ITEMS ON ADVANCED WORKPIECE MEASUREMENT SCREEN .................................................. 4-14 4.9 ADVANCED CIRCULAR WORKPIECE MEASUREMENT .............................................................. 4-14 4.10 SOFTKEYS OF ADVANCED CIRCULAR WORKPIECE MEASUREMENT ........................................ 4-15 4.11 PROCEDURES FOR ADVANCED CIRCULAR WORKPIECES MEASUREMENT ................................ 4-16 4.12 ADVANCED SQUARE WORKPIECES MEASUREMENT ............................................................... 4-17 4.13 SOFTKEY OF ADVANCED RECTANGLE WORKPIECES MEASUREMENT ...................................... 4-18 4.14 PROCEDURES FOR OPERATION OF ADVANCED RECTANGLE WORKPIECES MEASUREMENT ...... 4-19 4.15 TOOL LENGTH MEASUREMENT ............................................................................................. 4-19 4.16 SOFTKEY OF TOOL LENGTH MEASUREMENT .......................................................................... 4-20 4.17 ITEMS ON TOOL LENGTH MEASUREMENT .............................................................................. 4-20 4.18 PROCEDURES FOR TOOL LENGTH MEASUREMENT ................................................................. 4-21 M-CODE ................................................................................................................................... 5-22 5.1 SOFTKEY OF M-CODE .......................................................................................................... 5-22 5.2 M-CODE ON SCREEN ............................................................................................................ 5-23 ALARM..................................................................................................................................... 6-24 6.1 SOFTKEY OF ALARM ............................................................................................................. 6-24 6.2 PROCEDURES OF ALARM ....................................................................................................... 6-25 CALCULATOR......................................................................................................................... 7-26 7.1 SOFTKEY OF CALCULATOR ................................................................................................... 7-26 7.2 DISPLAY ITEMS .................................................................................................................... 7-27 7.3 CALCULATION ...................................................................................................................... 7-27 CUTTING PARAMETER OPTIMIZATION............................................................................ 8-28 8.1 SOFTKEY OF OPTIMIZE PARAM .............................................................................................. 8-28 8.2 ITEMS ON OPTIMIZE PARAM SCREEN ..................................................................................... 8-29 8.3 OPERATION PROCEDURES FOR OPTIMIZE PARAM ................................................................... 8-29 8.4 OPTIMUM PARAM ................................................................................................................. 8-30I

2.

3.

4.

5.

6.

7.

8.

CONTENTS 8.5 MAXIMUM PERMISSIBLE TOLERANCE ................................................................................... 8-30 8.6 90 DEGREE CORNER .............................................................................................................. 8-30 8.7 CONTOUR ERROR ................................................................................................................. 8-32 8.8 WORKPIECE WEIGHT ............................................................................................................ 8-33 8.9 QUANTIFICATION OF ACCELERATION ADJUSTMENT ............................................................... 8-33 8.10 PROGRAM COMMAND ........................................................................................................... 8-34 8.11 DIAGNOSE FOR ABNORMAL SITUATIONS ............................................................................... 8-34 8.11.1 Feed speed cannot be increased .................................................................................. 8-34 8.11.2 Abnormal surface of the mold .................................................................................... 8-35 9. THERMAL COMPENSATION SYSTEM ............................................................................... 9-41 9.1 SOFTKEY OF THERMAL COMPENSATION ................................................................................ 9-41 9.2 ITEMS ON THERMAL COMPENSATION SCREEN ....................................................................... 9-42 9.3 PROCEDURES FOR THERMAL COMPENSATION ....................................................................... 9-42 10. ADAPTIVE FEED RATE CONTROL (AFC) .......................................................................... 10-2 10.1 INTRODUCTION .................................................................................................................... 10-2 10.2 AFC PRINCIPLE .................................................................................................................... 10-2 10.3 CONTROL LINE ..................................................................................................................... 10-3 10.4 SYSTEM RESPONSE ............................................................................................................... 10-3 10.5 EMERGENCY PROTECTION .................................................................................................... 10-4 10.6 ADAPTIVE FEED CONTROL .................................................................................................... 10-4 10.7 OPERATION .......................................................................................................................... 10-6 10.8 OPERATION PROCEDURE OF AFC SCREEN............................................................................. 10-6 10.9 OPERATION PROCEDURE OF G CODE .................................................................................... 10-7 10.10 ALARM............................................................................................................................. 10-8 11. VERSION...................................................................................................................................11-9 11.1 SOFTKEY OF VERSION ............................................................................................................11-9 11.2 ITEMS ON VERSION SCREEN .................................................................................................11-10

II

CONTENTS

C h a r t

Ta b l e

o f

C o n t e n t s

Figure 1 Flow Chart of iConsole ........................................................................................ 1-1 Figure 2 i Console Main Screen ..................................................................................... 2-2 Figure 3 i Console Screen of Tool List ............................................................................ 3-5 Figure 4 i Console Screen of Measurement Selection.................................................... 4-8 Figure 5 i Console Screen of Workpiece Coordinate Setting Selection ........................... 4-9 Figure 6 i Console Screen of Basic Workpiece Measurement......................................... 4-9 Figure 7 Simple workpiece measurement Points of Measurement ............................... 4-12 Figure 8 i Console Selection of Advanced Workpiece Measurement............................ 4-13 Figure 9 i Console Screen of Circular Workpiece Measurement ................................... 4-14 Figure 10 i Console Screen of Circular Workpiece Measurement Calculation............... 4-15 Figure 11 i Console Screen of Rectangle Workpieces Measurement ........................... 4-17 Figure 12 i Console Calculation Screen of Rectangle Workpieces Measurement ......... 4-17 Figure 13 i Console Tool Length Measurement ............................................................ 4-19 Figure 14 i Console M-Code......................................................................................... 5-22 Figure 15 Alarm Screen.................................................................................................... 6-24 Figure 16 i Console Calculator ..................................................................................... 7-26 Figure 17 Optimize Parameter ......................................................................................... 8-28 Figure 18 Definition of 90 degree corner ......................................................................... 8-30 Figure 19 The best way for keeping speed and shortest time in the corner..................... 8-31 Figure 20 Car race roads, same as path tolerance of machining .................................... 8-31 Figure 21 AWEA Optimize Param.................................................................................... 8-32 Figure 22 Definition of contour error ................................................................................ 8-32 Figure 23 Saw shape path with very short distance corners............................................ 8-34 Figure 24 Simulation for cutting result with bad program (Should be a smooth surface) . 8-35 Figure 25 Cutting result with bad program (Should be a smooth surface) ....................... 8-36 Figure 26 Simulation for cutting result with bad program (Should be a smooth surface) 8-36 Figure 27 Cutting result with bad program (Should be a smooth surface) ....................... 8-37 Figure 28 Simulation for cutting result with bad program (Should be a smooth surface) . 8-37 Figure 29 Cutting result with bad program (Should be a smooth surface) ....................... 8-38 Figure 30 Simulation for cutting result with bad program (Should be a smooth curve surface) 8-38 Figure 31 Cutting result with bad program (Should be a smooth curve surface).......... 8-39 Figure 32 Simulation for cutting result with bad program (Should be a smooth curve surface)........................................................................................................................ 8-39 Figure 33 Cutting result with bad program (Should be a smooth curve surface) ............. 8-40 Figure 34 Thermal Comp................................................................................................. 9-41 Figure 35 Control of rough cutting ................................................................................... 10-2 Figure 36 Figure of PID Control Principle ........................................................................ 10-3 Figure 37 Adaptive Feed Control ..................................................................................... 10-4 Figure 38 Functional List ................................................................................................. 10-5 Figure 39 Softkey List ...................................................................................................... 10-6 Figure 40 Status of dynamic information system ............................................................. 10-6 Figure 41 Alarm List......................................................................................................... 10-8 Figure 42 Version Screen ................................................................................................ 11-9

III

Operation Manual of i Console

1. Operation Manual of iConsole1.1 Operation procedures of iConsoleMain Screen

Tool# List

WP offset

M-Code DOC M-Code

Alarm DOC

Calculator

CNC Param (Option)

Thermal Comp. (Option)

AFC (Option)

Version

WORK.P

TOOL.L

SIMPLE

COMP.

CIRCLE

SQUARE Figure 1 Flow Chart of iConsole

1-1


1.2 Operating instructions of i Console1. Select function in I Console, please start from MAIN page. 2. Press screen. to return to previous page, refer to figure 1-1 flow chart of i Console

3. Press will return to main screen directly. 4. Press cursor keys on the FANUC OP panel to move cursor up, down, left, right. 5. Press page down and page up on the FANUC OP panel to change page. 6. Two ways to input data (1) use keys on FANUC OP panel to input data (2) use corresponding soft keys under the screen to input data.

1-1


2. Main Screen

Figure

2 i Console Main Screen

2.1 Soft keys of main screenSoftkey Function Remark

Switch screen to tool page

Switch screen to workpiece coordinate

Switch screen to M-Code

Switch screen to alarm elimination2-2

Operation Manual of i Console Switch screen to Calculator

Switch screen to cutting parameter optimization Switch screen to spindle thermal compensation display Switch screen to Adaptive feed-rate control interface

Optional package

Optional package

Optional package

Switch screen to display version information

2.2 Items on main screenDisplay items F (Uppercase) S (Uppercase) M Function Display absolute coordinate (metric system /imperial system) Display mechanical coordinate Display residual distance to go Display G-CODE status Display actual feed rate Display actual spindle rate Display motor load of axis (%, Rated) Display Spindle motor load (%, Rated) Display M-code status (M03, M04, M19, M5)2-3

Operation Manual of i Console COOLANT SPD ROT SPD TL # MAZ POT # Display Coolant status Display Spindle status (M03, M04, M19, M5) Display tool list Display current spindle tool number Display current middle tool pocket of tool magazine Display current middle tool number of tool magazine Display current right side tool pocket of tool magazine Display current right side of tool number of tool magazine Display current left side tool pocket of tool magazine Display current left side tool number of tool magazine Time of power on Total process time Time for this process Total # workpiece machine Workpiece NO.

MAZ TL #

RIGHT POT #

RIGHT TL #

LEFT POT#

LEFT TL # Power on Run Time Cycle Time Tot. Parts Parts O#### N#####

Program # to be executed Line number of the program

2-4


3. Tool ListThis screen provides an interface for operators to manage the tool number in magazine and spindle. Press on softkey in main screen to enter Tool List screen.

Figure

3 i Console Screen of Tool List

3.1 Soft keys of tool listSoftkey Function Select a tool by entering the corresponding pocket #

Enable tool # to be changed

3-5


Rearrange tool # in ascending order.

Move the cursor to the spindle tool # field

Execute tool # change

Back to previous page

Switch to main screen

3.2 Items on tool list screen

Display items MAG .1 POT. NO TOOL. NO -D. SPINDLE TOOL NO.

Function Display tool capacity of the magazine Display tool pocket number Display tool number corresponding to the pocket Tool radius Display current spindle tool number

3.3 OperationThe followings are detail operating procedures of the screen.

3-6


3.3.1 Select pocket1. Enter the pocket # by using the numerical pad on FANUC OP Panel 2. Press to move the cursor to the position of assigned tool pocket.

3.3.2 Change tool number in magazine pockets1. Select a Pocket (see 3.3.1) 2. Press , after is pressed, tool number can be changed freely in every pocket. 3. Enter the Tool # by using the numerical pad on FANUC OP Panel 4. Press Input on FANUC OP Panel 5. Press pocket. , after is pressed, tool number cannot be changed in any

3.3.3 Change tool number on spindle1. Press 2. Enter the Tool # by using the numerical pad on FANUC OP Panel 3. Press to execute the command

3.3.4 Re-initializing tool tableTool number can be rearranged in ascending order by the following procedures. After executing the procedures, tool number will be the same as the pocket number. 1. Press , 2. Press Input on FANUC OP Panel

3-7


4. Workpiece CoordinateThis screen provides an interface for both workpiece coordinate and tool length measurement. Press on softkey in main screen to enter Tool List screen.

Figure

4 i Console Screen of Measurement Selection

4.1 Soft keys of workpiece coordinateSoftkey Function


Switch screen to selection of work coordinate measurement

Switch screen to tool length measurement

4-8


4.2 Simple workpiece coordinate measurement

Press on press on

softkey in Workpiece Coordinate to enter Selection screen. Then, softkey to enter Simple Workpiece Coordinate Measurement

Figure

5 i Console Screen of Workpiece Coordinate Setting Selection

Figure

6 i Console Screen of Basic Workpiece Measurement4-9

Operation Manual of i Console This screen provides a simple interface for locating the center point of a circular or rectangular workpiece.

4.3 Softkeys of simple workpiece coordinate measurementSoftkey Function


Selection of X axial direction

Selection of Y axial direction

Selection of Z axial direction

Initial point of the measurement. Center point between initial point and end point will be the workpiece reference point End point of the measurement. Center point between initial point and end point will be the workpiece reference point


4-10


4.4 Items on simple workpiece coordinate measurement screenDisplay items < RELATIVE COORDINATE > < EXT > Function Display mechanical coordinate

Display relative coordinate Display external offset coordinate value Display origin point of workpiece coordinates Valid values are from G54 ~ G59

(G##)

4.5 Procedures of workpiece coordinate settingFor a square workpiece as shown in Figure carried out. 7, the following procedure should be

1. Input workpiece coordinate number (select from G 54 ~ G 59 group) by using FANUC OP Panel. Ex. G54 G + 5 + 4 + Input 2. Install a edge finder onto the spindle 3. Press down softkey. 4. Move the edge finder along X axis until it touches the workpiece, as shown in Figure 7, initial point of X 5. Press down softkey.

At this time X axis of workpiece coordinate origin will be highlighted. X axis workpiece coordinate origin will be displaying (the present position [absolute] + initial position [absolute]) / 2. X axis relative coordinate will be displaying the difference between present position and initial position. 6. Move the edge finder along X axis until it touches the opposite side of the workpiece, as shown in Figure 7, end point of X 7. Press softkey

At this time, the X axis of workpiece coordinate origin has been set at the midpoint between initial point of X and end point of X as shown in Figure 7 8. Press down softkey. 9. Move the edge finder along Y axis until it touches the workpiece, as shown in Figure 7, initial point of Y4-11

Operation Manual of i Console 10. Press down softkey.

At this time Y axis of workpiece coordinate origin will be highlighted. Y axis workpiece coordinate origin will be displaying (the present position [absolute] + initial position [absolute]) / 2. Y axis relative coordinate will be displaying the difference between present position and initial position. 11. Move the edge finder along Y axis until it touches the opposite side of the workpiece, as shown in Figure 7, end point of Y 12. Press softkey

At this time, the Y axis of workpiece coordinate origin has been set at the midpoint between initial point of Y and end point of Y as shown in Figure 7

Initial point of Y

Initial point of X

End point of X

Y

XWork piece reference point

End point of Y

Figure

7 Simple workpiece measurement Points of Measurement

4.6 Advanced workpiece coordinate measurement

Press on

softkey in Workpiece Coordinate to enter Selection screen. Then,

press on softkey to enter Advanced Workpiece Coordinate Measurement This screen provides interfaces for : 1. Locating the center point of a circular workpiece by 3 measurement points 2. Locating the center point of a rectangular workpiece and compensating for the misalignment of the workpiece by 5 measurement points.

4-12


Figure

8 i Console Selection of Advanced Workpiece Measurement

4.7 Softkeys of advanced workpiece measurementSoftkey Function


Selection of workpiece number

Setting radius of edge finder

Input workpiece number or radius of edge finder

Switch screen to circle workpieces measurement

4-13


Switch screen to rectangle workpieces measurement

4.8 Items on advanced workpiece measurement screenDisplay items WORKPIECE MEASURE SELECT Select assigned workpieces# Function

WORK SELECT FINDER.RADS

Select measured workpieces type Radius of edge finder

4.9 Advanced circular workpiece measurement

Figure

9 i Console Screen of Circular Workpiece Measurement

4-14


Figure

10 i Console Screen of Circular Workpiece Measurement Calculation

4.10 Softkeys of advanced circular workpiece measurementSoftkey Function


Input A, B, C

Execution of circle workpieces measurement calculation

Calculation of circular workpieces of central point

4-15


Index of workpieces#

Input value of workpiece coordinate


4.11 Procedures for advanced circular workpieces measurement1. Input coordinates of workpiece group number (1~6) on the panel, press panel. 2. After pressing , setting radius of edge finder, then press of the panel. of the

3. Select screen of circular workpieces measurement 4. Measure calculation. 5. After pressing

of the panel. for

these three points in orders, then press

, the reference point of circular workpiece will be gotten. Check which will input the value of

number of the workpiece is correct, and pressing OFFSET to workpiece coordinate.

4-16


4.12 Advanced square workpieces measurement

Figure

11 i Console Screen of Rectangle Workpieces Measurement

Figure

12 i Console Calculation Screen of Rectangle Workpieces Measurement

4-17


4.13 Softkey of advanced rectangle workpieces measurement

Softkey

Function


Input A, B, C, D, E

To execute calculation of rectangle workpieces measurement

To calculate central point and tilting angle

Index of workpieces #

Input coordinates

Display angle


4-18


4.14 Procedures for operation of advanced rectangle workpieces measurement1. Input coordinate of workpiece group number (1~6) on the panel, press panel. 2. After pressing , setting radius of edge finder, then press of the panel. of the

3. Select screen of Rectangle workpiece measurement 4. Measure calculation. 5. After pressing

of the panel. for

these five points in orders, then press

, the reference point of Rectangle workpiece will be gotten. which will input the value

Check number of workpiece is correct, and pressing of OFFSET to workpiece coordinate.

4.15 Tool length measurement

Figure

13 i Console Tool Length Measurement

4-19


4.16 Softkey of tool length measurementSoftkey Function


Index of tool#

Input altitude of Z axis set point station

Present position - height of Z axis set point station

Input added attitude by manual

Input measured attitude by manual

4.17 Items on tool length measurementDisplay items NO. GEOMETRY WEAR G43 H MACHINE

Function Tool # Tool length Tool wear Value of tool length compensation Mechanical coordinates

4-20

Operation Manual of i Console HM.INP Setting altitude of Z axis

4.18 Procedures for tool length measurement1. Press INPUT key or soft key to input data.

2. First, input altitude of Z axis set point station then press . 3. Moves the spindle toward the Z- direction till tool tip touch the station, and press .

4. Press to add length value by manual if it is necessary, if the customer pads height of measured workpiece then input the value of padding height. 5. The column of shape will display the distance from tool tip to the top of workpiece, and then input the values to the column of G43 H.

4-21


5. M-Code

Figure

14 i Console M-Code

5.1 Softkey of M-CodeSoftkey Function


M code description.


5-22


5.2 M-Code on ScreenThis screen is for user of M-CODE. Use (Page Up / Page Down key) to turn pages.

5-23


6. Alarm

Figure 15 Alarm Screen

6.1 Softkey of alarmSoftkey Function


Alarm index


6-24


6.2 Procedures of alarmWhen alarm occurs, input alarm number from screen then press (AL index) to check the alarm of possible reasons. From screen, to see the axial traveling message of 1,001, 1,001 have represented the alarm number, but afterwards in addition alarm message of axial traveling. The column of ALARM and SOLVE which describe the possible reason of alarm created, the axes traveling of Alarm 1,001 that the possible reason is X8.0 = 0 either X8.1 = 0 or X8.2 = 0.

6-25


7. Calculator

Figure

16 i Console Calculator

7.1 Softkey of CalculatorSoftkey Function


Addition,1

2

Subtraction ,1

2

Multiplication,1

2

7-26


Division,1

2

SIN(45),45

COS(45),45

TAN(45),45

Radical sign operation, 10 ,10

To execute operation

Clear

7.2 Display ItemsThe input value by green color to demonstrate upper left side of calculator graphical representation The operation result by yellow big typeface to above demonstrate of calculator graphical representation.

7.3 CalculationThis calculator without calculating multiplication and division function first, then after addition and subtraction, only use for the basic calculation.

7-27


8. Cutting Parameter Optimization

Figure

17 Optimize Parameter

8.1 Softkey of optimize paramSoftkey Function


Set the current setting and servo parameter will be written to NC controller automatically.

Reset the parameter to default value and write to NC controller.

GUI interface description

8-28


CNC Parameter version

Switch to Main page

8.2 Items on optimize param screenACCELERATION OVERRIDE (Cutting mode) To provide more options for same workpiece and tolerance, the OPTIMIZE PARAM has cutting mode for setting. The cutting mode has five grades for acceleration adjustment. With the increasing of the speed, the vibration will increase and the quality of the surface will become worse. Grade 5 Rough machining Grade 4 Semi-rough machining Grade 3, 2, 1 is used for fine machining of the acceleration adjustment. Grade 3 Die mold for car or low surface roughness quality. Grade 2 For normal dies mold machining. Grade 1 Plastic mold or high surface roughness quality is needed. ALLOWABLE DEVIATION (Tolerance) When the structure of the machine is not changed, position error can not be prevented with increasing the speed. OPTIMIZE PARAM provide user to set maximum tolerance for the contour. There are two types of toleranceOne is 90 degree corner and the other is contour error. WORKPIECE WEIGHT For the bridge type machine of AWEA, the X axis is a table with workpiece loading. The loading has influence on the performance of moving. In order to get good performance and efficiency, OPTIMIZE PARAMTER can calculate different acceleration and servo parameters with different weights.

8.3 Operation procedures for optimize param1. Use UP/DOWN key to selectACCELERATION OVERRIDE (Cutting mode), ALLOWABLE DEVIATION (Tolerance), WORKPIECE WEIGHT 2. Use RIGHT/LEFT key to select cutting mode grade. 3. Input tolerance value with unit um. Push INPUT key to write the data to CNC.8-29

Operation Manual of i Console 4. Input workpiece weight value with unit Kilogram. Push INPUT key to write the data to CNC. 5. With setting all parameters above, push soft key and parameters will work after that. Message PRESS [SET PARAM] TO APPLY CHANGES! will soft key alert when the settings have been changed again. Please push and new settings will work. 6. To initial or quit the function, push soft key. 7. Soft key and should be used in MDI mode or Emergency STOP status. The alarm messages PLEASE SWITCH TO MDI MODE! and PLEASE PRESS DOWN EMERGENCY BUTTON! will show when the SET/RESET is pressed in the wrong mode.

8.4 Optimum paramOPTIMIZE PARAM with the GUI interface that can help user to understand the effect of parameter setting. This function can help the machine being more efficient and good performance.

8.5 Maximum permissible toleranceWhen the structure of the machine is not changed, position error can not be prevented with increasing the speed. OPTIMIZE PARAM provide user to set maximum tolerance for the contour. There are two types of toleranceOne is 90 degree corner and the other is contour error.

8.6 90 degree corner

Real path Corner error Command path

Figure

18 Definition of 90 degree corner

For example, suppose NC cutting path as race car road and spindle as race car. When the car passes by the corner, in order to keep the speed of inside and outside the corner the car cannot go the 90 degree path. The better way is going with a curve path. If the corner speed is increased, the radius of curve is increased also. Same concept is applied in FANUC controller, so the corner error should be taken into consideration in parameter setting.

8-30


Figure

19 The best way for keeping speed and shortest time in the corner

There are many kinds of race car such as F1, Touring, Rally, Modified truck. With the same 90 degree corner and speed, the inner offset (path error) has relations with the performance of race car. That means small car, high rigidness, good grip of ground will have small inner offset. On the contrary big car, low rigidness, low grip of ground will have bigger inner offset. It is impossible to keep 90 degree path with high moving speed. The cutting tolerance is decided by the machine structure. So the parameter setting is depended on the machine structure. Tolerance error is something like the width of the road. If the tolerance is not asked for good, the speed in the corner can be increased. If the tolerance is asked for good, the speed in the corner should be slow down to match the tolerance.

Figure

20 Car race roads, same as path tolerance of machining

In OPTIMIZE PARAM screen, the allowable deviation is provided for user. The control software will calculate the best corner speed by user settings. Before this function is released, the allowable deviation is restricted within 5 to 30um and must be adjusted by many machine types.

8-31


Contour error 90 degree error

Figure

21 AWEA Optimize Param

8.7 Contour errorContour error is made by servo following error and processing of interpolation. Contour error has relation with the centripetal acceleration. With the increasing of centripetal acceleration, the contour error will increase. If the centripetal acceleration is limited, the contour error will be limited also. Contour error from processing of interpolation is characteristic of FANUC controller kernel. Before this function is released, the allowable deviation is restricted within 5 to 30um and must be adjusted by many machine types.

Command path Real pathContour

error

Figure

22 Definition of contour error

8-32


8.8 Workpiece weightFor the bridge type machine of AWEA, the X axis is a table with workpiece loading. The loading has influence on the performance of moving. For example, with increasing the workpiece load, the friction will increase and need more motor torque and nature frequency has been changed. For the machine X=2m of AWEA, the servo motor only need to drive 1500Kg (working table)without any load. If there is a rated load on the table, the motor has to drive 5000Kg. Its quit difference for the motor in those two kinds of situation. Before the release of this function, there is only one acceleration parameter setting which take 75% of rated load into consideration. Therefore, when cutting with small workpiece, X axis does not export all power. OPTIMIZE PARAM provides workpiece weight setting that can make the machine having good efficiency and performance. For example Set grade to 5, tolerance to 200um and weight to 200Kg for rough machining, maximum acceleration of VP2012-HSS is up to 0.30G. If weight set as 2000Kg, accelerations will up to 0.17G of the same case. Set grade to1, tolerance to 10um and weight to 200Kg for fine machining, maximum acceleration of VP2012-HSS is up to 0.13G. If weight set as 2000Kg, accelerations will up to 0.11G in the same case.

the the the the

Attention Set the weight more light than it real has in purpose for increasing the acceleration, servo motor amplifier may export more current than the motor can be loaded. The servo alarm will alert in this situation.

8.9 Quantification of acceleration adjustmentIn order to provide more selections for the same weight and tolerance, OPTIMIZE PARAM has quantification for acceleration adjust. There are five grades for acceleration. With the increasing of the speed, the vibration will increase and the quality of the surface will become worse. Grade 5 This grade is used for rough machining. With the advance of the tool technology, high feed rate, high speed and low cut of every tooth are used for rough machining. In this machining, the material removal rate is very important. Therefore the stable of feed rate is needed. If feed rate is faster, the material removal rate will become more faster also, which means more efficient. The basic purpose of grade 5 is to keep stable feed rate without considering the surface roughness. Select the maximum tolerance with cutting the 1/3 of material removal part, the feed rate will more higher and stable. Grade 4 This grade is used for semi-machining. The setting for this grade is similar to grade 5, but when the speed is increasing, the vibration is lower than grade 5. Select the maximum tolerance with cutting the 1/3 of material removal part, the feed rate will more higher and stable.8-33

Operation Manual of i Console Grade 3, 2, 1 is used for fine machining and the tolerance can be 5 ~ 50 um. Grade 3 Die mold for car or low surface roughness quality. Grade 2 For normal dies mold machining. Grade 1 Surface of Plastic mold or high quality of roughness .

8.10 Program commandThis function can be active by G code. Format G400W___. M___. E___. W Workpiece weight (kg) M Cutting mode grade1 ~ 5 E Max. tolerance5 ~ 200 (um)

8.11 Diagnose for abnormal situations 8.11.1 Feed speed cannot be increasedSituation In mold cutting with the path which is a little bit like a long straight line, the path speed is very slow and can not arrive the command feed rate(F). Cause The path which is a little bit like a long straight line may be built by saw shape path. This path has many corners with very short distance. See the figure below. The corner may not be seen with eyes. In order to keep the tolerance, the controller should slow down the path speed.

Figure

23 Saw shape path with very short distance corners

Solution Use difference machining methods, path or redesign the CAM program to make the corner to straight line. Try to enter bigger value of the allowable deviation in OPTIMIZE PARAM setting if high precision is not necessary.

8-34


8.11.2 Abnormal surface of the moldSituation 1 The surface of workpiece has several blocks of abnormal lines Cause The possible reason for the abnormal lines is low precision setting of CAD/CAM transformation. The normal value of precision for plastic mold is Setting AFC parameter (or GUI of I console) M200; --------> Start AFC //Notice! Active AFC function before spindle rotation M3S1000;

Working program

G500T70M120S40R2; ------>Command setting AFC parameter (or GUI of i console) // G500 is for setting G code of AFC parameter // T70 is for fixing value of spindle target loading to 70% // M120 is for fixing the MAX.feed rate to120% // S40 is for fixing the minimum feed rate to 40% // R2 is for fixing system

Working program

M201 -------> Cancel AFC function M30; %

10-7


10.10

Alarm

Alarm code & message 3001 T CODE IS EMPTY 3002 TARGET IS TOO LARGE 3003 TARGET IS TOO SMALL 3004 M CODE IS EMPTY

Methods of eliminate alarm T CODE is empty , please input T CODE Target is too large, max allowable value is 100 Target is too small, min allowable value is 5 M CODE is empty, please input M CODE The Max. override is too large, Max. override allowable value is 150 The Min. override is too large, min. override allowable value is 100 N CODE is empty, please input N CODE The Min. override is too large, min. override allowable value is 99 The Min. override is too small, min. override allowable value is 40 R CODE is empty, please input R CODE RESPONSE setting is error, please reset RESPONSE range is in 1 ~ 3 The reasons of spindle load too high is as bellow: The target is too small The min override is unreasonable

3005 MAX. OVERRIDE IS TOO LARGE

3006 MAX. OVERRIDE IS TOO SMALL

3007 N CODE IS EMPTY

3008 MIN. OVERRIDE IS TOO LARGE

3009 MIN. OVERRIDE IS TOO SMALL

3010 R CODE IS EMPTY

3011 INVAID NUMBER OF RESPONSE

AL2080 SPD LOAD STILL TOO HIGH

Solutions: Readjust target of spindle load Reduce min override Press [CYCLE START] or press [Reset] to eliminate alarm

Figure

41 Alarm List

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11. Version

Machine Type Software Version Contact Us

Website and E-mail

Figure

42 Version Screen

11.1 Softkey of versionSoftkey Function


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11.2 Items on version screenDisplay items Machine Type Software Version Contact Us Website and E-mail Function Display recent software of corresponding machine Display recent software of published version Address ,Tel. and Fax of AWEA HsinChu ,Taichung Offer AWEA website and e-mail

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i-console

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