AMETEK Precitech, Inc.

Transcription

Super Turn Series Manual Supplement to
Nanoform 700 Ultra
Ultra Precision Machining System
M17958 Revision D April 29, 2010
Applies to Nanoform 700 Ultra A17700
These original instructions have been drafted and verified in the English language.
®
AMETEK Precitech, Inc.
44 Blackbrook Road
Keene, New Hampshire 03431
Tel: (603) 357-2511, Fax: (603) 358-6174
All rights reserved, including those to reproduce this manual or parts thereof in any form without
®
the prior consent of AMETEK Precitech, Inc.
Customer Service Department
Tel: 603-357-2511
Fax: 603-358-6174
General E-mail: service@ametek.com
Mike Wilson
Field Service Supervisor
e-mail: mike.wilson@ametek.com
Jenn Johnson
Sales Support Manager
e-mail: jenn.johnson@ametek.com
Tom Spiltoir
Service Engineer - Metrology
e-mail: tom.spiltoir@ametek.com
Chuck Currier
Service Engineer
e-mail: chuck.currier@ametek.com
Chuck Durgin
Service Engineer
e-mail: chuc.durgin@ametek.com
Kevin Maxwell
Service Engineer
e-mail: kevin.maxwell@ametek.com
Curt Mead
Service Engineer
e-mail: curt.mead@ametek.com
Ken Lefebvre
Service Engineer
e-mail: ken.lefebvre@ametek.com
Revision History
Rev
First
Used
By
Add language statement
04/06/10
?
Updated P-Tables to P915 Status
04/29/10
DAJ
Date
ECO
Revision
C
04/06/10
None
D
04/29/10
None
Pages
B
TABLE OF CONTENTS
SECTION 1 Machine Safety............................................................................... 1
Warning Labels................................................................................................. 3
Residual Risks .................................................................................................. 5
Electrical Hazards............................................................................................. 7
Machine Safety Interlocks ................................................................................ 9
Operator Actuated Safety Controls................................................................. 10
Operator Guards Operation, Testing, and Maintenance................................. 11
Permission/Password Matrix .......................................................................... 11
Nanoform 700 Ultra Noise Emissions............................................................ 12
Release of Person Trapped in or by Machine................................................. 13
Safety System Response Time ....................................................................... 14
SECTION 2 Fixture Mounting ......................................................................... 15
SECTION 3 On-Machine Probe Linearity/Repeatability Calibration Procedure
............................................................................................................................ 19
SECTION 4 Setup & Calibration of the Horizontal Tool Set Probe................ 27
SECTION 5 Setup & Calibration of the Vertical LVDT Tool Set Probe ........ 37
SECTION 6 Setup & Calibration of the Part Surface Probe ............................ 40
SECTION 7 Bar Code Scanner Operation........................................................ 55
SECTION 8 Machining & Inspection Process Sequence................................. 58
SECTION 9 Tool Change Process.................................................................... 69
SECTION 10 Program File Printouts ............................................................... 81
SECTION 11 P Variable Assignments ........................................................... 102
N700 Super Turn Series Manual
Machine Safety
SECTION 1
Machine Safety
M17958 - Revision D
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Machine Safety
Read the Manuals! The Operation and Maintenance manuals describe the proper
procedures for the safe interactions with the machine. Failure to read the manuals
may lead to machine damage and/or operator injury.
Lock Out-Tag Out - The placement of all hazardous energy under the
exclusive control of an authorized employee(s) performing the service or
maintenance, following a procedure established by the employer as required by
OSHA 29 CFR 1910.147, Isolation of Energy Sources-Machinery Safety
Directive 89/392EEC the Control of Hazardous Energy.
Note that the sliding operator door uses power to unlock. If the door is closed when
power is removed, it is locked. If access is required without applying power, basic
screwdrivers can release the door, but the machine controller will not recognize the
door being latched and closed until the bypass function is deactivated.
The Main Electrical Disconnect Switch - on the front of the machine allows a
lock to be inserted in the handle when the switch is in the OFF position. This
ensures that the Electrical System of the Machine is in a condition where it can
be safely serviced.
This Machine is equipped with an accessory receptacle located behind the
swinging cover at back corner of the machine. This receptacle is fed from a
separate power source in addition to the Machine Main Feed. In order to fully
(secure) LOCK OUT-TAG OUT this receptacle, the plug for the source conductor
must be pulled and covered with a lockable shell (boot) made expressly for this
purpose.
The Pneumatic Supply Lockout Valve - is located at the rear of the machine and
is clearly labeled. This lockable valve, also vents the machine air supply.
Removing and venting upstream air supply will not vent the machine air.
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Machine Safety
Warning Labels
An image and description of each label from the machine follows. Follow the
instructions provided for each warning label.
The exclamation point in a yellow triangle warning label indicates that a hazard
exists and the manual for the machine should be used to refer to the proper
procedure to understand the hazard and respond appropriately.
The lightning bolt in a yellow triangle warning label indicates that hazardous voltage
is present or can be present when the cover is opened.
M17958 - Revision D
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Machine Safety
The Sharp Point in a yellow triangle warning label indicates, a sharp point is present
or can be present in the area of the label.
This label is located on the sliding guard door that protects the operator during a
machining cycle. When this guard must be slid aside to allow operator access to
the cutting area, it is imperative that safety glasses be worn.
These labels are located on the operator s door. They refer to releasing a person
trapped by the primary axis movement. In EStop or when the machine is powered
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Machine Safety
down, axes brakes and friction can be manually overcome in there normal direction
of travel.
This label is located on the Pneumatic Cabinet door. The label indicates the
presence of compressed air hazard. For eliminating this hazard, a lockable air
shutoff/bleed valve is provided. Air must be shut off with the provided valve
because of a check valve up stream of it. The check valve retains air in the system
for safety purposes. The provided supply/bleed valve is located to bleed the retained
system air pressure.
Residual Risks
Residual Risks are the possible hazards that remain after the required safety
measures such as guards, interlocks, and warning labels are put into place. Many
are listed here but others require the operator to recognize the special risk of their
own circumstances and to take actions in preparation of these hazards.
Sharp Diamond Tool The cutting edge of the diamond tool is razor sharp. Also
the vacuum chuck can develop sharp edges at each groove when it is refaced.
The regular proximity of the operator hands to the tool and chuck when loading
and unloading the machine as well as when changing tools suggest the following:
The user program should include positioning the axes for safe unloading/loading
of parts. The tool axis should maximize clearance to the part. The work holding
axis should give clearance to the tool and minimize reach for part exchange. Do
not rely on the operator jogging the axes to these positions.
Have a supply of first aid products available for cleaning and bandaging razor
cuts.
Use a cover over the tool if it will not be used for a long time, or remove the
tool.
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Machine Safety
Consider special operator training on proper use and handling of diamond tool
products.
Wear Safety Glasses - Operators and maintenance personnel must wear safety
glasses whenever the Precitech spindle is running and the operator door is open. It is
good practice to wear safety glasses around the machine at all times.
Wear Leather Gloves Operators and Maintenance personnel must wear leather
gloves when handling chips and swarf.
Wear a Dust Mask - The diamond-turning process may produce swarf or chips
that float in the air. A protective mask must be worn over the operator s nose and
mouth to prevent inhaling or ingesting substances that may be toxic.
Dress Properly - Do not operate the PRECITECH Machining System while wearing
jewelry, loose fitting clothing, neckties, shirtsleeves, or unprotected long hair.
Stay Alert - Do not operate the PRECITECH Machining System while under the
influence of medication, drugs, or alcohol.
Use the Dowel Pin in the Vacuum Chuck The dowel pin in the center of the
vacuum chuck provides initial alignment of the fixture to the spindle, and
improves safety as the part will not fly off if severely unbalanced.
Use Maximum Available Vacuum Diameter Set the vacuum diameter of the
vacuum chuck to utilize the entire fixture face available. Use of a smaller
diameter limits the vacuum holding force, which increases the risk that the part
will fall off the vacuum chuck.
Modification to the part holding fixture- Removing material from, or adding parts
to the fixture may reduce the maximum safe speed and or create hazards. Mark
any modified fixtures with new maximum safe speed.
Lift Safely - Do not lift objects that are uncomfortable or back strain may occur.
Use a crane for heavy components.
Avoid Tripping or Slipping Hazards Keep the machine area clear of hoses and
wires that present tripping hazards. Be aware of liquids on the floor, clean up oil
spills and repair leaks immediately to prevent slipping injuries.
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Machine Safety
Safety Guards Must Be In Place - Operators must be sure that all guards are in
place while the PRECITECH Machining System is running to protect against bodily
injury.
Maintain the Machine Properly - Do not operate this machining system when it is
in need of repair or service. Proper maintenance will help avoid machine
downtime, loss of production and injury to personnel.
Do Not Disable Machine Safety Interlocks - Many safety features have been built
into the Machining System and should not be disabled. Special applications and
service may require temporary interlock override, please consult with Precitech.
Material Safety Data Sheet (MSDS) - PRECITECH provides MSDS for products
recommended for use on the machine. Persons likely to come in contact with these
materials should be familiar with the information contained in the sheets such as:
o
o
o
o
o
Product identification
First aid procedures
Personal protective measures
Health hazards
Spill procedures
Lockout Tagout - Follow your companies LOCK OUT-TAG-OUT procedure
when servicing the machine to prevent starting or energizing the machine. Lock
main power, machine mounted air supply valve and accessory power sources.
Note that the operator door uses power to unlock. If the door is closed when power
is removed it will remain locked until power is restored. If access is required to the
working zone during repairs, do not close the operator sliding door. There is a
bypass key to allow access for servicing. This key is provided with the machine and
should be kept by the maintenance personnel responsible for servicing the machine.
Electrical Hazards
Power is supplied to this machine through multiple sources and power removal for
servicing also has multiple levels.
With the main disconnect switched off, primary power is removed from most of the
machine. Power remains at the supply side of the main power switch, at the
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Machine Safety
accessory outlet, and other machine elements with separate cords such as the spindle
chiller.
EStop Power is removed from the spindle motors and slide motors. Position
feedback elements, the control computer, and the hydraulic power supply unit
remain powered.
Key Switch Off Power is removed from the machine control, hydraulic power unit,
axis and spindle drives. Power remains in the electrical cabinet.
Air pressure remains on.
Electrical/Electronic Troubleshooting - Must be performed by personnel trained to
troubleshoot electrical circuits. An electrical hazard exists when personnel exceed
the limitations of their training.
Hydraulic/Pneumatic Repair - Do not attempt to repair or service pneumatic or
hydraulic components while the Precitech Machining System is connected to the
pneumatic or hydraulic power sources or if either system remains under pressure.
M17958 - Revision D
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Machine Safety
Machine Safety Interlocks
Precitech Machining Systems are designed with mechanical, electrical, and
pneumatic components whose use is dedicated to protecting the operator and the
machine.
All Cabinet Doors and Service Access Panels have tool-operated latches or
fasteners to prevent casual entry.
The Electrical Cabinet is mechanically interlocked to prevent exposure to lethal
voltage.
The Air Accumulator Tank contains an adequate volume of air to allow the machine
spindle to stop safely should the air supply be interrupted. A check valve prevents
back flow from the accumulator tank should the supply hose be disconnected. A
relief valve releases air from the accumulator tank if the supply pressure exceeds
11.72 bar (170 psig).
An air pressure switch located in the pneumatic cabinet monitors the regulated air
pressure. If that pressure falls below 5.2 bar (95 psig), the Control will sense the
fault, dynamically brake the spindle, disable the spindle drive, and display an
error message.
A Vacuum Switch is located in the pneumatic cabinet that monitors the workholding chuck vacuum. If that vacuum falls below 15" Hg (38 cmHg), the
control will sense the fault, dynamically brake the spindle, disable the spindle
drive, and display an error message.
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Machine Safety
The Hydrostatic Reservoir has a liquid-level switch that will stop the motor to
protect the pump should there be an oil leak in the system.
The Hydrostatic Servo Drive has an electronic circuit that monitors the system oil
pressure. If pressure increases or decreases abnormally, the hydrostatic control
will sense the fault and signal the machine control to display an error message.
Software continuously monitors the axis feedback scales and will put the machine
into EStop upon the sensing of a failure of the feedback system, machine crash
event, or other abnormality.
Operator Actuated Safety Controls
Emergency Stop Button(s) EN954 Category 3: Red button with yellow label.
Standard systems are equipped with an emergency stop button on the operator
control station (optional Emergency stop buttons are available). Detent holds
the actuator down, once pressed. Verify with button latched down and
LATHE IN ESTOP in UPX message box.
Operator door switch EN954 Category 3: Mounted on or near top of the
machine enclosure. Signals machine controller, to the door being closed or
closed and locked. Is a locking mechanism, holding the door closed when the
spindle is over 50 RPM. Verify correct operation by, trying to open the door
with the spindle running over 60 RPM (Should not open). With the spindle
stopped and door open, DOOR OPEN should be displayed in the UPX
message box.
Main Power switch: A red lever type actuator located on the lower front of
the machine at the operator position. Serves as main electrical power
disconnect, able to accept a lock for locking off the machine power. Verify
that the POWER indicator on the operator consol is not illuminated.
Main Air shutoff: A lockable valve with bleed function. Located at the back
of the machine, on the left side of the Pneumatic Cabinet. Verify by closing
the valve, the main air pressure gage should read zero after allowing several
minutes for the system air pressure to bleed off.
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Machine Safety
Stop Button, EN954 Category 3: Red rectangular illuminated momentary.
Stops the part program or other motion when in progress. Does not stop the
spindle when in spindle mode. To stop the spindle, in spindle mode, call up
the direct command input (MDI) dialog box and type M5, then press enter
then press start. Verify by starting a part program, then press stop. The
program and the axes should stop.
Operator Guards Operation, Testing, and Maintenance
The sliding operator door is the main safety device keeping the operator safe from
machining hazards. These hazards include entanglement in the work spindle
rotation, exposure to the cutting fluid or cutting chips of possibly hazardous
materials, and possible flying tools, parts of tools, work pieces, or parts of work
pieces. The operator is safe if the door is closed, and exposed if the door is open.
To maintain operator safety, the sliding operator door is provided with a switch and
electrical lock. There are also operator password access levels that allow different
levels of access to the work zone. The door lock and access allowed are summarized
as follows:
Permission/Password Matrix
Standard (CE)
Door Open
Key switch on, password
level 0
Indications:
Door open
Machining Mode
No powered movement,
program edit or program
load.
Door Closed
Indications:
Machining Mode
Run MDI
Run program
Jog axes
Run spindle to rated
speed (via MDI or
program).
No program edit or load.
level 1
level 2
Super Turn (CE)
Door Open
Indications:
Door open
Machining Mode
No power movement.
No program edit, run or
load.
Indications:
Door open
Setting Mode
Indications:
Door open
Setting Mode
Indications: Machining
Mode
Run MDI, program, jog
M17958 - Revision D
Jog axes to 1 m/min, 50
RPM.
Run MDI. Load
program, no edit.
Indications:
Door open
Setting Mode
Door Closed
Indications:
Machining Mode
Run program.
No jog or MDI.
Mode
Jog axes.
Run MDI or Program.
Load program, no edit.
Set cutting tool.
Mode
Jog axes.
11
level 3
Axes jog to 1 m/min, 50
RPM.
Edit or load program.
No velocity controlled
spindle.
Indications:
Door open Maintenance
Mode
Hold to run and MDI
allowed.
Run spindle to 50RPM
(via MDI or program).
Edit or load or run
program.
Machine setup
parameters accessible
Machine Safety
axes
speed (via MDI or
program).
Edit or load program.
Mode
Axes jog to 1 m/min, 50
RPM.
Run MDI.
No program edit, run or
load.
Same as standard
Run MDI or Program.
No setting of cutting tool.
Same as standard
Hold to run and MDI
allowed.
speed (via MDI or
program)
Program edit or load.
Testing the proper function of the guard interlocks can be done by attempting to
perform each interlocked function and notice the machine response to each
combination of inputs. For example, open the operator sliding door with the
machine not in EStop and rotate the work spindle by hand to exceed 50 RPM. The
machine should go into EStop condition automatically.
Test proper operation of the vacuum interlock by mounting a small piece of paper on
the vacuum fixture (held only by vacuum), run the spindle at 45 rpm. Switch the
vacuum to off. Paper should stay on fixture. Now remove the paper, turn the
vacuum on high. A low vacuum warning should be displayed on the UPX and the
spindle should not start.
The window in the operator guard has been selected to provide operator safety as
well as to provide good long term durability to chemicals and cleaning solutions. It
is made of 0.25 inch thick laminated safety glass, with glass layers on both sides and
a layer of vinyl in the center. The glass layers provide good chemical resistance and
long term clarity. The vinyl layer in the center maintains the window in one piece
even when the glass layer has been broken. If an accident occurs and the window is
cracked or broken then it must be replaced to maintain the proper level of operator
safety. If the vinyl layer has become discolored this is a sign that there may be delamination of the layers and the window should be replaced. Replacement windows
are available from Precitech (or see the service section of the manual for part
number identification) and are replaced using standard hand tools.
Nanoform 700 Ultra Noise Emissions
With no access to an anechoic chamber, an "in situ" airborne noise emission test
was conducted on the Nanoform 700 Ultra located on the Precitech assembly
floor. The sound power level never exceeded 65 dB as measured in each of the
M17958 - Revision D
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Machine Safety
following locations and conditions: front, left side, rear, right side, machine off,
machine on, spindle stopped, spindle running, guard door closed, guard door
open.
Test was performed with an Extech 407706 Sound Level Meter set at the 60 dB
scale, "Slow" response, "A" weighting. The meter was mounted on a Velbon
Victory 451 tripod. All measurements were made at 1 meter from the machine
and 1.5 meters off the floor (as prescribed by Kris Swanson / Swanson Safety
Associates).
Per EN292-2 this noise emission data is to be accompanied by the following
statement:
The figures quoted are emission levels and are not necessarily safe working
levels. Whilst there is a correlation between the emission and exposure levels,
this cannot be used reliably to determine whether or not further precautions are
required. Factors that influence the actual level of exposure of the workforce
include the characteristics of the work room, the other sources of noise, etc. i.e.
the number of machines and other adjacent processes. Also the permissible
exposure level can vary from country to country. This information, however,
will enable the user of the machine to make a better evaluation of the hazard and
risk.
Release of Person Trapped in or by Machine
In the unlikely situation where a person or object has become trapped or captured by
the machine, this is most probably due to motion of the Z and X slideways or the
work spindle rotation. The machine is expected to be in EStop as a result of this
condition, either initiated by the operator or by the machine controller. In this
situation, the X and Z slideways can be pushed by hand to move the slides so that
the trapped object is freed. The force to overcome the slide brake is approximately
20 pounds of force (90 Newtons) and is easily produced by a single assistant or by
the trapped person directly. The spindle rotation is not braked and can be turned by
hand to free the trapped entanglement. These manual interventions will not affect
the machine performance and a routine re-homing of the slides will have the
machine back up and running. Any injury to the object or person trapped will
depend upon where on the machine the entrapment occurred.
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Machine Safety
Safety System Response Time
When an emergency stop is initiated, power to the axes and spindles is removed
in 140 milliseconds.
Time for the main spindle to come to a stop is 7.5 seconds with no fixture or part
mounted. Deceleration time will increase with the addition of fixturing and a
part.
A controlled stop takes 11 seconds with no fixture or part mounted. Deceleration
time will increase with the addition fixturing and a part.
The door remains locked until the spindle is at or below 50 RPM.
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Fixture Mounting
SECTION 2
Fixture Mounting
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Fixture Mounting
Safety: Refer to section 1 for operator safety warnings.
Wear Safety Glasses
Wear Protective Gloves
Remove any existing fixturing from the spindle. Do not remove setscrews from
the spindle as these are balancing screws and should not be removed. Use a stone
to remove any burrs from the spindle nose and from the mounting surface of the
fixture.
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Fixture Mounting
The fixture is held with (6) SAE 1/4-20 stainless steel socket head cap screws.
Holding the fixture with one hand, insert a bolt and start the threads into the
spindle face. Repeat with a second bolt before letting go as the fixture is not held
in place until two bolts have been started. Before tightening any of the bolts,
insert the remaining bolts so that they are all in place. Snug them all until they
are tight and then release each by ¼ turn until they are all in place. Snug the
bolts until the fixture is not loose and set up an indicator reading on the fixture
reference surface.
Reference surface
Zero the indicator, then examine the runout error motion of the reference surface.
Tap the fixture to bring the error motion smaller. The bolts may have to be reset
(loosened, then tightened again) once the fixture has been shifted. Once the
fixture is in alignment, the bolt tightness can be increased slightly.
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Fixture Mounting
Tap the fixture into alignment until the reference surface error motion is less than
2 microns (80 micro inches) TIR. Then snug the bolts and recheck the alignment.
In an alternating pattern fully tighten the bolts to 35 In.-Lb. and recheck the
alignment. Loosen and repeat until runout is within specification and the bolts at
properly tightened. Remove the indicator and tools from the machining zone and
you are done.
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Probe Linearity/Repeatbility Calibration Procedure
SECTION 3
On-Machine
Probe Linearity/Repeatability Calibration Procedure
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This Procedure is to perform linear calibration and check linearity and repeatability
of +/- 1mm mechanical LVDT linear displacement probes connected to the 4 channel
IGA board in a UPX controller.
If adjustments are made here, other calibration procedures will be necessary.
Repeatability is most important to the on machine metrology functions. Verifying
repeatability will give a good indication of probe and system condition, and might be
used to initiate further action.
Safety: Keep clear of moving machine elements. Personnel performing this
procedure should be properly trained in electrical safety.
Avoid collisions of machine elements and probes!
Tools Required:
Non conductive potentiometer adjustment tool
Shim stock, 0.5mm thick. Approximately 5mm x 30mm. Edges should be flat
and smooth.
Probe adjustment spanner, not normally needed (Precitech PN 168-0087).
Probes: A13883 spring extend and A17868 vacuum retract
Integrated Gage Amplifier: A17924
Probe Description
Part Surface Probe
Horizontal Tool Probe
Vertical Tool Probe
UPX display / labels
Probe F / SURF
Probe C / H.P.
Probe D / V.P.
Clean the probes and the surfaces to be probed.
Surface Probe
1. Move the Z axis to the right hand end of travel, to provide clearance to rotate the
B axis.
2. Rotate the B axis to align the probe body with the Z axis direction of travel (+/- 1
degree). The ruby tip should be toward the spindle. Be sure not to wind up the
coolant line and probe cable.
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3. On the machine control touch screen, select the Setup mode, then Servo Monitor
and Tools, then 4 Channel Gage Amp.
4 Channel
Gage Amp
4. Manually actuate the probe. Verify the UPX indicates a full 2mm of travel on
channel F.
a) If the 2mm of travel is displayed go to the next step.
b) If 2mm is not displayed, loosen the locknut with the spanner. Twist the probe
shaft in or out, until manual actuation of the probe, displays 2mm of travel.
The probe may need to be removed from its bracket to get to the locknut.
Tighten the locknut. If 2mm can not be achieved, replace the probe. Mount the
probe back in the bracket.
Probe Display
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5. Jog the Z and X axes to position the probe tip about 1mm from the apex of the ball
or the flat end of the fixture.
Surface probe
6. With the controller in metric units configuration, press the 0.2 mm increment
button. Repeatedly press the Z- jog button until the probe display is perfectly
centered at zero. Use smaller increments as needed.
7. Surface Probe Span adjustment: Increment the Z axis 4 times positive 0.2mm
each. Adjust SURF and SURFACE pots for 0.8000mm. Verify that (8) 0.2mm
increments negative result in 0.8000mm displayed. The tolerance is 0.003mm.
If after repeating the span adjustment the error is greater than 0.003 mm, replace
the probe.
Coarse span adjustments, located in the computer cabinet.
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Fine span adjustments, located in the computer cabinet
8. Linearity check: With the display showing -0.8000mm, increment the Z axis 8
times in the positive direction, each increment should be within 0.003mm of the
expected position. If the error is greater than the tolerance replace the probe.
9. Repeatability check: Increment the Z axis until the display reads 0.0000. Set the
Z axis jog increment to 2mm. Increment the Z axis (1) step positive, then (1)
negative. The tolerance is +/-0.0005mm. Repeat this 3 times. If the error is
greater than the tolerance replace the probe.
Horizontal Tool Probe
1. Move the Z axis to the right hand end of travel, to provide clearance to rotate the
B axis.
2. Rotate the B axis to visually align the cutting tool shank with the Z axis direction
of travel. The cutting tool tip should be toward the spindle. Be sure not to wind
up the coolant line and probe cable.
3. Manually actuate the probe. Verify the UPx indicates a full 2mm of travel on
channel C.
a. If the 2mm of travel is displayed go to the next step.
M17958 - Revision D
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b. If 2mm is not displayed, loosen the locknut with the spanner. Twist the probe
4. Jog the Z and X axes to position the probe tip about 1mm +/- from the apex of the
cutting tool.
5. Incrementall jog the cutting tool against the probe, zeroing the display. Align the
probe with the apex of the cutting tool by crowning . Alternately incrementing the
X and Z axes, keeping the diplay zeroed. When properly crowned, incrementing the
X axis in either direction will make the display more negative.
6. Increment the Z axis button until the probe display reads zero.
7. Horizontal Tool Probe, Span adjustment: Increment the Z axis 4 times positive
0.2mm each. Adust H.P. and HORIZONTAL TOOL PROBE for 0.8000mm.
Verify that (8) 0.2mm increments negative result in -0.8000mm displayed. The
tolerance is 0.003mm. If after repeating the span adjustment the error is greater
than 0.003mm, replace the probe.
8. Linearity check: With the display showing -0.8000mm, increment the Z axis (8)
times in the positive direction, each increment should be within 0.003mm of the
expected position. If the error is greater than the tolerance, replace the probe.
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9. Repeatability check: Increment the Z axis until the display reads 0.000. Set the Z
axis jog increment to 2mm. Increment the Z axis (1) step positive, then (1)
negative. The tolerance is +/-0.0005mm. Repeat this (3) times. If the error is
greater than the tolerance, replace the probe.
Vertical Tool Probe
1. Open the Manual Command Enter (MDI ) window. Type: M17, press enter then
start. This should extend the probe.
2. Manually actuate the vertical probe, checking that the D display indicates a full
2mm of travel.
a. If the 2mm of travel is displayed go to the next step.
b. If 2mm is not displayed, loosen the locknut with the spanner. Twist the probe
3. Open the Manual Command Enter (MDI ) window. Type: M18, press enter then
press start. This should retract the probe.
4. Jog the X and Z axes so the flat top section of cutting tool is under the vertical tool
probe. Type: M17, press enter then start. This should extend the probe.
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5. Vertical Tool Probe, Span adjustment: Record the D probe displacement. Insert
the shim stock.
6. Adjust V.P. and VERTICAL TOOL PROBE potentiometers for the original
displacement plus the thickness of the shim stock. Repeating this and the previous
step several times may be required. The tolerance is 0.003mm. If the error is
greater than 0.003mm, replace the probe.
7. Repeatability check: Remove the shim stock, note the D probed displacement.
With the MDI commands (M17 extended and M18 retract) retract and extend the
probe. The tolerance is +/-0.0005mm. Repeat this (3) times. If the error is
greater than the tolernace, replace the probe. Always retract the probe when done.
Type: M18, press enter then press start. This should retract the probe.
End
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Setup & Calibration of the Horizontal Tool Set Probe
SECTION 4
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LVDT Probe Overview
The Precitech Super Turn Series lathe configuration utilizes three LVDT probes for
the purpose of implementing four different measurements. One probe is used as a
vertical tool setting device, providing the operator the ability to precisely set the
height of the tool relative to spindle centerline. A second probe also related to tool
setting, is mounted in the horizontal plane parallel to the spindle. It is used to
determine the tool radius, and tool location relative to the B axis centerline. A third
probe serves as dual functionality, and is used as a surface probe to determine the
precise location of the part in the Z direction before machining, as well as a
measurement probe to precisely evaluate the part geometry following machining.
The results can be then used to make periodic corrections for upcoming part
machining.
The primary reference point for the entire system is the horizontal toolset probe, and
specifically is the center of the probe tip ball. (Not the apex of the ball). The cutting
tool and the surface/measurement probe are both referenced to this point. This
allows the location and radius size of each to be stored in the UPx control tool table,
which provides a convenient means to manage the respective offsets to one to the
other. When a tool bit is replaced the new tool parameters are then stored in the Tool
Table, and a known relationship to the surface/measurement probe is maintained.
Selection of each device then becomes a matter of selecting the desired tool number.
The tool number assignments in the case of the Super Turning Series machining
process are fixed. The cutting tool is always Tool #1. The surface/measurement
probe is Tool #8 when it is in a parallel (0 degree) orientation to spindle centerline,
and is Tool #9 when it is in the perpendicular (90 degree) orientation to spindle
centerline.
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Setting the height of the Horizontal Toolset Probe:
Remove the part holding fixture, and place the alignment fixture shown below on the
spindle face and apply vacuum. Place the indicator base on the B axis. Indicating on
the center pin, tap in the fixture such that it is aligned concentric to spindle
centerline. Crown the pin by moving the X axis, and set the indicator at zero at top
dead center (TDC). Unscrew the ruby tip from the toolset probe, and replace it with
the second supplied setup pin. Reposition the slides so that the indicator is at TDC
of the probe tip/pin. Adjust the height of the probe to match the height of the spindle
within 10 microns or better. Re-crown the pin to verify TDC. Return to the pin at
spindle centerline and verify zero reading at TDC.
Remove the setup pin from the toolset probe and replace the original toolset probe
tip. Remove the spindle fixture and store the parts together.
Setting the Toolset Probe Height
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Calibrating the Probe Tip Radius and B Axis Centerline Offset:
Remove the cutting tool if present and install the supplied calibration pin/tool shown
below in the tool holder.
Toolset Probe Radius and B Centerline Calibration
Close any open screens and press Manual Command Entry to access the MCE
window. From the MCE window, activate tool T0. (i.e. type T0 , Enter, START)
Jog the B axis such that it is near -45 degrees. Input a command to position it
precisely at -45 degrees ( B-45 , Enter, START). Note: Insure Z is retracted enough
to avoid interference. Select SETUP mode, TOOL TABLE, and select T10. The T10
screen is shown below.
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.
Tool Table T10 Screen
Verify or enter the nominal probe tip radius for the Toolset Probe tip in the LVDT
TOOLSET PROBE RADIUS field.
Touch the B AXIS CENTERLINE SETUP softkey. Touch the FIND B(X, Z)
CENTERLINE softkey shown below.
The screen shown below will be displayed. Enter the ARTIFACT RADIUS as
2.38506, and the ARTIFACT SWEEP as 35. (The SWEEP defines degrees each side
of center)
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Find B Axis Centerline Screen
Jog the axes to position the horizontal toolset probe approximately on center of the
calibration pin, and about 1mm away from the surface
Touch the BEGIN B-AXIS CL SETUP softkey, and then press the START
pushbutton. The probe will touch three points on the pin to determine the X1, Z1, B1
and RAD1 values. Verify that the measured radius (CALC RAD 1) is within +/.002mm of the ARTIFACT RADIUS. If it is not, calculate the difference between
the two and make note whether it was too large or too small, then return to the Tool
Table T10 screen shown above. If the measured radius was too large, make the
LVDT TOOLSET PROBE RADIUS larger by the difference amount. If the
measured radius was too small, make the probe radius smaller by that amount.
Return to step 6 above and repeat the process until the correct measured radius is
achieved.
Next, jog the Z slide back to avoid interference, and then touch the ROTATE B
AXIS 90 DEG + POSITIVE + softkey. The B axis will rotate +90 degrees. Jog the
axes to position the Toolset Probe approximately on center of the calibration pin,
and about 1mm off from the surface. Touch the BEGIN B-AXIS CL SETUP
softkey, and then press the START pushbutton. The probe will touch three points on
the pin to determine the X2, Z2, B2 and RAD2 values, and the X & Z axes B
Centerline values will be calculated. Verify that the results are shown, and then
touch the CLOSE softkey. Touch YES to save the results to the Tool Table. The
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LVDT X and Z B Centerline values are stored in the Tool Table under T10. Close
any open screens and remove the calibration artifact from the tool holder and store it
in a labeled container.
Calibrating the Toolset Probe X Offset:
Move the axes into a clearance position, then install a diamond tool in the tool
holder. For convenience, there are two supplied work spindle fixture options for this
calibration. One mates to the existing #1214 part holding fixture, and the other can
be mounted to the vacuum chuck using the machine vacuum generator.
Mating Fixture to #1214 Fixture
Alternate Fixture held by vacuum
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Insert a pointer in the work spindle fixture and align it to run true. Move the tool so
that the tool tip is near the pointer. Examine the vertical alignment and adjust the
tool vertically if necessary. Jog the axes into clearance, then remove the pointer and
insert the 17mm radius brass stud into the part holding fixture. Reposition the axes
to put the tool visually at part center in the X direction, and slightly off the part in
the Z direction. Select tool #5 in the Tool Table. Enter the nominal radius for the
diamond tool in the RADIUS field. Touch the LOAD TOOL POSITIONS softkey,
and then touch YES. Touch SAVE CHANGES, then CLOSE the tool table. From
RUN mode, select the 17rcx.pgm part program, and START the program. STOP the
program during the cutting path, and with SHIFT turned on, increment the Z slide in
to touch off on the part surface. Use Continuous Jog to jog the tool back from the
part surface, and then shift in the desired cut depth. Restart the program to cut the
part surface. Continue with additional cutting passes, until the part surface is fully
cleaned up. Evaluate the tool height and the X tool centering relative to spindle
centerline, with offline measurement devices. Optimize the tool height by adjusting
the tool holder, and adjust the X abs position in the tool table for tool #5, until ideal
tool centering is achieved.
Align the B axis to the zero position. Select tool #6 in the tool table. Enter the
nominal radius of the diamond tool in the RADIUS field. Set the SWEEP to 70
degrees. Touch the LVDT TOOL SETTER softkey. Touch the X/Z softkey shown
below.
Set the X PROBE OFFSET to 0.0.
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Position the slides such that the Toolset Probe is aligned approximately on center of
the diamond tool and within 1mm of touching the tool edge. Touch START
PROBE TOOL #6 softkey, and then press the START pushbutton. When the routine
finishes, calculate the LVDT X probe offset by subtracting the tool #5 X ABS
position that was previously recorded in step 11 above, from the current
position that is shown. Enter the difference in the X PROBE OFFSET field as a
negative value. The offset value should be in the area of -157mm. The tool is now
also set up for calibration of the vertical LVDT tool set probe. SAVE the data and
close any open screens.
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CALIBRATION RECORD FOR THE LVDT TOOL SET PROBES
SETTING HEIGHT OF HORIZONTAL PROBE
Goal
Actual
Fixture TIR
0.005 mm Max
Height Difference
0.010 mm Max
Operator
Date
HORIZONTAL LVDT TOOL SETTER RUBY PROBE TIP RADIUS
Example
Actual
Artifact Radius
2.38506 mm
LVDT Tool Set
1.5840 mm
Probe Radius
Sweep
35 Degrees
X1
Z1
B1
RAD1
1.5840
RAD1=Probe
YES
If difference over 0.002 mm, adjust
Radius?
LVDT Tool Set Probe Radius, repeat
Operator
Date
HORIZONTAL LVDT TOOL SETTER OFFSET TO B AXIS CENTERLINE
Example
Actual
X2
Z2
B2
RAD2
1.5840
B(X) CL
273.0000 mm
B(Z) CL
-231.0000 mm
Save Results
Yes
Results shown in T10 Yes
tool table?
Operator
Date
LVDT TOOL SETTER OFFSET TO SPINDLE CENTERLINE
Goal
Actual
X Center Error of
0.001 mm
Turned Stud
Height Error of
0.002 mm
Turned Stud
X Center ABS Value -157.0000 mm
Vertical Probe Height Under 0.002 mm
Operator
Date
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Setup & Calibration of the Vertical LVDT Tool Set Probe
SECTION 5
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Initially a tool must be setup at the proper spindle centerline height by cutting a part,
measuring height error using an offline microscope, and adjusting the tool holder
manually to correct for the error. Once a tool is properly set, the vertical LVDT is then
mechanically adjusted to read zero at the correct tool height.
Vertical Toolset Probe
From COMMAND INPUT, execute an M18 command to raise the probe tip. Jog the
slides to position the probe tip directly above the tool. Execute an M17 command to
lower the probe tip onto the tool.
Select SETUP mode, touch MORE, and then touch SERVO MONITOR & TOOLS.
Open the GAGE AMPLIFIER screen by touching the
softkey. The Vertical
Toolset Probe is shown as Channel D. Loosen the 2 socket head cap screws which
secure the probe bracket, and adjust the probe height until channel D reads zero.
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Tip: Slightly snug the mounting screws with the height reading appearing to be
slightly low, and then lightly tap the probe bracket down until zero is attained. Then
secure the mounting screws.
Execute an M18 command to raise the probe tip, and then retract the tool from the set
position by jogging the Z slide. CLOSE the Gage Amplifier window, and CLOSE
Servo Monitor & Tools.
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Setup & Calibration of the Part Surface Probe
SECTION 6
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Setting the B axis measurement positions:
The B axis reference position for the surface probe (T8) is set to 0.0 when the
surface probe is parallel to spindle centerline. Using the integrated gage amplifier
and the electronic gage head, find the B ABS position where the gauge head
remains near zero when the gage tip is traversed back and forth along the probe
body. The gage setup is shown below.
Setting the B Reference Position
Record the B axis ABS position at this location and enter it in the TOOL TABLE
for Tool # 8, in the
field. Touch the SAVE CHANGES softkey.
Calculate the T9 B Abs Position by adding +90 degrees to this position, and enter
the new value in the same field for Tool # 9. Tool number 9 is used to measure
the fixture reference surface and the equator, with the measurement probe rotated
+90 degrees. Touch SAVE CHANGES.
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Setting the height of the Surface/Measurement Probe:
Remove the part fixture from the work spindle, place the setup fixture on the
spindle face, and turn vacuum ON to hold in place. Indicate on the setup pin, and
tap in the fixture to run true to spindle centerline. Remove the ruby probe tip
from the surface probe and replace it with the setup pin shown. Position the
surface probe approximately aligned with spindle centerline. Crown the top of the
pin which is attached to the spindle fixture, and set the indicator zero at top dead
center (TDC). Now move the gage tip to the pin on the surface probe, and crown
for the high point. Adjust the surface probe height until the gage reads near zero
at TDC. Tip: The surface probe is mounted using spring washers, so the probe
height can be moved without loosening the lock nuts by either pushing down
with the jack screw or by prying up gently on the lock nuts. DO NOT pry on the
probe shaft or body.
Setting Height of Surface Probe
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Calibrating the T8 X ABS and Tip Radius for the Surface/Measurement
Probe:
Install the #1214 part holding fixture to the work spindle per the instructions in
section 2 of this manual. With the mounting bolts finger tight, indicate the
reference diameter and tap the fixture into alignment with the rotation axis to
better than 2 microns TIR. Tighten the fixture bolts to (TBD) inch lbs of torque,
and recheck that the alignment is still within specification. Mount the
#136550100 Part Master on the fixture. From SETUP mode, select TOOL
TABLE, and Tool #10. The screen for Tool #10 is shown below.
To calibrate the X Center position and probe tip radius, the Ultracomp Setup Aid
is used. Set the ARTIFACT RADIUS to 18.035. Set the ARTIFACT SWEEP to
40 degrees, and enter the nominal probe tip radius (Ultracomp Tip Rad). Set the
LVDT TOOLSET MAX INFEED to 2.5.
Touch Ultracomp SETUP AID, and select the X/Z mode shown below.
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The screen shown below will appear.
Position the slides such that the surface probe is approximately on center and
within 1mm of the Part Master. Touch BEGIN Ultracomp Setup, and then
press the START pushbutton. The routine will probe the Part Master at three
points and display the X and Z center ABS positions, and the calculated part
radius. Compare the calculated radius value to the known 18.035 Part Master
radius. If the calculated radius is not within 0.5um, calculate the difference and
make note of the error being large or small. CLOSE the window to return to the
Tool Table #10 screen. Adjust the current Ultracomp Tip RAD by the difference.
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If the calculated radius was too small, make the Ultracomp Tip RAD smaller by
the amount of error. Likewise, if the radius was too large make the tip radius
larger. Repeat step 4 until the calculated radius is calibrated. Touch CLOSE and
SAVE the data to the Tool Table. Record the Ultracomp X ABS and the
Ultracomp Tip RAD shown in Tool #10. Enter the X ABS value in the X ABS
field for Tool #8. Enter the Tip RAD value in the RADIUS field for both Tool #8
and Tool #9.
Calibrating the Z ABS Positions for Tool #8 Surface/Measurement Probe:
Remove the Part Master from the fixture and mount the setup fixture shown
below. Install the flat brass stud in the fixture.
From COMMAND INPUT activate Tool #5 and move X to 0.0 position. (Note:
Tool #5 X zero position was previously established in an earlier setup.) Position
the Z slide to locate the tool slightly off from the part surface. Select tool #5 in
the Tool Table. Touch the LOAD TOOL POSITIONS softkey, and then touch
YES. Touch SAVE CHANGES, then CLOSE the tool table. From RUN mode,
select the flat.pgm part program, and START the program. STOP the program
during the cutting path, and with SHIFT turned on, increment the Z slide in to
touch off on the part surface. Use Continuous Jog to jog the tool back from the
part surface, and then shift in the desired cut depth. Restart the program to cut the
part surface. Record the Z ABS position where the cut took place on the part
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surface as TOOL Z AT PART. (Note: For this example, actual machine position
values will be used to clarify sign conventions.)
TOOL Z AT PART = -158.964914
Cancel any SHIFT value by entering an MCE command of G92 .
Move X axis to the (+LVDT X OFFSET) (i.e. 157.584) position. This will
position the probe in line with the Toolset Probe. Select SETUP mode, touch
MORE, and then touch SERVO MONITOR & TOOLS. Open the GAGE
AMPLIFIER screen by touching the
softkey. The Horizontal Toolset
Probe is shown as Channel C. Jog the Z slide in (minus) until the tool touches the
probe, then use the incremental jog feature to zero the gage amp reading. Record
this Z ABS position as TOOL Z AT PROBE.
TOOL Z AT PROBE = -226.884314
Now calculate the PART TO LVDT Z CENTER distance as:
PART TO LVDT = TOOL Z AT PROBE TOOL Z AT PART
PROBE RADIUS
PART TO LVDT = -226.884314 (-158.964914) 1.554
PART TO LVDT = - 69.4734
TEST
From COMMAND INPUT, activate Tool #8 and move B axis to 0.0 position. Jog
the slides to position the surface probe on the part surface, and watching Channel
F, adjust the Z position until the gage amp reads 0.0. Record the current Z ABS
position as SURFACE PROBE AT PART.
SURFACE PROBE AT PART = -53.520288
Next calculate the SURFACE PROBE AT TOOLSET PROBE position as:
SURF PROBE AT TSET PROBE = SURF PROBE AT PART + PART TO
LVDT
SURF PROBE AT TSET PROBE = -53.520288 + (-69.4734)
SURF PROBE AT TSET PROBE = -122.993688
Enter the SURF PROBE AT TSET PROBE position in the Tool Table,
Tool #8.
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Touch SAVE CHANGES after it appears.
The figure below shows the intent of the calibration procedure, being to reference
the surface/measurement probe tip to the toolset probe center. Both probes would
be at their respective zero/null position when aligned as shown.
Calibrating the Tool #9 Z ABS for the Surface/Measurement Probe:
Jog the surface probe away from the part. From COMMAND INPUT select Tool
#9 and move B axis to 0.0. Position the probe tip near the part surface as shown
below.
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T9 Z abs Setup
While viewing with an eye loop, increment the Z slide in until the probe tip is
very near the part surface. (Note: This position is not extremely critical, as it is
only used to reference the probe in the Z plane during part measurement. The
measurement software technique does not demand an exact Z reference position.)
Record this position as T9 AT PART SURFACE.
T9 AT PART SURFACE = -116.409384
Calculate the T9 Z ABS as:
T9 Z ABS = T9 AT PART SURFACE + PART TO TSET LVDT
T9 Z ABS = -116.409384 + (-69.4734)
T9 Z ABS = -185.8828
Enter the T9 Z ABS position in the Tool Table, Tool #9.
Touch SAVE CHANGES after it appears.
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Calibrating the Tool #9 X ABS for the Surface/Measurement Probe:
Remove the setup fixture from the part holding fixture. Activate T0, which makes
Command Position coincide with Absolute Position. Position the X axis at zero
or at the home position. Move the Z axis to the -205.0 position. Reposition the
X axis to bring the probe near the reference surface of the fixture.
This is the Z position where the surface probe is aligned with the reference
diameter on the part fixture. The probe should be positioned as shown below.
Calibrating T9 X ABS
While viewing channel F on the gage amplifier, increment the X axis until the
gage amp reads zero. Rotate the spindle by hand, and position it in the middle of
the run-out range. Re-zero the gage amp reading. Record the X abs position as T9
AT REF SURF.
Calculate the T9 X ABS as:
T9 X ABS = T9 AT REF SURF + REF SURF RADIUS + PROBE RADIUS
T9 X ABS = -10.149316 + 11.07150 + 1.572746
T9 X ABS = 2.494930
Note: The reference radius for the 12/14 fixture is 11.0715mm
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The reference radius for the 11/13 fixture is 11.0769mm
The probe radius is currently shown under T9 RADIUS
This calibration can be performed using either fixture.
Enter the result in the T9
field, and SAVE the changes.
Establishing the Surface Probe Z reference Position(s) to the Part Fixture(s):
To safely guard the surface probe from bottoming out in a component failure type
condition, the surface probe needs to know roughly where to look for the part
surface. The maximum hard travel of the probe is approximately 3mm, so
typically the maximum allowed probe infeed is set to 2.5mm. If the surface probe
does not find the part within 2.5mm of the start point, the cycle is aborted and a
PROBE AWAY error message is displayed. The position at which the probe
starts to look for the part is calculated based on part parameters which define the
specific part in the user P-Table file, as well as a known fixture dimension.
Specifically, the part dimension is from the reference diameter on the taper to the
pole of the part. This is specified in the user P-table. A known dimension for each
fixture was determined at the factory which defines the distance from the
reference diameter on the fixture taper to the end of the fixture. The surface probe
is then referenced to the end of each fixture, which is then used in the probe start
calculation. The fixture end reference position is not a critical calibration, and is
only used to determine the relative probe starting point. It will likely not require
any adjustment, unless the probe location is moved. A separate fixture end
reference position must be defined for each fixture. The reference positions are
command CMD positions with tool #8 active, and are parameter settings which
reside in the surface.probe file, which resides on the /pgm directory. The
parameter entries in the file are shown below.
; surface.probe
09/23/2009
; Surface Probing routine
; The setup parameters below MUST be configured to the specific
; machine setup for each of two fixtures.
;
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;--------------------- Setup Parameters -----------------------P50=2.0
; Probe clearance from null (pre-travel + clearance)
P51=.4174 ; 1214 Fixture end to reference diameter dimension
P52=13.7898 ;1214 Tool #8 active, CMD position at fixture end
P53=2.965 ; 1113 Fixture end to reference diameter dimension
P54=16.5891 ;1113 Tool #8 active, CMD position at fixture end
Activate Tool #8, and position the surface/measurement probe on the end of the
part fixture as shown below. Adjust the Z slide position until gage channel F
reads zero. Record the Z CMD position, and insert the value in the
/pgm/surface.probe file for the respective fixture. P52 is assigned the CMD
position value for the 12/14 fixture, while P54 holds the value for the 11/13
fixture.
Surface Probe Z Reference Position
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CALIBRATION RECORD FOR THE PART SURFACE LVDT PROBE
B AXIS POSITION WHEN Z TRAVEL PARALELL WITH SURFACE PROBE
Goal
Actual
Alignment TIR
0.001 mm/mm Max
Tool #8 B ABS POS
181.0000 degrees
value
SAVE Data
Yes
Tool #9 B ABS POS
271.0000
value
Save Data
Yes
Operator
Date
SETTING HEIGHT OF SURFACE PROBE
Goal
Actual
Fixture TIR
0.005 mm Max
Height Difference
0.010 mm Max
Operator
Date
SURFACE LVDT PROBE RUBY TIP RADIUS
Example
Actual
Tool #10 Artifact
18.0350 mm
Radius
LVDT TS Probe
1.5840 mm
Radius
Artifact Sweep
40 Degrees
LVDT Tool Set Max
2.5 mmpm
2.5 mmpm, Do not adjust
Infeed
X Center ABS
Z Center ABS
CALC RADIUS
18.0350
Calc Radius=Artifact
YES
If difference over 0.0005 mm, adjust
Radius?
LVDT TS Probe Radius, repeat
Save Results
Yes
Enter X ABS to Tool
Yes
#8 and SAVE
Enter Probe Radius to Yes
Tool #8 Probe Radius
field and SAVE
Enter Probe Radius to Yes
Tool #9 Probe Radius
field and SAVE
M17958 - Revision D
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Operator
Date
SURFACE LVDT PROBE TOOL #8 Z POSITION OFFSET (SEE DIRECTIONS)
Example
Actual
TOOL Z AT PART
-158.964914
TOOL Z AT PROBE -226.884314
PART TO LVDT
-69.4734
SURFACE PROBE
-53.520288
AT PART
SURFACE PROBE
-122.993688
AT T.S. PROBE
Enter to tool #8
-122.993688
Z ABS POS
SAVE CHANGES
YES
Operator
Date
SURFACE LVDT PROBE TOOL #9 Z POSITION OFFSET (SEE DIRECTIONS)
Example
Actual
TOOL #9 AT PART -116.409384
SURFACE
TOOL #9 Z ABS
-185.8828
POS
Enter to tool #9
-185.8828
Z ABS POS
SAVE CHANGES
YES
Operator
Date
SURFACE LVDT PROBE TOOL #9 X POSITION OFFSET (SEE DIRECTIONS)
Example
Actual
TOOL #9 AT REF
-10.149316
SURFACE
TOOL #9
2.494930
X ABS POS
Enter to Tool #9
2.494930
X ABS POS
SAVE CHANGES
YES
Operator
Date
SURFACE LVDT PROBE Z POSITION OFFSET FROM FIXTURES
Example
Actual
P51
0.4174
P52
13.7898
P53
2.965
P54
16.5891
SAVE CHANGES
YES
Operator
Date
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Bar Code Scanner Operation
SECTION 7
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The user interface provides the ability to scan job codes using a bar code reader.
The job code must coincide with a P-Table file name, which resides on the UPx Data
Store. The Data Store is mapped as a shared Network Drive on the users host
system, and is where all user P-table files reside. When the job code is scanned, the
UPx software appends a .p extension to the scanned code, and then searches for the
specific file name in the Data Store. If the file name is found, it is then copied from
the Data Store to the UPx hard drive, as /pgm/part_data.p. If the file is not found, a
corresponding error message is displayed. The scanned P-table file, regardless of its
original name, is always copied to the lathe as part_data.p. The scanned job code is
also shown on the run screen, to provide user recognition. If the bar code reader
becomes damaged, the user can manually enter the Job Code by touching the
PRESS HERE FOR KEYBOARD ENTRY softkey. The user would then type the
job code, excluding the .p file extension. The UPx software will automatically
append the .p file extension to the job code.
To select the Job Code selection mode, touch the
softkey, from the
RUN mode. Next scan the bar code to select the job, or use the manual entry
selection.
Scan Job Code Screen
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The scanned or entered job code is then displayed on the RUN screen as shown
below.
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Machining & Inspection Process Sequence
SECTION 8
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Main Run Screen
Precitech Super Turn Series Process Sequence
The Part Program (P878.pgm) is activated automatically at Power ON. The loaded
part program is shown on the RUN screen. If there is a different program loaded the
operator must reload P878.pgm.
Scan Job Code
From the main RUN screen, the machine Operator touches the SCAN JOB CODE
softkey. The Operator scans the bar code, which identifies the associated P-Table
parameter file for the specific part number.
The UPx Control connects to the UPx Data Store, and looks for the specified PTable file. If the file is not found, a FILE NOT FOUND error message is
displayed. If the file is located, it is then copied to the UPx as a standard file named
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part_data.p . The UPx loads part_data.p, and then requires the Operator to confirm
that the correct part fixture number (which is specified in the P-Table file) is
installed on the machine.
The Operator must confirm Yes for the Run Program mode to be activated.
Run Program Screen
Installing WorkspindleFixture
Install the part holding fixture to the work spindle. With the mounting bolts finger
tight, indicate the reference diameter and tap the fixture into alignment with the
rotation axis to better than 2 microns TIR. Tighten the fixture bolts to 35 In.-Lb of
torque, and recheck that the alignment is still within specification.
Loadking Of Part
The operator loads a part to be machined. The operator is also required to clean
debris off of the LVDT probe tip and part so that the probe will measure accurately.
The operator then closes the access door.
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Starting Of The Program Cycle
The Operator then presses the START pushbutton. The cycle will not start unless
both access doors are closed. The program surface.probe is then started. The
program checks that the usable tool sweep is not expired. If there is no remaining
unused tool sweep, the program is immediately aborted with an Error Code 1
(shown in the P-Watch window) and the error message INSERT CHANGE
REQUIRED is displayed.
The program checks that all relevant Part definition parameters are non-zero. If one
is zero, the program aborts with an Error Code 2 , displaying the message PART
DEFINITION ERROR .
The program checks that all relevant Machining parameters are non-zero. If one is
zero, the program aborts with an Error Code 3 , displaying the message
MACHINING PARAMETER ERROR .
The program checks for verification that the Pole to Fixture Reference Diameter
parameter is non-zero. If it is zero, the program is aborted with an Error Code 4 ,
displaying the message POLE DIMENSION NOT SPECIFIED .
The program checks that a valid fixture number is specified. The fixture number
conditionally identifies a related set of predefined parameters which are used to
determine the general part location in the Z plane, for probing the part. If the fixture
number is not valid, the program aborts with an Error Code 5 , displaying the
message INVALID FIXTURE NUMBER .
Surface Probing Routine
Surface probing next occurs to determine the precise location of the part surface in
the Z direction. A position offset is captured, which is relative to the tool center and
the surface/measurement probe. If the MEASURE NOW feature is selected in the
user interface, execution continues with the part measurement cycle. If it is not
selected, program execution (part machining) continues as described below.
Part Machining Routine
The required stock removal (in the Z direction) from the raw part face is calculated
based on the nominal raw part diameter and the finished part radius, which are both
specified in the part specific P-Table file. This value is subtracted from the above
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position offset, to set the finish pass location at the desired depth below the raw part
surface.
The Rough Pass machining cycle is executed. At the end of the roughing pass, the
tool contact point angle (B axis position) is incremented by variable P30 in degrees.
In this manner the tool angle is shifted prior to each finish pass cycle, providing a
fresh spot on the tool and spreading the tool wear across the tool face.
The Finish Pass machining cycle is executed. In both Rough and Finish cycles, the
stock removal is controlled by adjusting the current part radii dimensions, which
achieves consistent stock removal about the surface.
The machine moves to the part load/unload position. The part measurement counter
is evaluated, and if the count is equal to the set Measure Frequency, an alert message
is displayed as a reminder to measure the part. The user may then select MEASURE
MODE if desired, or continue with additional part cutting.
Part Measurement Routine
At this time the process stops for operator involvement. The operator must open the
doors and access the working zone. The ruby stylus tip for the measurement probe
must be cleaned and the freshly machined part must be cleaned so that the
measurement will be accurate.
If this routine is being executed on an infrequent basis, such as once for every 10
parts, then it is also a good time to review the quantity of machining chips present
and clean these out from the machining zone. Wearing protective gloves, collect the
chips by hand and dispose of them properly. It is also allowed to use a vacuum
cleaner, brush, or squeegee to collect the chips. It is not allowed to use an air gun as
this can displace cutting chips into places on the machine where they may cause
damage to the machine. The operator must close the door to proceed with the
measurement routine.
Part Measurement Routine Overview
he Precitech Super Turn Series lathe configuration provides the ability to measure
the part equator radius using the on machine LVDT surface probe. The resultant
measurement error may then be used as an automatic correction adjustment in the
next machining cycle. The user has the option to select a measurement interval,
which then alerts the operator with a displayed message that it is time to measure the
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part. The operator then has the option to measure the part, or decline the
measurement and continue cutting. The message alert is a reminder only, as part
measurement is allowed to be selected at any time part cutting is not in process.
Whenever a part fixture is remounted on the spindle, it is a requirement that the
automated Fixture Calibration routine is executed. The calibration routine
determines the amount of mechanical run-out in the mounting of the fixture, and
adjusts the reference surface radius parameter to compensate for this run-out. It is
however equally important that the user mechanically aligns the fixture to run
concentric to spindle rotation to less than 2um, prior to running the calibration cycle.
Each fixture has an associated Part Master and supporting P-Table which defines the
specific parameters of the respective master. It is very important that the correct Part
Master for the respective fixture is used with that fixture for calibration, or possible
damage to the probe could occur. The associated P-Table file for the respective
fixture is automatically loaded when the user selects the fixture he wishes to
calibrate. The 11/13 Fixture uses file 1113master.p and the 12/14 Fixture uses
1214master.p .
Part Measurement Fixture Calibration
Once the fixture has been mounted on the spindle and indicated in concentric to
spindle centerline to < 2um, it is then necessary to run the calibration routine. Place
the corresponding Part Master on the fixture. From the RUN mode select
MEASUREMENT SETUP. The screen below will be displayed.
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Measurement Setup screen
Touch the corresponding BEGIN softkey for the fixture number which is now
mounted. It is very important to touch the matching softkey, as damage to the probe
could occur if the wrong one is chosen. The automated calibration routine will begin
execution. The operational sequence is such that it probes the Part Master at the pole
first to determine the precise part location. The B axis then rotates CCW to position
the probe perpendicular to spindle centerline. The spindle (C axis) is then Homed,
which provides a consistent rotational position for calibration/measurement. The
probe is then moved to the fixture reference radius first, followed by two points on
the Part Master equator. The spindle is then rotated 180 degrees, and the
measurement of the two points on the equator is repeated. The software then
calculates the compensated fixture reference surface radius and stores this value in
persistent P-variable P9029. The new fixture reference radius value is automatically
saved, and used in upcoming part measurements.
Part Measurement
The MEASUREMENT SETUP screen shown above, provides an entry field for
setting the Part MEASUREMENT FREQUENCY. This is where the user sets the
frequency at which the TIME TO MEASURE alert message will be displayed. A
setting of 0 specifies no message reminder, a setting of 3 would produce the
message after every 3rd part, and so on.
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Part measurement is initiated from the RUN mode, by touching the
softkey. This opens the PART MEASUREMENT screen shown
below.
Part Measurement screen
The part measurement program automatically uses the currently loaded P-Table file
for the specific part number. Touching the MEASURE EQUATOR softkey starts the
part measurement program. The sequence of operation is identical to the fixture
calibration sequence which is described above, with the exception that the equator is
only measured once, taking 2 points, and the 180 degree spindle rotation does not
occur. When the measurement cycle is complete, the calculated RADIUS ERROR is
displayed and the ACCEPT / REJECT softkeys appear. At this point in the process
the Radius Error value is held in variable P515. If the user chooses to ACCEPT the
measurement, the Radius Error correction value is then transferred to persistent Pvariable P9022, which is then used in the machining part program as a radius
correction value for the next part. If the user chooses to REJECT the measurement,
they may then either measure again, or CLOSE the window to return to the RUN
mode. In either case the P9022 value remains unchanged from its previous setting.
The current P9022 radius correction value is visible in the P-Watch window on the
RUN screen. It may be cancelled at anytime the user desires by executing a
COMMAND INPUT entry of P9022=0 .
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Tool Change Process
SECTION 9
Tool Change Process
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Tool Change Process
Precitech Super Turn Series Tool Insert Change Process
The Precitech Super Turn Series machining system supplies a sequenced tool insert
setting routine, which guides an operator through a complete insert change and setup
process. Some of the steps require manual adjustment or confirmation from the
operator, and others are fully automated. The sequence is driven by forced
execution of specific steps or programs related to each step of the process. The next
step can not be executed without completing the prior. Each step executes a specific
program related to that step.
The automated routines require some position information in order to move the tool
to required locations for setting the tool. The nominal tool radius for the tool and the
measurement sweep full angle must be entered in the Tool Table, Tool #1, in order
for the automated routine to properly measure the tool geometry. The measured
radius replaces the nominal value in the Tool Table, once the measurement is
complete and the data is accepted. Therefore, typically the nominal radius and sweep
only have to be entered once, unless the tool radius size is changed appreciably. The
TOOL TABLE is accessed from SETUP mode, and is shown below.
Tool Table, Tool #1
If similar tool inserts are used, there is seldom the need to modify these values. If a
different size or type tool insert or tool holder is used, it will likely be necessary to
correct the tool values in the tool table to suit the new setup. It may also be
necessary to tailor the position commands in the programs which are associated to
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Tool Change Process
each sequence step, to properly position the toolset probe relative to the insert. These
programs are described below.
The Insert Change Procedure is compromised of seven programs which sequence the
insert setting process, and are user accessible. The files reside on the /pgm/tl
directory and are named s1.pgm through s7.pgm, with the exception of the Insert
Mapping program which is named Tool_map.pgm. They are accessible through the
EDIT mode, FILE UTILITY selection. On the Insert Change Procedure screen
shown below, s1.pgm corresponds to softkey 1, s2.pgm to softkey 2, and so on. Step
#6 calls the insert mapping program (Tool_map.pgm). Most of the programs are
very short, and the positions to tailor are easily recognizable. The button description
makes obvious which program would require modification, if the probe is not prepositioning at the desired location. The insert set routine always sets the tool as Tool
#1 as related to the UPx Tool Table.
Insert Change Guide screen
Upon pressing softkey 1, MOVE TO LOAD POSITION, the machine axes will
move to a position appropriate for the operator to change the tool insert.
The operator then changes the insert and cleans the ruby tips for the tool setter
LVDT probes. Once the tool insert is changed, the operator presses the second
softkey 2, which acknowledges to the machine that the tool has been changed.
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Tool Change Process
Upon pressing softkey 3, SET TOOL HEIGHT, the vertical LVDT probe is
automatically raised and the machine axes move to place the tool tip under the
probe. Once in position, the LVDT is lowered and a measurement is taken.
The operator is then responsible for adjusting the tool height until the measured
value is 0.0 +/- 0.005 mm. Once in position the operator presses softkey 4, to
acknowledge the insert height is now set.
The softkey 5 will command the slides to perform a tool set of the newly installed
insert. The screen below shows the results of this automated insert set routine.
Results of finding the Insert center and radius
The operator reviews the results, and then touches the DONE softkey. They must
then choose to accept the results or reject the data. If rejected, the newly measured
data is discarded and the tool data for tool #1 is left unchanged. If accepted, the tool
data for tool #1 is updated and the previous data is discarded.
The softkey 6 opens the insert mapping screen, which is shown below.
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Tool Change Process
Insert Mapping screen
The mapping routine is an automated program which utilizes the LVDT Toolset
probe, to probe multiple points about the perimeter of the tool edge, and create an
error map of the tool geometry. The collected error data is maintained in a table of Pvariables for use by the main part program, and is also saved in a file. Up to 29
points may be collected about the tool edge.
Parameters in the Tool Mapping program (Tool_map.pgm) specify: B Starting
Angle, Measurement Spacing (in degrees), and Number of Entries in the table. The
Starting Angle will always be the first entry in the table, and will always be zero
error. As the mapping program executes, the collected data is stored in a temporary
table of P-variables. The first entry in the table is stored in P-variable P8000. The
second point resides in P8001, and so on.
The operator starts the automated mapping routine by touching the BEGIN ERROR
MAPPING softkey. When the mapping routine is complete, the operator is then
required to ACCEPT or REJECT the results. Accepting the results, transfers the
temporary P-variable table to persistent P-variables P9050 to P9079, which are then
also saved in a file. If the machine power is turned off, and then restored, the tool
map P-variables are restored from the values in the file. If the operator REJECTS the
results, the previous insert map remains unchanged.
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Tool Change Process
The main part program is constructed to monitor the current B axis tool angle
position, and linearly interpolate between correction points, to then apply the
corresponding tool radius error compensation for the specific angle.
When mapping a tool, it is advisable to map a larger sweep angle than the intended
use of the tool, to insure a full range of correction data.
The softkey 7 will move the slides of the machine to the part load/unload position.
This is the end of the insert change process, and is a requirement to confirm
completion of the sequence. This confirmation is used to reset the B axis offset to
the beginning of the usable tool sweep, upon the next execution of the machining
cycle.
Insert Change Procedure Programs
Below is a listing of the programs that are sequentially executed to create the insert
change procedure:
Step 1:
; s1.pgm
; MOVE TO TOOL CHANGE POSITION
g71
g90
g01
g92
g59
t0
g4f.5
m110
g4f.5
If(P2004>119 and P2004<209) ; Force CCW always
Z-50 B119 F2000
Endif
X115 Z-50 B300 F2000
M2000.001
; flag to tell 'toolChange' we're here!
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Tool Change Process
Step 2:
;s2.pgm
;TOOL CHANGE IS COMPLETE (Confirms step 1 only)
g71
g90
g01
g92
g59
t0
M18
g4f1
m2000.002
; flag to tell 'toolChange' we're here
Step 3:
;s3.pgm
; SET TOOL HEIGHT
g71
g90
g01
g92
g59
t0
M18
m75.1
;sync the probe read
If(P2012<.05)
;probe didn't raise?
P579=4
;set error code
exit
Endif
x255.2 z-231.73 b0 F2000
m17
;lower probe onto tool
g4f0.5
m2000.003
; flag to tell toolChange we're finished
Step 4:
;s4.pgm
; CONFIRM HEIGHT SET & RAISE LVDT
t0
g4f1
m18
;raise LVDT
m2000.004
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Tool Change Process
Step 5:
;s5.pgm
; DO LVDT TOOLSET
g71
g90
g01
g92
g59
t0
M75.1
If(P2012<.5)
; vertical probe didn't raise
P579=4
; set error code
exit
Endif
z-220 f500
x276.441 z-229.44
g4f1
M2000.027
;
P9025=1
;
P9022=0
;
g4f1
m2000.005
;
b-35
calls the toolset routine
flag to pgm that tool is changed
clear radius offset from equator error
flag to tell toolChange we're finished
Step 6:
;Tool_map.pgm
10/22/2009
;Program to measure multiple points about the perimeter of the tool,
;and map tool waviness and virtual center errors.
;This runs as sequence number 6 in the TOOL CHANGE GUIDE.
P41=1
;fixture = ok
;watch:P8000=1st point W
;watch:P8001=2nd point W
;watch:P8002=3rd point W
;watch:P8003=4th point W
;watch:P41=fixture status
;---------------------- Setup Parameters ----------------------------
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P600=-35
P9032=5
P603=19
Tool Change Process
;Starting B angle @ X0 Z0 (degrees)
;Measurement increment (degrees)
;Number of P-vars in the array
;---------------- Internal Program variables -----------------------P610=P600
;P611=
P612=0
;P613=
;P614=
;P615=
;current B angle = starting angle
;current W value
;array index for p-var number assignment
;point counter
;W offset to make 1st point = 0 correction
;calculated Z @ probe null position
;---------------------- Main Program -------------------------------P560=0
;Program status = started
If(P603>29)
P579=8
P560=-1
EXIT
Endif
G90
G01
G59
G92
T1
M110.1
;ERROR = TOO MANY POINTS
;Program status = Done & error
;Abort if specified # of points > 29
;Absolute mode
;linear
;clear all programmable offsets
;clear all G92 Presets
;Mapped tool is always T1
;Get the lvdt probe X offset & Probe radius
Z50 F1000
X(-P2006) B(P610) F500
;X to Tset LVDT X Offset
P615=P590+P2007
Z(P615+5) F1000
;Z null = Tool rad + probe radius
;move to clearance position
While(P612<P603)
;Loop for specified number of points
Z(P615+2) F300
G04 F.5
B(P610) F1000
Z(P615) F100
G04 F1.5
M75.1
;Z to 2mm off from probe null
;move B to the next mapping point
;move Z/tool to ~probe nullposition
;wait for 1.5 seconds for things to settle
;get the analog probe value
If(P612=0)
P614=P2011
P8000=0
Else
P(8000+P612)=P2011-P614
Endif
;if it's the 1st point in the map
;store the W offset for the first point
;1st pt correction value = 0.0
P610=P610+P9032
P612=P612+1
;increment the B angle
;increment the array index
;store the probe W reading - W offset
Endwhile
Z100 F1000
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;Z to safe retract
77
G04 F.5
P560=1
M2000.006
Tool Change Process
;Program status = done & valid
;tells the host that Toolset seq #6 is done
Step 7:
;s7.pgm
; GO TO PART LOAD POSITION
g71
g90
g01
g92
g59
t0
P579=0
; clear tool change required error code
P9025=1
; flag to pgm that tool is changed
P9022=0
; clear radius offset from equator error
x280 z-50 f2000
m2000.007
; flag to say we're finished
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79
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80
Program Printouts
SECTION 10
Program File Printouts
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Name and File Locations
Program Printouts
Description
In the /pgm directory:
P915.pgm
surface.probe
flat.pgm
17rcx.pgm
P579error.codes
part_data.p
1113master.p
1214master.p
Main Paramacro program
Surface/Part Probing program
Part program for cutting a Flat.
Used for Surface probe calibration
Part program for cutting a 17mm convex radius.
Used for Toolset probe calibration
Text file which specifies the error message
related to the P579 error code number
The machine resident P-Table file.
The scanned job P-table gets copied to here.
P-table for 1113 Part Master
In the /pgm/tl directory:
s1.pgm
s2.pgm
s3.pgm
s4.pgm
s5.pgm
s7.pgm
m1.pgm
cal_fixture.pgm
Tool_Map.pgm
check_results.pgm
save_results.pgm
"Move To Insert Load Position" program
"Press When Insert Is Installed" program
"Set Insert Height" program
"Press When Tool Height Is Set" program
"Set Insert Center" program
"Move To Part Load Position" program
Equator Measurement Program
Fixture Calibration Program
Tool Mapping Program
Program to check Tool Map Corrections
Program to save data when prompted by operator
/upx.setup/autop_cfg.dat
Configuration File for automated network communications (Bar
Code Scanner file selection)
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P915.pgm
Program Printouts
Main Paramacro program
;P915.pgm
;Precitech Proprietary Information
04/28/2010
;Similiar to P878.pgm, with the following modifications.
;
1. Remaining tool sweep (P9021) is now calculated based
;
on P9020, which is the current B/Tool offset.
;
2. P5 was added to the watch window, and the unused
;
measurement variables P9022, P9029, P502, P515 removed.
;
3. P28, P29 added to define a blend zone between the toric
;
and the sphere to avoid instantaneous b-motion
;
P562, P563, P564 also added to do the blend zone calcs
;
4. During path generation, P575 is now incremented at the
;
end of the loop, not the beginning
;
5. P6 is added as a "material on" variable that basically
;
is a tool radius offset. P2 and P3, the spherical and
;
toric radii will now be the finished part dimensions;
;
the path will be the finished path, but the P6 offset
;
will mean that there will be P6 "material on" the part
;
which will then be taken off in subsequent polishing
;
operations
;
6. P33 and P34 are the angles before and after the toric
;
that define the width of the equator correction zone
;
P35 is the hieght of the equator correction which ramps
;
up from zero at P33 degrees before the equator, reaches
;
a maximum of P35 material on at the equator, and ramps
;
down to zero again at P34 degrees after the equator.
;
P34 cannot be so big that the equator correction zone
;
extends into the spherical or blend part of the surface
;
as the zone will end immediately if the toric while loop
;
is exited (P34<40 deg)
;Z=tool radius (P1) when the tool is touching at the pole of
;the finished turned part
;NOTE: The Part and Machining Parameters shown below are
;loaded from a 'P' table file. The values shown are typical
;and for reference only.
;------------------ Part Parameters -----------------------;Below is a list of p-table parameters to be used for reference
;the actual values used by the program will be taken from the
;p-table
;P2=18.0350
;P3=18.0120
;P4=0.01549
;P5=0.0015
;p6=0.0025
;p7=133.1
;P8=47.5
;P9=0.05
;Finished Spherical radius
;Finished Toric radius
;Toric center X offset
;Start of toric correction value
;"material on" offset, the part will have this
;much material left to be polished off
;Starting angle of the Toric
;Starting angle of the sphere
;.05 Angular increment
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Program Printouts
;P28=0.2
;blend zone extends 0.2 deg into the sphere
;P29=0.2
;blend zone extends 0.2 deg into the toric
;----------------------------------------------------------;--------------- Machining Parameters ---------------------;P10=1000
;P11=0
;P12=0.063
;P15=.75
;P16=.002
;P9030=.2
;P9031=
;P18=
;Spindle rpm
;unused
;Feed per rev
;start of pull-off in X (must always be > 0)
;pull off distance in Z(0 = no pull-off)
;Tool/part radius offset (user adjustable)
;Tool correction radius offset from mapping
;Nominal Raw Ball Diameter
;P20=1
;P21=.05
;P22=1
;P23=.05
;Number of Rough Passes
;Rough Cut Depth
;Number of Finish Passes
;Finish Cut Depth
;P30=.25
;P31=70
;P32=70
;Tool Contact Angle Increment (each part)
;Starting tool/B end angle (at x0 Z0)
;Total usable tool sweep
;------------------ Watch Params --------------------------;NOTE:!!!
;
;
;
P40, P41, & P579 must be included as watch parameters for
Host usage. They can be at positions 16 -> 20 in the list
which will not be displayed in the watch window, as only
15 are displayed.
;watch:P9020=tool B offset
;watch:P9021=sweep remaining
;watch:P5=toric correct start
;watch:P9030=user rad offset
;watch:P9031=mapped rad offset
;watch:P1=total radius Offset
;watch:P9025=tool just changed
;watch:P565=Stock Removal
;wathc:P560=Program Status
;watch:P579=error code
;watch:P40=fixture number
;watch:P41=P table load status
;watch:P50= 1.75
;watch:p19=12.3014
;watch:P60= z-probe position
;watch:P51=0.4174
;watch:P52=16.5909
;watch:p53=2.965
;watch:p54=17.2391
;watch:P17= 0
;-------------------------- Main Program -----------------------------
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Program Printouts
If(P579>0 or P41<0) EXIT ;Error detected in surface.probe program so abort
If(P9032=0)
P579=7
EXIT
Endif
;If Tool map angle = 0
;ERROR = "TOOL IS NOT MAPPED"
;abort program
g01
g71
g90
g40
g18
g92
g59
g13
;linear interpolation
;metric mode
;absolute programming mode
;cancels G41/G42 tool radius compensation
;XZ plane for interpolation
;Cancel any active G92 preset
;clear G59 offsets
;feedrate relative to X and Z only
M101
;Find the part surface (calls surface.probe program
;prior to running this program and stores the surface
;position in 'P0' which is used below.)
Z(P0+50) F1500
T1
m7.5
;Retract from surface
;Tool #1 is cutting tool
;Turn ON flood coolant
P565=P18/2-P3+P4-P6 ;Stock removal = Raw Dia/2 - finished toric radius + Toric
Offset
; - material on condidtion
P566=P2*COS(P8)-P3*COS(ASIN((P4+P2*SIN(P8))/P3)) ;Calculate the Toric Z Offset
P567=ASIN((P2*SIN(P8)+P4)/P3)
;Calculate the Ending toric angle
P1=(P20*P21)+(P22*P23)+P9030+P590-(P9022-P9023)+P6
;Total Radius Offset = Total cut depth + user rad offset
; + tool rad - (Equator rad error - X center error) + material on condition
If(P9030>0)
;If user radius offset > 0
G59 X(P9023) Z(P0-P565) B(-P9020) ;Z zero position is at pole - stock
removal depth
Else
G59 X(P9023) Z(P0-P565-P9030) B(-P9020) ;keeps the ball center at consistent
location
;if one is cutting a ball multiple
times
;for setup or testing purposes
Endif
M4 S(P10)
X(-P1-P2-6)
ball
G81
;Start spindle at 'P10' speed.
Z(P1+6) B(P7) F1500 ;move to a clearance position 6mm off from the
;wait for the spindle to reach speed
;--------------------- Pass Loops ------------------------P574=0
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;Reset the pass counter
85
While(P574<P20)
P1=P1-P21+P9031
correction
G59 B(-P9020)
Gosub 1000
P574=P574+1
Endwhile
Program Printouts
;Loop for Rough Passes
;Decrement Radius offset by rough cut depth + tool
;Set B offset
;cut the surface
;bump the pass counter
P9020=P9020-P30
P577=P31/2 - P32
P9021=ABS(P577-P9020)
;decrement the tool contact point B offset
;B end pos = start position - total sweep
;Remaining sweep = end pos - current B offset
;The tool mapping routine gives a tool radius correction
;value depending upon which part of the tool is being used
P616=((-P9020+35)/P9032) ;determine the tool correction angle
P617=FIX(P616)
;get the lower integer value
P618=P616-P617
;get the fractional value
P9031=P(9050+P617)+P618*(P(9050+P617+1)-P(9050+P617)) ;calculate radius
correction
P574=0
While(P574<P22)
P1=P1-P23+P9031
correction
G59 B(-P9020)
Gosub 1000
P574=P574+1
Endwhile
;Reset the pass counter
;Loop for Finish Passes
;Decrement Radius offset by Finish cut depth + tool
m9
m5
P9024=P9024+1
;coolant OFF
;spindle OFF
;bump the part measurement counter
T0
G59
Z-180 F2000
X280 Z-85
;Tool #0 which is relative to HOME position
;cancels any active G59 offset
;safe retract position
;Part Load position
If(P9024=P9027)
P579=6
P9024=0
Endif
;If it is time for measure reminder
;Display TIME TO MEASURE alert message
;Reset 'time to measure' counter
EXIT
;End of MAIN program
;B Offset for new contact point on tool
;cut the surface
;bump the pass counter
;------------------------ END Main -------------------------------;-----------------Surface Profile Subroutine ---------------------;A series of points (x, z, and b position) will be calculated on the
;part profile. The tool tip will trace a linear path from point to
;point on the part profile. The size of each straight line segment
;is determined by the angular increment [P9]
N1000
P575=P7
M17958 - Revision D
;label for subroutine call
;set starting angle = start of toric
86
z(P1+6) F1500
X(-P1-P2-6)
Program Printouts
;safe Z position 6mm off the pole
;safe X position away from the equator
P573=-(P1+P3)*SIN(P575+P9)+P4
;calculate first X point on the torus
P572=(P1+P3)*COS(P575+P9)+P566-P2 ;calculate first Z point on the torus
Z(P572) B(P575) F800 ;move Z to correct depth and position B
X(P573-1) F300
;X to 1mm off from the surface
X(P573-P5) F75
;move X to the cut start position
;--------- LOOP FOR THE TORIC PART OF THE SURFACE --------WHILE (P575 > (P567+P29))
;loops the toric until reaching the
;blend zone portion of the curve which
;starts P29 degrees before the end of
;the toric zone
P573=-(P1+P3)*SIN(P575)+P4
P572=(P1+P3)*COS(P575)+P566-P2
;calculate the next X point on torus
;calculate the next Z point on torus
;A toric start correction can be used to increase or decrease the
;amount of material on the backside of the head by shifting the
;x-point of the toric out.
;This correction adds [P5] of excess material at the start of the cut
;and the extra material linearly falls to zero at the equator.
If(P575>90)
;if the angle > 90
P573=P573-P5*(P575-90)/(P7-90) ;calculate Start of Toric correction
Endif
;An equator correction will increase of decrease the x-position
;at the equator region of the partt. Starting at P33 degrees before 90
;and ending at P34 degrees after 90, reaching the full value (P35)
;at 90 deg
If(P575<P33+90 AND P575>90)
P573=P573-P35*(90+P33-P575)/P33
Endif
If(P575<=90 AND P575>90-P34)
P573=P573+P35*(90-P575-P34)/P34
Endif
X(P573) Z(P572) B(P575) F(p10*P12);move to the next X, Z, B, position
P575=P575-P9
;Decrement the angle
ENDWHILE
;------- LOOP FOR THE BLEND PART OF THE SURFACE ------WHILE (P575 > (P8-P28))
M17958 - Revision D
;loops to the end of the blend zone which
;extends P28 degrees into the spherical
;zone
87
Program Printouts
;a radius correction term will vary the radius from the toric radius
;to the spherical radius in a smooth manner throughout the blend zone
;sin(X*90)^2 (0<X<1) gives a smooth transition with a continuous
; acceleration profile, but non-continuous jerk
P561=(SIN((P567+P29-P575)/(P567-P8+P28+P29)*90)*SIN((P567+P29-P575)/(P567P8+P28+P29)*90))
; SIN((SIN((P567+P29-P575)/(P567-P8+P28+P29)*90)*SIN((P567+P29-P575)/(P567P8+P28+P29)*90))*90)
;sin(sin(X*90)^2*90)^2 (0<X<1) gives a smooth transition with continuous jerk,
;but a higher peak acceleration than sin(X*90)^2
;P561=SIN((SIN((P567+P29-P575)/(P567-P8+P28+P29)*90)*SIN((P567+P29-P575)/(P567P8+P28+P29)*90))*90)*SIN((SIN((P567+P29-P575)/(P567P8+P28+P29)*90)*SIN((P567+P29-P575)/(P567-P8+P28+P29)*90))*90)
P562=P561*(P2-P3)
;an x and z correction term will shift the toric centerpoint from the
;centerpoint of the toric to the centerpoint of the sphere throughout
;the blend zone in a smooth fashion
P563=P561*(P4)
P564=P561*(P566)
;the new x and z coordinates will be calculated
P573=-(P1+P3+P562)*sin(P575)+(P4-P563)
P572=(P1+P3+P562)*cos(P575)+(P566-P2-P564)
X(P573) Z(P572) B(P575) F(p10*P12) ;move to the next X, Z, B, position
P575=P575-P9
ENDWHILE
;------- LOOP FOR THE SPHERICAL PART OF THE SURFACE ------WHILE (P575 >= 0)
;loop until the angle is <= 0
P573=-(P1+P2)*SIN(P575)
;calculate the next X point on sphere
P572=-(P1+P2)*(1-COS(P575))+P1 ;calculate the next Z point on sphere
If(P15<=0) P15=.0001
;forces p15 to always be > 0
;A correction factor at the pole of the part is available to eliminate
;any positive or negative features that occur there.
;This correction factor adds a linear z-move, that starts at [P15]mm
;from the center of that part and ends with the z-position [P16]mm
;from the theoretical pole of the sphere.
IF(-P573<P15)
;if X is within P15 of center (correction at the pole)
P572=P572+P16*(1+P573/P15)
;calculate an alternate Z value
ENDIF
M17958 - Revision D
88
Program Printouts
X(P573) Z(P572) B(P575) F(p10*P12) ;move to the next X, Z, B, position
P575=P575-P9
ENDWHILE
X0 Z(P1+6) F700
P570=(P9020+P31/2)
B(P570) F1500
;move 6mm off from the pole
;calculate B ABS 0 adjusted by g59 offset
;move B to ABS 0.0
RET
;return to main program
;----------------- END Surface Profile Subroutine --------------------
surface.probe
Surface/Part Probing program
; surface.probe
10/06/2009
; Surface Probing routine for P878 hard turning
; The setup paramters below MUST be configured to the specific
; machine setup for each of two fixtures.
;
;--------------------- Setup Parameters -----------------------If(P17>0)
P50=1.75
;Probe clearance from null (pre-travel + clearance)
Else
P50=1.75+P17 ;Probe clearance from null (pre-travel + clearance)
Endif
P51=.4174
;1214 Fixture end to reference diameter dimension
P52=14.441
;1214 Tool #8 active, CMD position at fixture end
P53=2.965
;1113 Fixture end to reference diameter dimension
P54=17.2391
;1113 Tool #8 active, CMD position at fixture end
;------------------- Error Checking -----------------------If(P41<0) EXIT
; P-table loaded but fixture # not confirmed
If(P9025=1)
P9020=P31/2
P9021=P32
P9026=0
P9025=0
Endif
;
;
;
;
;
P579=0
If(P9021<P31-P32)
P579=1
EXIT
Endif
Tool has just been changed (set = 1 in s5.pgm)
Set tool angle to starting end angle @ X0 Z0
Set sweep remaining to total usable sweep
Reset degrees of tool used up
clear tool changed flag
;
;
;
;
clear program error flag
tool sweep is used up
ERROR = "INSERT CHANGE REQUIRED"
Abort program if B offset exceeds max
If(P2=0orP3=0orP4=0orP7=0orP8=0orP18=0)
P579=2
; ERROR = "PART DEFINITION ERROR"
EXIT
Endif
M17958 - Revision D
89
Program Printouts
If(P9=0orP10=0orP12=0orP22=0orP23=0)
P579=3
; ERROR = "MACHINING PARAMETER ERROR"
EXIT
Endif
If(P19=0)
P579=4
EXIT
Endif
;pole to fixture ref diam not specified
;ERROR = "POLE DIMENSION NOT SPECIFIED"
If(P40=1214)
;Fixture # 12/14 is specified
P60=P52-P51+P19+P50
;calculate the start pt to look for part
;start = fixture end - ref dia to end + ref dia to pole + clearance
Else
If(P40=1113)
;Fixture # 11/13 is specified
P60=P54-P53+P19+P50
Else
P579=5
;ERROR = "FIXTURE NOT SPECIFIED"
EXIT
Endif
Endif
;--------------------- Probing Routine-------------------------M105S100
G01
G40
G71
G92
G90
G59
M5
M9
M18
M5
T0
G4 F.5
M110
Z-75 F2000
;probe infeed in mm/min
;T0, so referenced to home position
;read ABS positions
;Z retract
If(P2004>245 or P2004<10)
B10 F3600
;Force CW if need be
Endif
T8
P586=P590
B0 X0 Z(P60) F2000
G4F0.3
M100
flat.pgm
;Tool 8 holds the probe positions
;store the surf probe tip radius
;move B, X & Z into position
;wait 0.3 seconds
;seek null
Part program for cutting a Flat.
Used for Surface probe calibration
g01
g90
M17958 - Revision D
90
Program Printouts
g71
g40
g59
t5
m3s1500
g81
m7.1
z5 f300
x12 f500
z0 f300
x0 f25
g4f.5
z5 f300
m9
m5
17rcx.pgm
Part program for cutting a 17mm convex radius.
Used for Toolset probe calibration
;17mm Convex Radius
g01
g71
g90
g18
g40
t5
/m3 s1500
/g81
/m7.1
z10 f500
b0 f500
x12 f500
g41 x10 z-3.252273 f300
g02 x0 z0 r17 f25
g04 f.5
g46
g01 z10 f500
g40 x10 z10
m5
m9
P579error.codes
;
;
;
;
;
Text file which specifies the error message
related to the P579 error code number
P579error.codes
P579 error codes....
Entries are of form '##':'description'
P579 must be in the 'watch' window for this funtion to work
## are from 0: to 20: can be 80 chars long
00:
01:
02:
03:
DO NOT USE
INSERT CHANGE REQUIRED
PART DEFINITION ERROR
MACHINING PARAMETER ERROR
M17958 - Revision D
91
04:
05:
06:
07:
08:
09:
10:
11:
12:
13:
14:
15:
16:
17:
18:
19:
20:
Program Printouts
POLE DIMENSION NOT SPECIFIED
FIXTURE NOT SPECIFIED
TIME TO MEASURE
INSERT IS NOT MAPPED
-TOO MANY POINTS
-
part_data.p
The machine resident P-Table file. The scanned job Ptable gets copied to here. Contents variable dependent
upon scanned job code.
1113master.p
P2=18.0375
P3=18.01139
P4=0.01549
P7=133.1
P8=47.5
P9= 0.06
P10=1700
P12=0.050
P15=.75
P16=.002
P18=36.198
P19=10.589
P20=0
P21=.05
P22=1
P23=.1
P30=.25
P31=70
P32=70
P40=1113
P41=1
;Spherical radius
;Toric radius
;Toric Starting Agle
;Starting rpm
;Feed per rev
;Start of pull-off in X
;pull off distance Z
;Nominal RAW Part/Ball diameter (before machining)
;Reference diameter to pole dimension
;Rough Cut Depth
;Finish Cut Depth
;B starting end angle @ X0 Z0
;Required fixture number
;Flag host that new P-table loaded
1214master.p
P2=18.035
P3=18.012
P4=0.0155
;Spherical radius
;Toric radius
M17958 - Revision D
92
P7=122.1
P8=47.5
P9= 0.06
P10=1200
P12=0.063
P15=.75
P16=.002
P18=35.993
P19=7.714
P20=0
P21=.05
P22=1
P23=.1
P30=.25
P31=70
P32=70
P40=1214
P41=1
Program Printouts
;Toric Starting Angle
;Starting rpm
;Feed per rev
;Starting pull-off in X
;pull off distance Z
;Rough Cut Depth
;Finish Cut Depth
M17958 - Revision D
93
m1.pgm
Program Printouts
Equator Measurement Program
;m1.pgm
;Equator ONLY Measurement Program
10/04/09
;Notes:
;
'W' is the probe reading.
;
'point Angle' is measurement point relative to the pole.
;
The equator is at 90 degrees.
;-------------------- Watch Parameters --------------------------;watch:P500=Ref Surf Radius
;watch:P501=Ref Surf Z pos
;watch:P502=Meas Ref Surf W
;watch:P506=1st point w
;watch:p510=2nd point w
;watch:P515=Equator Rad Err
;watch:P0=surface location
;watch:P560=program status
;watch:P40=fixture number
;watch:P9028=C reference pos
;watch:P3=Toric Radius
;watch:P9029=cal'd ref radius
;-------------------- Setup Parameters --------------------------P566=P2*COS(P8)-P3*COS(ASIN((P4+P2*SIN(P8))/P3)) ;Toric Z Offset
p560=0
;Program Status = Started
If(P40=1214)
If(P9029=0)
P500=11.0715
Else
P500=P9029
Endif
P501=-205.
Else
If(P40=1113)
If(P9029=0)
P500=11.0769
Else
P500=P9029
Endif
P501=-205.
Else
P579=5
P560=-1
EXIT
Endif
Endif
;12/14 Fixture
;Ref radius not calibrated
;Reference Surface radius (diameter/2)
P502=0
;Ref radius = calibrated radius
;Reference Surface Z ABS position
;11/13 Fixture
;Program Status = Done & Error
;Measured Reference Surface W (probe value @ surface)
M17958 - Revision D
94
P503=91.5
P504=0
P505=0
P506=0
;1st
;1st
;1st
;1st
point
point
point
point
Angle
X
Z
w
P507=88.5
P508=0
P509=0
P510=0
;2nd
;2nd
;2nd
;2nd
point
point
point
point
Angle
X
Z
w
Program Printouts
;P511 - P515 used for equator error calculation
;----------------------------------------------------------------P560=0
;Program status = in-process
M101
;call surface.probe to find the ball location
T8
;Tool #8 is part probe setup when parallel to spindle
G59Z(P0-P590) B0 ;offset Z for surface probe tip radius
Z30 F2000
;safe retract point
B-179 F3600
;force B minus direction
T9
;Tool #9 is part probe at 90 degrees to spindle
X-30 Z50 B0 F2000 ;move to measurement area
;----------------- Reference Surface Calibration ----------------T0
Z(P501-P0+P586) F2000
;Z to reference surface pos
M27.1
;Activate & Home C Axis
G04 F.5
C(P9028) F3000
T9
X(-P500-P590-1.5) F500
X(-P500-P590) F100
;X to reference surface pos
G04 F2
M75.1
;get the probe value
P502=P2014
;store probe reading
;------------------ 1st Point Measurement -----------------------P504=-(P3+P590)*SIN(P503)+P4
P505=(P3+P590)*COS(P503)+P566-P2
;X pos
;Z pos
X(P504-2) F1000
Z(P505) F2000
X(P504) F100
G04 F2
M75.1
P506=P2014-P502
X(P504-2) F500
;X to clearance position
;Z to measurement point
;X to measurement point
;store corrected probe reading
;------------------ 2nd Point Measurement -----------------------P508=-(P3+P590)*SIN(P507)+P4
P509=(P3+P590)*COS(P507)+P566-P2
;X pos
;Z pos
X(P508-2) F500
Z(P509) F300
X(P508) F100
M17958 - Revision D
95
Program Printouts
G04 F2
M75.1
P510=P2014-P502
X(P508-5) F1000
Z25 F2000
Z85 B90 C355
M26
;move to retract position
;Back to RPM mode
;---------------- Calculate Equator Error ----------------------P511=-P509+P505
;delta Z
P512=-P510+P508+P506-P504
;delta W-X
P513=P511*P511 + P512*P512
;length squared
P514=SQRT((P3+P590)*(P3+P590)/P513 - 0.25)
P515=0.5*(P510-P508+P506-P504) + P511*P514 + P4 ;equator radius error
G04 F.5
P560=1
cal_fixture.pgm
;Program Status = done & valid
Fixture Calibration Program
;cal_fixture.pgm
10/08/09
;Calibration routine that calibrates the fixture reference radius
;using a known part master equator radius. This routine compensates
;for fixture run-out that my occur at installation, and must be run
;everytime a fixture is installed.
;Notes:
;
'W' is the probe reading.
;
'point Angle' is measurement point relative to the pole.
;
The equator is at 90 degrees.
;-------------------- Watch Parameters --------------------------;watch:P500=Ref Surf Radius
;watch:P501=Ref Surf Z pos
;watch:P502=Meas Ref Surf W
;watch:P506=1st point w
;watch:p510=2nd point w
;watch:P3=toric radius
;watch:P0=surface location
;watch:P560=program status
;watch:P9028=C reference pos
;watch:P558=1st Equ rad err
;watch:P515=2nd Equ rad error
;watch:P559=Average Rad error
;watch:P9029=calibrated ref rad
;-------------------- Setup Parameters --------------------------p560=0
;Program Status = Started
M17958 - Revision D
96
Program Printouts
P566=P2*COS(P8)-P3*COS(ASIN((P4+P2*SIN(P8))/P3)) ;Toric Z Offset
If(P40=1214)
P500=11.0715
P501=-205.
Else
If(P40=1113)
P500=11.0769
P501=-205.
Else
P579=5
P560=-1
EXIT
Endif
Endif
;12/14 Fixture
;11/13 Fixture
;Reference Surface radius
;Program Status = Done & Error
P502=0
;Measured Reference Surface W (probe value @ surface)
P503=91.5
P504=0
P505=0
P506=0
;1st
;1st
;1st
;1st
point
point
point
point
Angle
X
Z
w
P507=88.5
P508=0
P509=0
P510=0
;2nd
;2nd
;2nd
;2nd
point
point
point
point
Angle
X
Z
w
;P511 - P515 used for equator error calculation
;----------------------------------------------------------------P560=0
;Program status = in-process
M101
;call surface.probe to find the ball location
T8
;Tool #8 is part probe setup when parallel to spindle
G59Z(P0-P590) B0 ;offset Z for surface probe tip radius
Z30 F2000
;safe retract point
B-179 F3600
;force B minus direction
T9
;Tool #9 is part probe at 90 degrees to spindle
X-30 Z50 B0 F2000 ;move to measurement area
;----------------- Reference Surface Calibration ----------------T0
Z(P501-P0+P586) F2000
;Z to reference surface pos
M27.1
;Activate & Home C Axis
G04 F.5
C(P9028) F3000
T9
X(-P500-P590-1.5) F500
X(-P500-P590) F100
;X to reference surface pos
G04 F2
M75.1
;get the probe value
P502=P2014
;store probe reading
Gosub 1000
P558=P515
C(P9028+180) F3000
M17958 - Revision D
;measure the equator
;Store equator radius error
;Rotate C 180 degrees
97
Gosub 1000
P559=(P558+P515)/2
P9029=P500+P559
X(P508-5) F1000
Z25 F2000
Z85 B90
G04 F.5
P560=1
M26
EXIT
Program Printouts
;Average error
;calculate new ref radius
;Program Status = done & valid
;Back to RPM mode
;------------------ 1st Point Measurement -----------------------N1000
P504=-(P3+P590)*SIN(P503)+P4
;X pos
P505=(P3+P590)*COS(P503)+P566-P2 ;Z pos
X(P504-2) F1000
Z(P505) F2000
X(P504) F100
G04 F2
M75.1
P506=P2014-P502
X(P504-2) F500
;------------------ 2nd Point Measurement -----------------------P508=-(P3+P590)*SIN(P507)+P4
P509=(P3+P590)*COS(P507)+P566-P2
;X pos
;Z pos
X(P508-2) F500
Z(P509) F300
X(P508) F100
G04 F2
M75.1
P510=P2014-P502
X(P508-2) F500
;---------------- Calculate Equator Error ----------------------P511=-P509+P505
;delta Z
P512=-P510+P508+P506-P504
;delta W-X
P513=P511*P511 + P512*P512
;length squared
P514=SQRT((P3+P590)*(P3+P590)/P513 - 0.25)
P515=0.5*(P510-P508+P506-P504) + P511*P514 + P4 ;equator radius error
return
M17958 - Revision D
98
check_results.pgm
Program to check Tool Map Corrections
;check_results.pgm
P41=1
Program Printouts
10/22/2009
;fixture = ok
;Program to verify the Tool_map.pgm progarm results for tool mapping
;watch:P8050=1st point W
;watch:P8051=2nd point W
;watch:P8052=3rd point W
;---------------------- Setup Parameters ---------------------------P600=-35
P9032=5
P603=19
;Starting B angle @ X0 Z0 (degrees)
;Measurement increment (degrees)
;Number of P-vars in the array
;---------------- Internal Program variables -----------------------P610=P600
;P611=
P612=0
;P613=
;P614=
;P615=
;P616=
;P617=
;P618=
;current B angle = starting angle
;current W value
;array index for p-var number assignment
;point counter
;W offset to make 1st point = 0 correction
;calculated Z @ probe null position
;Pointer to radius correction entry/table
;lower integer value
;fractional value
;---------------------- Main Program -------------------------------P560=0
;Program status = started
If(P603>29)
P579=8
P560=-1
EXIT
Endif
;ERROR = TOO MANY POINTS
;Program status = Done & error
;Abort if specified # of points > 29
G90
G01
G59
G92
M17958 - Revision D
99
T1
M110.1
Z100 F1000
X(-P2006) B(P610)
Program Printouts
;Get the lvdt probe X offset & Probe radius
;X to Tset LVDT X Offset
;(This aligns tool with probe)
P615=P590+P2007
Z(P615+5) F1000
;Z null = Tool rad + probe radius
;move Z to 5mm from null
While(P612<P603)
;Loop for specified # of points
P616=((P610+35)/P9032)
;determine the correction angle
P617=FIX(P616)
;get the lower integer value
P618=P616-P617
;get the fractional value
P9031=P(8000+P617)+P618*(P(8000+P617+1)-P(8000+P617))
;calculate the interpolated radius correction value
Z(P615+2) F300
G04 F.5
B(P610) F1000
Z(P615+P614+P9031) F100
G04 F1.5
M75.1
;Z to clearance position
P(8050+P612)=P2011
;store probe W reading
P610=P610+P9032
P612=P612+1
;increment the B angle
;increment the array index
;move B to the next check point
;move to the corrected Z position
;wait 1.5 seconds for things to settle
;get the analog probe value
Endwhile
Z50 F1000
;safe retract position
G05 F.5
P560=1
;Program status = done & valid
M17958 - Revision D
100
save_results.pgm
Program to save data when prompted by operator
;save_results.pgm
P41=1
Program Printouts
10/22/09
;Fixure = ok
;This program saves the results from the Tool Mapping program
;(Tool_map.pgm) to persistent P-variables which are saved and
;restored through power OFF etc. The main program (P878.pgm)
;reads P9050 -> P9079 for the tool correction values.
P619=0
P620=29
;base index
;number of entries
While(P619<P620)
;loop till all pvars are transfered
P(9050+P619) = P(8000+P619)
P619=P619+1
;increment the index
Endwhile
G04 F2
m2000.006
/upx.setup/autop_cfg.dat
Configuration File for automated network communications
(Bar Code Scanner file selection)
test
test
0
mount_smb //DSSERVER:192.168.4.150/data /NETFILES
part_data.p
M17958 - Revision D
101
P Variable Assignments
SECTION 11
M17958 - Revision D
102
Shown here are the P variable assignment designations within the UPX controller.
Following are printouts of the four P tables of assigned variables used to machine
the four acceptance test parts. Also refer to the attached foldout page showing a
visual representation of the P numbers as they are represented by ball geometry.
P-Variable
P1
P2
P3
P4
P5
P6
P7
P8
P9
P10
P11
P12
P13
P14
P15
P16
P17
P18
P19
P20
P21
P22
P23
P24
P25
P26
P27
P28
P29
P30
P31
P32
P33
P34
P35
P36
P37
P38
P39
Description
Total Part Radius Offset
Spherical Radius of finished part
Toric Radius of finished part
Toric Center X Offset
Start of Toric Correction value
Material on condition from the finished part path
Starting Angle of the Toric
Starting Angle of the Sphere
Angular increment for the toolpath generation points
Spindle RPM
unused
Feed per Revolution
unused
unused
Start of pull-off in X
Pull Off Distance
User adjustable tool/part radius offset
Nominal Raw Part/Ball Diameter (prior to machining)
Reference Diameter to Pole Dimension
Number of Rough Passes
Rough Cut Depth
Number of Finish Passes
Finish Cut Depth
unused
unused
unused
unused
[deg] amount that the blend zone extends into the sphere
[deg] amount that the blend zone extends into the toric
Tool Contact Angle Increment (Each part, finish pass)
B Starting End Angle (at X0.0 Z0.0)
Total usable Tool Sweep
[deg] angle before the equator that the equator correction starts at
[deg] angle after the equator that the equator correction ends at
[mm] equator correction value at the equator
unused
unused
unused
unused
M17958 - Revision D
103
P40
P41
P42
P43
P44
P45
P46
P47
P48
P49
P50
P51
P52
P53
P54
P55
P56
P57
P58
P59
P60
Required Fixture Number (MUST BE IN P-WATCH WINDOW)
Flags host that P-table just loaded (always set = -1) (MUST BE IN P-WATCH)
unused
unused
unused
unused
unused
unused
unused
unused
Surface Probe clearance from null (used for start probing position)
1214 Fixture End to Reference Diameter Dimension
1214 Tool #8 active, CMD Position at Fixture End
1113 Fixture End to Reference Diameter Dimension
1113 Tool #8 active, CMD Position at Fixture End
unused
unused
unused
unused
unused
Calculated Surface Probe Start Position
P500 Fixture Reference Surface Radius
P501 Fixture Reference Surface Z position
P502 Measured Reference Surface W (probe value at surface)
P503 1st Measure point Angle
P504 1st Measure point X
P505 1st Measure point Z
P506 1st Measure point W
P507 2nd Measure point Angle
P508 2nd Measure point X
P509 2nd Measure point Z
P510 2nd Measure point W
P511 - 515
Used for Equator Error Calculation
P540 - 543
P544 - 549
P550
P551
P552
P553
Used for Pole Error Calculation
Reserved for multi probe measurement program
1214 Fixture Reference Surface Radius (Diameter/2) (11.0715)
1214 Fixture Reference Surface Z ABS pos
(-205.0)
1113 Fixture Reference Surface Radius (Diameter/2) (11.0769)
1113 Fixture Reference Surface Z pos
(-205.0)
P555 - 556
Reserved for multi probe measurenment program
P558 Stored 1st Equator radius error in fixture cal routine
M17958 - Revision D
104
P559 Averaged equator radius error from fixture cal routine
P560
P561
P562
P563
P564
P565
P566
P567
P568
P569
P570
P571
P572
P573
P574
P575
P576
P577
P578
P579
Measure program status (0=started, 1=done&valid, -1=done&error)
Smoothing factor for the blend zone
Radius correction factor for the blend zone
X-correction factor for the blend zone
Z-correction factor for the blend zone
Calculated Stock Removal from Raw Surface
Toric Z Offset
Ending Angle of the toric
Calculated number of B increments for full surface
unused
B at ABS 0.0, adjusted for G59 offset
unused
Calculated Z Move Position
Calculated X Move Position
Pass Counter
Current Surface Angle
Measure Only Flag (Set by host software)
unused
unused
Program Error Code (MUST BE IN P-WATCH WINDOW)
P590 Active Tool Radius
P600 - 618
P2004
P2006
P2007
P2011
P2012
P2013
P2014
P2015
P2016
Used in Tool mapping program (Tool_map.pgm)
Captured B Axis Position from M110 Command
LVDT X Offset
(From M110.1 command)
Toolset LVDT Tip radius (From M110.1 command)
Gauge 'C' Position
Gauge 'D' Position
Gauge 'E' Position
Gauge 'F' Position
Gauge 'A' Position
Gauge 'B' Position
P8000 - 8029 Reserved for Temporary Tool map results
P8050 - 8079 Reserved for Tool Correction check out results
Note: P9020 - P9079 are Persistent P-Variables which are saved to a file,
and are also restored after machine shutdown.
P9020 Tool #1 B Offset
P9021 Tool Sweep Remaining
P9022 Measured Radius Offset
P9023 Measured X Offset
M17958 - Revision D
105
P9024
P9025
P9026
P9027
P9028
P9029
P9030
P9031
P9032
Part Measurement Counter
Tool was just replaced indicator/flag
Amount of Tool sweep currently used up
Measure frequency
C Reference Position (Position moved to after Homing)
Current Reference Radius from Fixture Cal Routine
User radius offset
Tool Correction Radius offset from Tool Mapping
Angle Increment Spacing of mapped tool
P9050 - 9079 Reserved for Tool Mapping
***** END OF P VARIABLE ASSIGNMENTS ******
M17958 - Revision D
106
P tables used to machine four test parts as part of machine acceptance
136563100.p
P-table file for the equivalent user Drawing Number
P2=22.0355 ;Finished Spherical radius [mm]
P3=22.0120 ;Finished Toric radius [mm]
P4=0.01280 ;Toric center X offset [mm]
P5=0.0015
;Toric start correction value [mm]
P6=0.0025
;material left on for polishing [mm] on radius
P7=123.6
;Toric Starting Angle [deg]
P8=47.5
;Starting angle of the sphere [deg]
P9=0.05
;.06 Angular increment [deg]
P10=300
;1000 ;Starting rpm
P12=0.050
;Feed per rev [mm]
P15=1.0
;start of pull off distance in x [mm]
P16=0.007
;pull off distance in z [mm]
P18=44.203 ;Nominal RAW Part/Ball diameter (before machining) [mm]
P19=22.105 ;22.105
;Reference diameter to pole dimension [mm]
P20=0
;Number of Rough Passes (not used)
P21=0.05
;Rough Cut Depth [mm] (not used)
P22=1
;Number of Finish Passes (not used)
P23=0.1
;Finish Cut Depth [mm] (not used)
P28=0.2
;0.2 ;blend zone extention into sphere region [deg]
P29=0.2
;0.2 ;blend zone extention into toric region [deg]
P30=0.5
P31=70
P32=70
P40=1214
P41=-1
P33=0 ;angle before the equator at which the equator correction zone starts
P34=0 ;angle after the equator at which the equator correction zone ends
P35=0
;maximum height of the equator correction
1365026100.p
P2=18.0350
P3=18.0120
P4=0.01549
P5=0.0015
P6=0.0025
P7=138.1
P8=47.5
P9= 0.05
P10=300
P12=0.050
P15=1.1
P16=0.007
P18=36.198
P19=10.589
P20=0
P21=0.05
P22=1
P23=0.1
P28=0.2
P29=0.2
P-table file for the equivalent user Drawing Number
;Finished Spherical radius [mm]
;Finished Toric radius [mm]
;Toric center X offset [mm]
;Toric start correction value [mm]
;material left on for polishing [mm] on radius
;Toric Starting Angle [deg]
;Starting angle of the sphere [deg]
;.06 Angular increment [deg]
;Starting rpm
;Feed per rev [mm]
;start of pull off distance in x [mm]
;pull off distance in z [mm]
;Nominal RAW Part/Ball diameter (before machining) [mm]
;Reference diameter to pole dimension [mm]
;Number of Rough Passes (not used)
;Rough Cut Depth [mm] (not used)
;Number of Finish Passes (not used)
;Finish Cut Depth [mm] (not used)
;blend zone extension into sphere region [deg]
;blend zone extension into toric region [deg]
M17958 - Revision D
107
P30=0.5
P31=70
P32=60
P40=1113
P41=-1
P33=0 ;angle before the equator at which the equator correction zone starts
P34=0 ;angle after the equator at which the equator correction zone ends
P35=0 ;maximum height of the equator correction
136550100.p
P2=18.0375
P3=18.0145
P4=0.01549
P5=.0015
P7=127.1
P8=47.5
P9= 0.09
P10=1000
P12=0.050
P15=1
P16=.005
P18=36.198
P19=7.714
P20=0
P21=.05
P22=1
P23=.1
P30=.5
P31=70
P32=70
P40=1214
P41=-1
P-table file for the Part Master
;Spherical radius
;Toric radius
;Toric start correction value
;Toric Starting Agle
;Starting rpm
;Feed per rev
;start of pull off distance in x
;pull off distance in z
;Rough Cut Depth
;Finish Cut Depth
M17958 - Revision D
108
DETAIL D
SCALE 500 : 1
P-VARIABLE'S DESCRIPTIONS:
P2
P3
P4
P7
- RADIUS OF POLAR SPHERE
- RADIUS OF TORIC
- TORIC X-OFFSET FROM SPHERICAL CENTER
- STARTING ANGLE FOR THE TORIC CUT, MEASURED FROM THE
CENTER OF THE TORIC, SHOULD BE ~3 LARGER THAN THE
THEORETICAL ANGLE SO THAT THE TOOLPATH STARTS OFF THE PART
P8 - ANGLE FROM THE POLE TO THE SPHERE TORIC INTERFACE
MEASURED FROM THE CENTER OF THE SPHERE
P18 - RAW BALL DIAMETER BEFORE TURNING, USED TO DETERMINE HOW
MUCH STOCK MUST BE REMOVED FROM THE POLE OF THE PART
P19 - BALL TIP TO REFERENCE DIAMETER, USED TO DETERMINE
WHERE THE PART PROBE EXPECTS THE PART TO BE
P556- TORIC Z-OFFSET FROM THE SPHERICAL CENTER
[THIS IS CALCULATED FROM P2, P3, P4, P8]
DIM "E"
TORIC Z-OFFSET
[P566]
(DERIVED FROM
P2, P3, P4, P8)
2X DIM "D"
TORIC X-OFFSET
[P4]
47.50°
[P8]
C
DIM "B"
SPHERE RADIUS
[P2]
BALL TIP TO
REF DIAMETER
[P19]
DIM "A"
TORIC RADIUS
[P3]
RAW BALL DIA
(FINISHED TURNING
DIA + 2*STOCK
REMOVAL)
[P18]
TORIC
STARTING
ANGLE
[P7]
P915 CUSTOMER CONFIDENTIAL
C
SECTION C-C
UNLESS OTHERWISE SPECIFIED
TOLERANCES
.X ±.03
.XXX ±.005
ANGLES
.XX ± .010
.XXXX ± .0002
± 0° 30'
DIMENSIONS IN INCHES
USED ON
REMOVE BURRS, BREAK SHARP EDGES
& CHAMFER THREADED HOLES .03 MAX.
SIGNATURE
DWN
DATE
DAJ
9/28/2009
CHKD
APPD
SCALE:
SHEET
63
4:1
WT: 155.01 LB
1
OF
1
FINISHED SURFACE
ROUGHNESS
PROPRIETARY
THIS DRAWING INCLUDING ALL
SUBJECT MATTER, EMBODIES
CONFIDENTIAL INFORMATION
OF AMETEK PRECITECH INC.
AND IS LOANED WITH THE
UNDERSTANDING THAT IT WILL
NOT BE USED FOR ANY
PURPOSE EXCEPT THAT FOR
WHICH
LOANED
UNLESS
WRITTEN
PERMISSION IS
GRANTED BY PRECITECH AND
THAT IT SHALL BE RETURNED
UPON DEMAND.
44 BLACKBROOK RD (603) 357-2511
KEENE N.H. 03431 FAX (603) 352-0306
P915, P-TABLE VARIABLE DEFINITIONS
IN PRECITECH PARA-MACRO PROGRAM
CONTACT INFORMATION @
http://www.precitech.com/
DWG. NO.
P915AB
REV:
A
REVISIONS
REV. ECO NO.
CUTTING TOOL
P565
DESCRIPTION
DATE
APPROVED
P1
P6
Z=0
P2
P28
P1....= EFFECTIVE TOOL RADIUS
P2....= POLISHED SPHERE RADIUS
P3....= POLISHED TORIC RADIUS
P4....= TORIC X-OFFSET
P6....= MATERIAL LEFT ON ABOVE POLISHED PROFILE
P7....= TORIC START ANGLE (TOOLPATH START ANGLE)
P8....= SPHERE START ANGLE
P18..= RAW BALL EQUATOR DIAMETER
P28..= ANGLE THAT BLEND ZONE INTRUDES INTO THE SPHERE REGION
P29..= ANGLE THAT BLEND ZONE INTRUDES INTO THE TORIC REGION
P565= AMOUNT OF STOCK REMOVED
P566= TORIC Z-OFFSET
P567= TORIC ENDING ANGLE
P8
P29
P567
P566
P3
P7
P4
RAW PART PROFILE
P18/2
TURNED PROFILE
X=0
POLISHED PROFILE
TOLERANCES
.XX ± .010
.X ±.03
.XXX ±.005
.XXXX ± .0002
ANGLES
USED ON
± 0° 30'
SIGNATURE
DWN
DAJ
DATE
3/23/2010
CHKD
APPD
SCALE:
4:1
SHEET
63
WT: 0.00 LB
1
OF
1
FINISHED SURFACE
ROUGHNESS
PROPRIETARY
NOT BE USED FOR ANY
WHICH
LOANED
UNLESS
WRITTEN
PERMISSION IS
UPON DEMAND.
44 BLACKBROOK RD (603) 357-2511
KEENE N.H. 03431 FAX (603) 352-0306
P-VARIABLE'S DESCRIPTIONS
P915.PGM
DWG. NO.
P915BB
REV:
A
REVISIONS
EQUATOR CORRECTION:
LINEARLY CHANGES THE Z-COORDINATE
OF THE TOOLPATH, STARTING AT PXX,
REACHING A MAXIMUM DEVIATION OF PXX
AT THE EQUATOR AND ENDING AT PXX
P33
REV. ECO NO.
P34
DESCRIPTION
DATE
APPROVED
TOOL RADIUS CHANGE:
INCREASING THE TOOL
RADIUS CAUSES THE
PART RADIUS TO INCREASE
BY THE SAME AMOUNT
P35
TOOL RADIUS CHANGE
CENTER CORRECTION:
INITIATES A LINEAR PULL OFF
IN THE Z DIRECTION FROM
THE PATH PROFILE, STARTING
P15 MM FROM THE CENTER OF
THE PART REACHING A
MAGNITUDE OF P16 AT THE
CENTER OF THE PART
P15
P16
TORIC START CORRECTION:
DEVIATES THE TOOLPATH P5
IN THE X-DIRECTION AT THE
START OF THE TOOL PATH AND
THEN LINEARLY GOES TO ZERO
AT THE EQUATOR OF THE PART
X-CENTER SHIFT:
SHIFTS THE TOOLPATH IN
THE X-DIRECTION SO
THAT THE PART IS EITHER
CUT PAST CENTER
(SHOWN) OR IS NOT CUT
TO CENTER
X-CENTER SHIFT
P5
TOLERANCES
.X ±.03
.XXX ±.005
ANGLES
USED ON
SIGNATURE
DWN
.XX ± .010
CHKD
.XXXX ± .0002
APPD
± 0° 30'
DAJ
SCALE:
4:1
SHEET
63
DATE
2/25/2010
WT: 0.00 LB
1
OF
1
FINISHED SURFACE
ROUGHNESS
PROPRIETARY
NOT BE USED FOR ANY
WHICH
LOANED
UNLESS
WRITTEN
PERMISSION IS
UPON DEMAND.
44 BLACKBROOK RD (603) 357-2511
KEENE N.H. 03431 FAX (603) 352-0306
TOOLPATH MODIFICATION DESCRIPTIONS
P915.PGM
DWG. NO.
P915CC
REV:
A

AMETEK Precitech, Inc.

Transcription

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