TRAK® LPM Programming, Safety, and Operating Manual Document: 26728 Version: 051013 Southwestern Industries, Inc. 2615 Homestead Place Rancho Dominguez, CA 90220-5610 USA T | 310-608-4422 |F | 310-764-2668 Service Department: 800.367.3165 e-mail: sales@southwesternindustries.com | service@southwesternindustries.com | web: southwesternindustries.
Copyright 2013, Southwestern Industries, Inc. All rights are reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, mechanical, photocopying, recording or otherwise, without the prior written permission of Southwestern Industries, Inc. While every effort has been made to include all the information required for the purposes of this guide, Southwestern Industries, Inc.
Table of Contents 1.0 Introduction 2.0 Safety 2.1 2.2 Safety Publications Danger, Warning, Caution and Note Labels and Notices Used in this Manual Safety Precautions 3 3.0 Description 10 3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.2 3.2.1 3.2.2 3.2.3 3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6 3.3.7 3.3.8 3.3.9 3.3.10 3.3.11 3.3.12 3.3.13 3.3.14 3.3.15 3.3.16 3.3.17 3.3.18 3.3.19 3.3.20 3.3.21 3.3.
7.0 7.1 7.2 7.3 7.3.1 7.3.2 7.3.3 7.4 7.5 7.6 7.7 7.8 7.9 8.0 8.1 8.2 8.3 8.4 8.5 8.6 8.6.1 8.6.2 8.6.3 8.6.4 8.6.5 8.6.6 8.6.7 8.6.8 8.7 8.7.1 8.7.2 8.7.3 8.8 8.8.1 8.8.2 8.8.3 8.9 8.10 8.10.1 8.10.2 8.10.3 8.11 8.11.1 8.12 8.13 8.14 8.14.1 8.15 8.16 9.0 9.1 9.2 9.
13.7 13.8 Feedrate and Speed Overrides Data Errors 14.0 14.0.1 14.1 14.2 14.2.1 14.2.2 14.3 14.3.1 14.3.2 14.4 14.5 14.6 14.7 14.8 14.9 14.9.1 14.9.2 14.11.3 14.12 14.12.1 14.12.2 14.12.3 14.12.4 14.13 14.13.1 14.13.2 14.13.3 14.13.4 14.13.
1.0 Introduction Congratulations! Your TRAK LPM Milling Machine with the ProtoTRAK PMX CNC is a brand new concept in smaller lot production. It combines the simplicity of the ProtoTRAK programming method with innovative systems in tooling, workholding and job management. The TRAK LPM is more than a machine. It is a system of machining that helps you to reduce set ups for smaller run production jobs. This manual will describe the operation of the machine and the ProtoTRAK PMX CNC. 1.
Section 12 Machine Set Up: The few operations you must do with the machine idle as you make the final preparations to run your new job. Also includes the powerful Checklist so that you can be sure you haven’t overlooked anything. Section 13 Run: Instructions on running a program to machine your part. Section 14 Program In/Out: Storing and managing your programs as well as creating a Master Program. Section 15 4th Axis Option: Instructions on how to run and program a 4th axis option.
2.0 Safety The safe operation of the LPM depends on its proper use and the precautions taken by each operator. Read and study this manual and the LPM Programming, Operating, and Care Manual. Be certain every operator understands the operation and safety requirements of this machine before its use. Never run the machine with enclosure doors open Always wear safety glasses and safety shoes.
Safety & Information Labels Used On The LPM Milling Machine It is forbidden by OSHA regulations and by law to deface, destroy or remove any of these labels 4 Southwestern Industries, Inc.
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2.3 Safety Precautions 1. Do not operate this machine before the LPM Installation, Maintenance, Service and Parts List Manual, Operating & Care Manual have been studied and understood. 2. Do not run this machine without knowing the function of every control key, button, knob, or handle. Ask your supervisor or a qualified instructor for help when needed. 3. Protect your eyes. Wear approved safety glasses (with side shields) at all times. 4. Don't get caught in moving parts.
19. Use proper cutting tools for the job. Pay attention to the rotation of the spindle: As viewed from above, left hand tool for counterclockwise rotation of spindle, and right hand tool for clockwise rotation of spindle. 20. To prevent damage to the workpiece or the cutting tool, never start the machine (including the rotation of the spindle) if the tool is in contact with the part. 21.
3.0 Description This section will provide an overview of features and specifications found on the TRAK LPM. 3.1 Control Specifications The new ProtoTRAK PMX CNC retains the basic operations strategies found in all other models of ProtoTRAK and TRAK CNCs. 3.1.1 ProtoTRAK PMX Hardware Specifications Jog wheel for TRAKing and positioning 12.
• Convenient choice of dimensional references: Machine Home, Part Zero, Abs Zero and Ball Lock locations Program Mode Features • Auto Geometry Engine • Geometry-based programming • Tool Path programming • Scaling of print data • Multiple fixture offsets • Programming of Auxiliary Functions • Event Comments • Three-axis Geometry conversational programming • Incremental and absolute dimensions • Automatic diameter cutter comp • Circular interpolation • Linear interpolation • Look –graphics with a single butto
• Drill • Bolt Hole • Mill • Arc • Circle pocket • Rectangular pocket • Irregular Pocket • Circular profile • Rectangular profile • Irregular Profile • Circle Island • Rectangular Island • Irregular Island • Helix • Thread milling • Engrave • Tapping • Face Mill Edit Mode Features • Delete events • Erase program • Spreadsheet editing • Global data change • G-Code editor • Clipboard to copy events between programs • Move between subprograms in a master program Program Set Up Mode Features • Program diagnosti
• Convenient ATC capacity Machine Set Up Mode Features • Advanced diagnostic routines • Software travel limits set in the factory • Prompted Tool loading and ATC Management • Checklist to assure nothing is forgotten • Single key press to get to step needing attention Run Mode Features • TRAKing • 3D CAM file program run • 3D G code file run with tool comp • Real time run graphics with tool icon • Countdown clock for total part cycle time or manual tool change • Error alarms prevent Run when set up steps are
To tell if the DXF File Converter is active on your ProtoTRAK PMX CNC, go to the options screen using Service Code #318. If the AutoCAD DXF option is in black letters, it is activated. If it is in gray letters, you will need to purchase the option to activate it. The DXF Option consists of an Activation Password, and may require an additional software update. To download the latest version of our DXF software, go to our website at www.southwesternindustries.
2. Go to the ProtoTRAK PMX CNC on which the option is to be installed, use Service Code 318 to go to the Software Options Screen. 3. Highlight the option you wish to install and press the softkey labeled INSTALL. 4. A screen will appear that advises you how to purchase the option. Near the bottom of the screen there will be a Hardware Key Serial Number and an Option Serial Number. Write down both of these numbers. 5.
RESTORE: clears an entry, aborts a keying procedure INC/ABS: switches all or one axis from incremental to absolute or absolute to incremental position IN/MM: causes Inch to Metric or Metric to Inch conversion of displayed data LOOK: part graphics in Program Mode MODE: to change from one mode of operation to another CURSOR: moves cursor of highlight in tables, lists or choices and pages between event.
3.2.2 Run Panel The Run Panel is the lower panel on the front of the pendant.
AIR: controls air blast from spindle to help clear chips. Press to turn air on (ON LED is lit). Press again to turn air on (AUTO LED is lit) when commanded by the program in Run Mode. Press again to turn air off. WASH: press to activate chip wash to help move chips down to the chip auger location. DOOR LOCK: activates the door lock mechanism whenever a program or other automatic move is running.
3.3 Machine Description 19 Southwestern Industries, Inc.
3.3.1 Overall Machine Dimensions Width of LPM without chip cart and auger chute 89.75” Depth of LPM 88” Height of LPM with head all the way up 103” Width of LPM with chip cart and side doors open 157” Minimum height to fit LPM through doorway (Z cable carrier collapsed) 85” Machine weight 7650 lbs. 3.3.2 Machine Specifications Table Dimensions Table size Number of tee slots and pitch Tee slot width Table maximum load Ball Lock ® hold down force torque 35.38” X 19.63” 5 @ 100 mm 0.710” or 18 mm 1000 lbs.
3.3.3 Maximum Spindle Torque and Horsepower The following graphs illustrate the continuous and peak torque vs. RPM and horsepower vs. RPM for the LPM machine at the spindle. Peak torque and horsepower values can only be attained for a short period of time before the spindle drive will fault out to protect the motor.
Note - Maximum work capacities are dependent on a lot of variables that cannot be controlled by the machine manufacturer. Each one of the following will have an impact on the above numbers: speeds, feeds, cutter, cutter sharpness, material, setup, coolant and machine adjustments. 3.3.4 Electrical Cabinet The electrical cabinet is found at the rear of the LPM on the right side. The electrical cabinet contains the main control hardware for the machine.
3.3.9 Spindle Motor & Drive The spindle motor is 10 HP and drives the spindle via a timing belt. The ratio between the spindle and spindle motor is 1 to 1. The RPM range for this machine is 150 to 8000 RPM. 3.3.10 Automatic Draw Bar Assembly The automatic drawbar is an assembly consisting of an air cylinder and an actuator that unclamps the tool. Tooling is changed by means of the Automatic Tool Changer (ATC), or can be done manually by pressing and holding the “Unclamp” button.
3.3.12 Tool Changer The tool changer is an armless carousel type automatic tool changer that has a capacity of 16 tools. The carousel is mechanically indexed by means of a Geneva mechanism. The position of the carousel is controlled by a signal from Home Position Sensor. As an additional safety feature, the ATC also has Tool Detect Sensor at the “ready position”.
Limit Switch Cam Locations Axis End Location of Cam Bracket X-axis Negative End Left hand side of the table (front) X-axis Positive End Right hand side of the table (front) Y-axis Negative End On the base casting, beneath the saddle (back) Y-axis Positive End On the base casting, beneath the saddle (front) Z-axis Negative End On the column casting (upper) Z-axis Positive End On the column casting (lower) ATC Home Position ATC shroud Sensor ATC Sliding Body, Bracket-Sliding Body Support, left home ATC Slidin
3.3.18 Pneumatic System The machine requires a supply of compressed air between 85-100 psi with a recommended air supply of ½” I.D. Air pressure to pneumatic components, the ATC slide mechanism, air blast and air purge (internal spindle) can be controlled individually by means of the adjusting valves located at the back of the LPM. CAUTION! Always observe low air pressure and low oil level warnings. 3.3.
4.0 Basic Operation This section covers the basic operation of the machine and control issues that apply to more than one Mode or are not covered in the sections on the individual Modes. 4.1 Machine and Control Power On To turn the ProtoTRAK PMX CNC on, turn on the main breaker on the rear control cabinet. The Windows operating system and the ProtoTRAK PMX CNC software will take a few seconds to load from the system's flash memory.
message “Machine has not been homed” will appear and can be cleared by performing the Homing operation. 4.2.3 Warming Up The Machine A proper warmup cycle is necessary to extend the life of the machine as well as maintaining repeatability. Putting a cold spindle under load can produce premature bearing failure. Warming up the spindle allows bearings, supports and shaft to reach their designed dimensions through thermal expansion.
Operations that cannot be performed are: a. DRO Mode b. Tool load and unload c. RUN 4.3 Spindle Operation The three buttons on the front control, FORWARD, STOP, REVERSE, will operate the spindle in DRO, Part Fixture Mgmt., and Run mode. 4.4 Electronic Handwheel 4.4.1 Manual Axis Movement In DRO mode all axis can be moved by the Electronic Handwheel on the front control panel. The center EHW button turns on the Hand Wheel and the operator can then choose which axis to move.
4.7 Emergency Stop Press the button to shut off power to the spindle motor and axis motors. Rotate the switch to release. 4.8 Enclosure The LPM is fully enclosed enabling flood coolant and/or air blow aiding in efficient machining of any workpiece. Three access doors permit easy chip removal and fixture placement. 4.8.1 Front Door The door is automatically locked during tool change operations. During RUN mode the door can be opened. This will stop the spindle and all axis motion.
4.9.3 Coolant Hose A coolant hose is supplied to aid in cleaning the machine of chips. The coolant pump must be turned on to use this hose. To increase the pressure through the hose, turn off the coolant valves located below the spindle. 4.9.4 Checking Coolant Levels The coolant level should be higher than the baffles located near the coolant pumps and can be checked visually. 4.10 Air A single air line is required and located at the rear of the machine.
4.12 ATC Operation 4.12.1 Advancing The Carousel The tool carousel button is located on the front control panel and can rotate the carousel clockwise or counterclockwise. The door must be closed in order for the carousel to rotate. 4.12.2 Manual Tool Load and Unload The green button located on the front of the spindle headstock is the clamp and unclamp button. Manually loading and unloading tools can only be done with the door open. 4.
Math Helps are powerful routines that enable you to use the data you have available to calculate missing print data. For example, Math Help type 28 enables you to solve an entire right triangle by giving two known pieces of data. To exit from the Math Help, press the Mode key. Math Help 28 In this example, by entering the length of line A and the value of angle G, the other values are calculated You may have the Math Help solutions load directly into your program.
5.0 Definitions, Terms & Concepts 5.1 ProtoTRAK PMX CNC Axis Conventions Hint: It is much easier to program if you imagine the tool is moving and think of the tool movement rather than focus on the machine table and saddle movement. X Axis: positive X-axis motion is defined as the table moving to the left when facing the mill. Consequently, measurement to the right is positive on the workpiece. Y Axis: positive Y-axis motion is defined as the table moving toward you.
Connection of an incline plane and another event Connection of two events that lie in different planes Using Geometry Programming, it is impossible for the ProtoTRAK PMX CNC to calculate a tool path for these cases without creating a problem: in cutting the geometry desired in the first event, the tool ends up out of position for the next event.
5.4 Absolute and Incremental Reference The ProtoTRAK PMX CNC may be programmed and operated in either (or in a combination) of absolute or incremental dimensions. An absolute reference from which all absolute dimensions are measured (in DRO and program operation) can be set at any point on or even off the workpiece. To help understand the difference between absolute and incremental position, consider the following example: Each point has both an absolute and an incremental reference in the X-axis.
Rectangle or Irregular (POCKET or PROFILE): X1 and Y1 corner, Z RAPID and Z END programmed Helix: The X END, Y END, Z RAPID, and Z END programmed. Sub: The reference position as defined for the specific events above for the event prior to the first event that was repeated. A.G.E. Profile: The appropriate reference position as defined for the specific events above for the last event that is programmed. For example, if an ARC event followed a MILL event, a 2.
Examples of tool left. Tool center means no compensation either right or left. That is, the centerline of the tool will be moved to the programmed points. Hint: to determine tool left or right, imagine that you are sitting on the tool as it is moving. 5.8 Tool Diameter Compensation when Contouring in Z with Part Geometry Left and right tool diameter offsets are always those projected into the XY plane. Tool offsets in the Z direction are always up and assume the use of a ball end mill.
Ball end mill position with respect to program points. Tool starts so end mill is tangent to BC. R from center of tool is perpendicular to BC. Note how the tool at the beginning point (point B) starts below (in the Z direction) point B so that it can actually touch this point. If this were not true, a cusp would remain to the left of point B. Now consider a similar example milling from A to B to C in the XZ plane.
5.10 Conrad Conrad is a unique feature of the PROTOTRAK PMX CNC that allows you to program a tangentially connecting radius between connective events, or tangentially connecting radii for the corners of pockets and frames without the necessity of complex calculations. For the figure below, you program an Arc event from X1, Y1 to X2, Y2 with tool offset left, and another Arc event from X2, Y2 to X3, Y3 also with tool offset left.
A Conrad is added between an arc and a line. 5.11 Memory and Storage Computers can hold information in two ways. Information can be in current memory or in storage. Current memory (also known as RAM) is where the ProtoTRAK PMX CNC holds the operating system and any part program that is ready to run. While a program is being written, it is in current memory. For the ProtoTRAK PMX CNC, storage of programs is on a USB thumb drive or on a networked drive. We strongly recommend you habitually back up programs.
6.0 DRO Mode The ProtoTRAK PMX provides a large display of the position of each axis in DRO Mode. This enables you to see the current position of your TRAK LPM and to make adjustments easily. With the Power Feed capability you are able to make some simple cuts easily. This screen in DRO mode typically is not used to establish part zero for production. Refer to section 6.2 for information on the multiple reference locations that are available to simplify machine setups. DRO Mode 6.
Note: This will also reset the incremental dimension and add the value that was just input in the ABS screen, if the absolute position is being displayed when it is preset. Recall Absolute Position of All Axes: Press INC/ABS. Note the dimension for each axis is labeled INC or ABS. Press INC/ABS again to revert to the original reading. Recall Absolute Position of One Axis: Press X or Y or Z, INC/ABS. Note the INC or ABS label for each axis. Repeat to get selected axis back to original reading. 6.
BALL C –This displays the distance the machine is from the center of Ball Lock C and the top of the table. HOME – This displays the distance the machine is from Machine Home and the top of the table. PART ABS – after pressing this softkey you will be prompted to type in the part number. Type 0 for none, and parts 1 – 4 of the Master Program. If you do not have multiple parts in a Master Program, your part is Part 1. The numbers you see will be referenced from the absolute 0 of the part you choose.
6.5 Return to Absolute Zero At any time during manual DRO operation you may automatically move the table to your absolute zero location in X and Y by pressing the RETURN ABS 0 soft key. When you do, the message window will read "Ready to Begin: Press Go when Ready”. Make sure your tool is clear and press the GO key. The machine will move in rapid the Z axis to tool change position and then move the table to your X and Y absolute zero position. You will be at zero and in manual DRO operation. See Section 6.
7.0 Program Mode Part 1: Getting Started & General Information 7.1 Programming Overview The ProtoTRAK PMX CNC makes programming easy by allowing you to program the actual part geometry as defined by the print. The basic strategy is to first fill in the initial program information in the Program Header screen and then program the features of the part by selecting the soft key event types (geometry) and then follow all instructions in the Data Input Line.
The Program Mode Header Screen 7.3 Program Header Screen The first screen you see when you enter the Program Mode is the Program Header Screen. The Program Header Screen gives you options that apply to the entire program. The softkey selections allow you to enter the program at any point. The program name and general programming options you choose in the Program Header Screen will be in the program as "Event 0". 7.3.
When the Program name prompt is highlighted, the Data Input Line will show "Program Name:" At this point you may: Press number keys. Press Help to access alpha keys and special characters in the ProtoTRAK PMX CNC. Use a keyboard plugged into the ProtoTRAK PMX CNC to name the program. Pressing the Help hard key when the Program Name is highlighted calls up alpha keys. Program name input without a keyboard.
When you are finished with the program name, press SET to enter it into the current memory. Note: It is not necessary to enter a part number. If none is entered and a GO TO soft key is pushed, the system will assume a part number 0. 7.3.2 General Program Options Use the cursor keys to select general programming options. Scale: Allows a scale factor between .1 and 10. An input of 5 means the part will be 5 times as big as the programmed dimensions. A value of 1.0000 is assumed if nothing is input.
7.3.3 Program Header Softkeys The following softkeys are encountered in the Program Header Screen. The first five listed below are always there. The last four appear when relevant to the general programming option. GO TO BEGIN: puts the Program Header on the left side of the screen and the Event #1 on the right side. GO TO END: puts the last programmed event on the left side of the screen and the next event to be programmed on the right side.
7.6 Softkeys within Events Once a geometry (Event) such as MILL or BOLT HOLE is selected, the softkeys will change. Soft keys used while programming an event. DATA BOTTOM: puts the Highlight on the last input. INSERT EVENT: use this to insert a new event into the program. This new event will take the place of the one that was on the right side of the screen when you pressed the INSERT EVENT key. That previous event, and all the events that follow, increase their event number by one.
In the figure above, the header screen has been completed and is on the left side. Select an event type from the soft keys When the MORE softkey is selected, the soft keys change to: More events. After an event type is selected from the softkeys, the prompts for that event will appear on the right side of the screen. The data you need to enter to program the event will appear in the Data Input Line.
LIST STEP: displays the list of events on the left side of the screen and with a purple highlight on the first event. As LIST STEP is pushed, the highlight shifts to the next event. As this happens, that event is also highlighted in the graphics by having its color change to purple. START EVENT NUMBER: will prompt you to enter an event number for highlighting. This is useful for moving quickly to a particular event in a large program. XY: displays a view in the XY plane. YZ: displays a view in the YZ plane.
8.0 Program Mode Part 2: Program Events Events are fully defined pieces of geometry. By programming events, you tell the ProtoTRAK PMX CNC what geometry you want to end up with; it figures the tool path for you from your answers to the prompts and the tool information you give it in the SetUp Mode. 8.1 POSN: Position Events This event type positions the table and spindle at a specified position.
screen where you may choose to have a fixed amount of material taken per peck or have the cutter move up just enough to break the chip before continuing to feed down. RPM: is the spindle RPM for the event. INC SET will use the RPM of the previous event. Z Feedrate: is the drilling feedrate Tool #: is the tool number you assign If a bore is selected and entered, you can change the tool path of the bore from the default tool path of feeding in and feeding out at the programmed rpm.
# of Variable Pecks: the factory setting is for each peck to be successively smaller, taking the largest cuts at the beginning and the smallest at the end. When the highlight is on this prompt, you may change this setting by pressing the HELP key. This will take you to a screen where you may choose to have a fixed amount of material taken per peck or have the cutter move up just enough to break the chip before continuing to feed down. RPM: is the spindle RPM for the event.
In ARC events when X Center, Y Center, and Z Center are programmed incrementally, they are referenced from X End, Y End, and Z End respectively. An ARC event may be programmed with a CONRAD if it is connective with the next event (this next event must lie in the same plane as the Arc event). Note: When an arc is 180 degrees, there are several paths that all have the same beginning, ending, and center locations.
8.6 POCKET Events This event selection gives you a choice between, circle pocket, rectangular pocket and irregular pocket within the XY plane. Pockets include machining the circumference, as well as all the material inside the circumference of the programmed shape. If a finished cut is programmed, it will be made at the completion of the final pass. The cutter will arc in and arc out of the finish cut and position itself the finish cut dimension away from the part before moving the tool out of the part.
The prompts for the rectangular pocket: X1: is the X dimension to any corner Y1: is the Y dimension to the same corner as X1 X3: is the X dimension to the corner opposite X1; incremental is from X1 Y3: is the Y dimension to the same corner as X3; incremental is from Y1 Z Rapid: is the Z dimension to transition from rapid to feed Z End: is the Z dimension at the bottom of the pocket; incremental is from the previous event Conrad: is the value of the tangential radius in each corner Direction: is the clockwis
Fin Cut: is the width of the finish cut. If 0 is input there will be no finish cut. See Section 8.6.7 for a bottom finish cut. RPM: is the spindle RPM for the event. INC SET will use the RPM of the previous event. FIN RPM: is the spindle RPM for the finish cut. Z Feedrate: is the Z feedrate from Z rapid to Z end XYZ Feedrate: is the milling feedrate in in/min from .1 to 800, or mm/min from 5 to 20320 Fin Feedrate: is the finish cut milling feedrate in in/min from .
In order to use a zigzag ramp, the X or Y move must be larger than the diameter of the tool plus the radius of the tool, minus the finish cut of the pocket. The formula is: the pocket x or y move > tool diameter + tool radius - fin cut If the tool is too large for the zigzag ramp, the ProtoTRAK PMX CNC will give an error message during program run and will then default to plunge. This will occur for each pass of the pocket depth. 8.6.
XYZ Feedrate: is the milling feedrate in in/min from .1 to 800, or mm/min from 5 to 20320 Fin Feedrate: is the milling feedrate for the finish cut Tool #: is the tool number you assign Note – if you press the HELP key when you are on the X1 prompt, you can adjust the step over distance of the face mill. The default is 95% of the cutter width. You can adjust it from 1 to 99%. 8.7 ISLAND Events Within the Pocket event choices, you may also select a circular, rectangular or irregular island.
FIN CUT ISL: Finish cut for the Island. If 0 is input, there will be no finish cut. See the previous section for a bottom finish cut. X1 POCKET: X dimension for one corner of the rectangular pocket that surrounds the island. Y1 POCKET: Y dimension for one corner of the rectangular pocket that surrounds the island. X3 POCKET: X dimension for the opposite corner of the rectangular pocket that surrounds the island.
X3 POCKET: X dimension for the opposite corner of the rectangular pocket that surrounds the island. Y3 POCKET: Y dimension for the opposite corner of the rectangular pocket that surrounds the island. CONRAD PCKT: the value of the tangential radius in the corners of the rectangular pocket that surrounds the island. FIN CUT PCKT: finish cut along the perimeter of the pocket. If 0 is input, there will be no finish cut. See the previous section for a bottom finish cut. RPM: is the spindle RPM for the event.
Y3 POCKET: Y dimension for the opposite corner of the rectangular pocket that surrounds the island. CONRAD PCKT: the value of the tangential radius in the corners of the rectangular pocket that surrounds the island. FIN CUT PCKT: finish cut along the perimeter of the pocket. If 0 is input, there will be no finish cut. See the previous section for a bottom finish cut. RPM: is the spindle RPM for the event. INC SET will use the RPM of the previous event. FIN RPM: is the spindle RPM for the finish cut.
RPM: is the spindle RPM for the event. INC SET will use the RPM of the previous event. FIN RPM: is the spindle RPM for the finish cut. Z Feedrate: is the Z feedrate from Z rapid to Z end in in/min from .1 to 700, or mm/min from 5 to 17780 XYZ Feedrate: is the milling feedrate in in/min from .1 to 800, or mm/min from 5 to 20320 Fin Feedrate: is the milling feedrate for the finish cut Tool #: is the tool number you assign 8.8.
The Irregular Profile is a series of events that are programmed to machine continuously. The first event of the series will be called an IRR PROFILE and it will define the beginning point of the profile and other information that applies to the entire profile.
Tool Offset: is the selection of the tool offset to right (input 1), offset to left (input 2), or tool center--no offset (input 0) relative to the programmed edge and direction of the cutter movement RPM: is the spindle RPM for the event. INC SET will use the RPM of the previous event. Z Feedrate: is the Z feedrate from Z rapid to Z end in in/min from .1 to 700, or mm/min from 5 to 17780 XYZ Feedrate: is the feedrate from beginning to end in in/min from .
Above, holes 1-4 are mirrored across the Y axis to 5-8, respectively, about a line X OFFSET from X=absolute 0 ROTATE is used for polar rotation of parts that have a rotational symmetry around some point in the XY plane.
Press the SUBROUTINE (SUB) soft key to call up the Repeat, Mirror, and Rotate options. 8.10.1 REPEAT Press the REPEAT soft key.
8.11 COPY Events Copy Events are programmed exactly like Subroutine Events. The only difference is that in Copy the events are rewritten into subsequent events. If, for example, in event 11 you copy repeated events 6, 7, 8, 9, 10 with 2 repeats, events 6-10 would be copied with the input offsets into events 11-15, and recopied into 16-20. Copy Events may be REPEAT, MIRROR, ROTATE or DRILL to TAP. Copy is very useful.
PITCH - the distance from one thread to the next in inches or mm. It is equal to one divided by the number of threads per inch. For example, the pitch for a 1/4-20 screw is 1 20 = .05 inches RPM: spindle RPM Tool #: is the tool number you assign 8.12 THREAD MILL Event To program a Thread Mill Event press the THREAD MILL soft key. This event includes an automatic move in and out by 0.050” of the thread.
Pause Events are useful if you want to stop the program to make a measurement, change a fixture, etc. NOTE: In general, you should avoid programming a Pause Event between two connective events. The Pause Event will cause the events to NOT be connective. To program a Pause Event press the PAUSE softkey. Because there is no input required, simply press SET to load and the event counter will advance by one and the Select Event screen will reappear. In run, press the GO key after a pause to continue. 8.
8.15 ENGRAVE Event The Engrave Event allows you to machine numbers, letters and special characters as part of a part program. See below for the letters and special characters that are available in the Engrave Event. When programming with the Engrave Event, the ProtoTRAK will construct a box to contain the text you define.
The above figure shows the text and special characters available for the Engrave event. Notice the field that is labeled “Text Length”. This field will display the total length of your programmed text and will update as you enter each character. 8.16 Auxiliary (AUX) Functions Event Auxiliary operations are programmed as events in the ProtoTRAK PMX CNC to make it easier to turn functions on and off for the entire program.
Position 7 8 9 4th Axis Auto Clamp OFF 4th Axis Auto Clamp ON Cornering – Blend or Exact Stop or work piece. The position along the X axis may be changed using a Service Code. Turns off the auto clamp feature on 4th axis units that require air to run. Turns on the auto clamp feature on 4th axis units that require air to run. The default if no AUX event is program is to auto clamp. Allows the program to blend a corner or exact stop in the corner. When you blend moves, some accuracy will be lost.
3. Please note that if you do use corner blending in your program, we will automatically get into exact position on the following moves or events. a. Bore and drill event – the final depth that you program in your event will get into exact position. b. All position or rapid moves will get into exact position. For example, if you are rapiding out of a hole in Z and then positioning in X and Y to a new hole location, the control will get into exact position.
b. Surfacing type programs that are comprised of small moves that have small angles between the moves should not require a G64 or corner blending to be turned on to avoid hesitation. c. All moves that are tangent to each other also will not have exact stop (G61) apply. Please note that when making a 90° outside corner with tool compensation applied, we generate an arc to machine the sharp corner so these moves are tangent. d.
9.0 Program Mode Part 3: The Auto Geometry Engine (A.G.E.) Programming This entire section deals with the Auto Geometry Engine which is automatically started when you program an Irregular Pocket (Section 8.6.3) or an Irregular Profile (Section 8.8.3). The A.G.E. is powerful software that works behind the easy-to-use geometry programming of the ProtoTRAK PMX CNC. It is treated in its own section because it works differently than the other event types. Unlike other events, the A.G.E.
Once the profile header screen is finished, you choose between an A.G.E. Mill and an A.G.E. Arc to define the shape. Where: A.G.E. MILL: A straight line from one X Y point to another. A.G.E. ARC: Any part of a circle. END A.G.E.: Ends the A.G.E. programming for the Irregular Pocket or Irregular Profile. ABORT A.G.E.: Aborts all A.G.E. events. The data for all the events is lost. 9.2 A.G.E. Mill Prompts Press the A.G.E. Mill key. A.G.E. Mill prompts. Enter what you know, skip or guess the ones you don’t.
LINE ANGLE: is the angle of this mill line (moving from begin to end) measured counterclockwise from the positive X axis (that is 3 o’clock) GUESS: This softkey will appear when the prompt is on X or Y dimensioned data. Press the Guess key before you press INC SET or ABS SET to enter the data as a guess. See Section 9.7 for using Guess and Section 9.8 for using the Graphics to enter a Guess. 9.3 A.G.E. Arc Prompts Press the A.G.E. ARC key. Prompts in A.G.E.
type, the words OK or NOT OK appear, depending on whether that particular event is defined. Once the OK flag appears for the event, you do not need to enter more information. Skip past the rest of the prompts with the down cursor hard key. If you leave the Program Mode and then return, pressing the GO TO END softkey will take you automatically to the first NOT OK event. 9.6 Ending A.G.E. Any time all the events are of an Irregular Profile are OK, the A.G.E. may be ended.
The X End dimension has been entered as a guess - note the letter G Guesses should always be entered as absolute dimensions. Once entered, the guessed data will have a 'G' next to it. Guessed data will be labeled this way in all the events that are flagged NOT OK. Once an event is OK, the guessed data will be replaced by calculated data. If you wish to edit your guesses, placing it on the right side of the screen will cause your original guessed data to reappear.
When you use the graphics to guess dimensions on arcs, you may load in guesses for both the X/Y End and the X/Y Center before leaving the LOOK screen. When you have not first pressed the Guess key, pressing LOOK gives you the same screen as in regular programming. Whether you enter the guesses as key presses or by using the graphics, the drawing of the LOOK screen distinguishes between events that are fully defined and those that rely on guessed data. OK events are represented by solid lines.
9.11 Tangency Tangency can occur between a mill and arc or an arc and arc. Specifically it means that the two events share one and only one point. You would answer yes to the TANGENCY prompt if the event you are programming is tangent to the previous event. The information that events are tangent helps the Auto Geometry Engine calculate other dimensions. You can often tell by looking at the print if events are tangent: tangent intersections tend to blend smoothly, without a sharp corner.
10.0 Edit Mode Within Program Mode, you can recall and re-input specific data prompt by prompt. The changes you make in the Edit Mode affect only the program in current memory. In order to preserve the changes for future use, the program must be stored again under the same name in the Program In/Out Mode. 10.1 Delete Events To delete a group of events in the program, press DELETE EVENTS. The Data Input Line will prompt for the first event to be deleted.
The first time the screen appears, the data is sorted by event number. Each row represents the data for the event number shown in the first column on the left. The event number is always displayed in the first column, but the other data displayed on the table can be changed. Soft Keys in Search Edit: PAGE FWD: pages forward through the table. PAGE BACK: pages backwards through the table. SORT: enables you to change the sort to any of the data displayed. See Section 10.2.
After you press the HELP hard key, the screen will display all the different parameters that can be displayed on the spreadsheet. To either select or deselect any parameter, simply highlight that parameter and press SET. When you are finished, press the Return softkey and return to the spreadsheet. 10.2.2 Sorting Data Data may be sorted by any of the data types displayed in the column head. Red letters show which column is used for sorting the data.
After sorting by Event Type, the highlighter is placed on the Z feed of the first Mill Event 3. Press the CHANGE ALL softkey. All the Z Feeds in the Mill events are highlighted. 89 Southwestern Industries, Inc.
Pressing the Change All softkey highlights the Z feed for all the Mill events. 4. Type in the new Z Feed value and press INC SET or ABS SET. 90 Southwestern Industries, Inc.
Type the new Z Feed and then SET to change all the highlighted values from 50 to 40. In this example, the Z feed is changed from 50 to 40 for all the Mill Events. 10.3 Erase Program Use the ERASE PROG soft key to erase the program from the current memory. Erasing the program from current memory will not affect any programs that are stored. If you have made changes to the program and wish to save this modified program, you will need to store it. See Section 14.4 10.
Inspect the events you want to copy. Make sure that the dimensioned data uses Absolute references in the first event to be copied and in all events where it will be important. Incremental references may be used, but keep in mind where the Incremental reference will be made from. See the section on Incremental Reference Position in this manual. In addition, you may want to modify this program in order to get all the events you want together.
10.5 G-Code Editor The G-Code Editor allows the edit of G-Code programs that are opened as .GCD or PTG files. Once edited, the program may be re-saved as .GCD or PTG files. ProtoTRAK Geometry-style programs may not be saved as .GCD or PTG files. Use the G-Code Editor to modify G-Code programs. You must connect a mouse and keyboard in order to use the G-Code Editor. When you enter the G-Code Editor, the G-Code program is displayed starting at the first Block Number.
The find and replace routine. Click in the FIND WHAT box and enter the item you want to find. Click on THE FIND NEXT box and the G-Code Editor will locate the next occurrence of that item. Successive clicks on Find Next will continue to search through the program. Use Match Whole Word to limit the search to the entire word. For example, if you want to find G2, but not G20 or G22, select Match Whole Word Only.
Any change made in the editor will be applied the next time you run the program. To permanently save these changes, go to PROG IN/OUT screen and use the save feature. 10.6 Update GCD The UPDATE GCD button will show up when a .PTG file is loaded into memory. This feature allows you to update the G code file that is linked within the .PTG file. This is useful when you go back to your offline computer and update your G code file and then want to re-insert it into your .PTG file. If you load just a .
Once this is done, press TAB and go to the directory where the new file resides. Highlight the new file, press SELECT and then COMPLETE. The new G code file will now be linked to your .PTG file. Now go and resave your program. 96 Southwestern Industries, Inc.
10.7 Next Program The NEXT PROG button shows up in edit mode when you open a master program. It allows the user to select which program they would like to view when performing any of the editing functions. When this button is pressed, the program name up in the status line will change to show which program will now be edited. 97 Southwestern Industries, Inc.
11.0 Program Set Up Mode The Program Set Up Mode lets you do the set up steps that do not involve the machine. You can do these steps while the machine is running another job. Move between the Current and Staged view by pressing the C/S button on the upper left side of the Program Panel. Program Set Up 98 Southwestern Industries, Inc.
11.1 Part/Fixture Management This is where you set the ball lock location for where you want to run your part(s) and also where you set your part zero locations relative to the ball lock location. Part/Fixture Management Part – displays the number of parts in your program. If you are running a master program, you can have up to 4 parts in 4 columns. Single programs will only display a single program and column.
you see in the small DRO in the lower left hand corner. When staging your next job, measure the distance from the bottom of your fixture plate to the part Z zero. This can be done by sitting your fixture plate on a surface plate and using a height gage. Parts/Fixture – this tells the control how many of the same part you are running per fixture. To use this feature each part must have the same offset relative to the first part.
parts, you can save 8 pictures per program and 8 additional pictures within the master program for a total of 40 pictures. NEXT allows you to view the next picture that is attached to a given part. Pressing this button allows you to toggle between each picture. Note: Once you add pictures, you must resave the program in the Program In/Out Mode for the pictures to be saved.
A keyboard is necessary to enter text into the notes section. TAB moves you from one section to the next. You may want each section to have the same kind of information from program to program. NEXT it moves you through the four pages of notes available. NEXT PROG moves you through the notes you may have for each part in a master program. Just like pictures you can have up to 5 notes sections if you are running a master program with 4 parts.
11.1.5 Part/Fixture Management LOOK If you press the LOOK key on this screen, it will bring up a screen showing where your have placed your fixtures on the table. 103 Southwestern Industries, Inc.
11.2 Tool Management The Tool Management screen is where you go to assign your programmed tools to be added to or removed from the automatic tool changer (ATC). Tool Management Screen Lets look at the different sections and fields that make up this screen. ATC Table The ATC table displays all the tools that are either currently loaded in the ATC, or are assigned to be added (which is done later in the TOOL LOADING page. See Section 12.1). It also displays all manual tools currently assigned.
Dia – The tool’s programmed diameter, carried over from the Part Program Tool Table. Type – Tool description, carried over from the Part Program Tool Table. Z Offset – This is the offset of the tool in relation to the machine’s Base Tool Offset, as set in service code 502. Z Mod – A modifier used in addition to the Z offset. Use a negative modifier to cut with the tool deeper into your part, or a positive value to go higher. Dia Mod – A modifier used in addition to the diameter of the tool.
Current vs. Staged Modes The C/S button on the program panel allows the user to toggle between what we call Current Mode and Staged Mode. The staged feature allows the user to be able to program and setup the majority of the next job while the machine is running. Current Mode refers to the current program that you are running on the machine. Staged Mode refers to a program that you are setting up to be run after the current job is finished. When you press this button the machine toggles between these modes.
Staged Mode will once again be identical. For example, this may be necessary if you changed a modifier in Current Mode for a tool that you will be using on the next part. The buttons in Staged Mode that are gray are not available to the user. This is normally the case when the feature or function requires some sort of interaction with the machine. For example, in Machine Setup Mode, the TOOL LOADING softkey is gray, since you cannot change tools in staged when you are running a program in current mode.
11.2.1 TOOL CRIB When a tool is removed from the ATC table, you have the option of storing it in the Tool Crib Section. The Tool Crib is a separate page that will keep track of up to 100 tools that have already been previously defined. By storing it in the Tool Crib, you have the ability to quickly assign it back into the ATC along with its offset.
removed from the table, the tool itself will be marked to be removed from the TOOL LOADING screen, so that the tool can be physically taken out of the ATC. 11.2.3 NOTES This will take you to the notes page where there are several text boxes that allow you to enter any notes related to your tool setup or descriptions. These are the same notes that are also found on the Part / Fixture Management page. Notes are saved within each PT7, PTM or PTG program. 11.2.
minus sign from a Z End dimension, the system would give you an error message that the Z End should not be higher than the Z Rapid. The displayed graphic is automatically sized to fit the screen. The path shown on the screen represents the center of the tool. Position and drill events are drawn in yellow. Rapid moves are in red. Programmed geometry is in blue. The white rectangular box that is shown on the screen represents the travel limits for the machine.
FIT TABLE: When this button is pressed, the screen will be resized to show the entire extents of the machines table. RETURN: returns to the previous softkeys, retaining the adjustments that were made to the drawing. 11.4 Run Strategy Run Strategy lets you direct the ProtoTRAK PMX to run your master program either Tool-by-Tool or Part-by-Part. If you select PART by PART, the program runs the first part through to completion, then does the 2nd part through to completion and so on for parts 3 and 4.
11.5 Tool Recon (Reconciliation) Tool Reconciliation Tool Reconciliation is the process of renumbering like tools to the same tool number within different part programs in your master program. For example, in the table above, program 1 and 2 both use a 0.500 Ctr Drill but in program 1 the tool is called tool # 1 and in program 2 it is called tool # 2. This means we need to rename the tool in program 2 to tool # 1.
The control will reconcile your tools only the 1st time you enter this mode. The 2nd time you enter this mode, the column labeled Rec will show the same numbers that are found on the column to the left of the it. You still have the ability to rename each tool if you wish. Once this is done, hit the SAVE button. Notes - Tool Reconciliation is applicable only when running a master program. 113 Southwestern Industries, Inc.
12.0 Machine Set Up Mode In Machine Set Up Mode you do the set up that must be done with the machine stopped and the door open. This part also includes the Checklist for easy reference to the steps you must complete to machine your job correctly. Machine Set Up Screen 114 Southwestern Industries, Inc.
12.1 Tool Loading 12.1.1 Tool Status Box At the very top of the screen below the status line is a tool status box. It represents what the control thinks is the status of the tool in the spindle and ATC. The following describes each box from left to right. ATC Pos – This refers to the position of the ATC in relation to the spindle. The ATC location directly to the left of the spindle will be displayed in this box. As the ATC rotates, this field will update.
12.1.2 Tool Loading Table ATC Loc – This box displays the ATC location the given tool is residing in. Tool # - This displays the tool # this tool has been assigned in your program. Diameter – This displays the diameter of your cutting tool. Type – This displays the description of the cutting tool (ie: center drill). Z Offset – This displays the difference in length between the cutting tool and the base tool supplied by SWI.
12.1.4 ADD TOOL ADD TOOL is used to add a new tool to the ATC. The ADD TOOL prompt is invoked when you assign a new tool from you program to the ATC in tool management mode. To add a tool to the ATC, highlight the tool you want to add with the blue cursor box and press ADD TOOL. If the tool loading table shows a remove tool box for the same tool location, then you will have to remove the tool first before adding the new tool. A message box will appear on the screen when the add button is pressed.
Status Lights – there are 3 different colors used to determine the status of a given step. Green (go) – Items that have been completed or do not need any attention will be green. For the top 6 items, pressing OK turns these boxes green. The bottom 6 boxes will turn green once the activity have been completed. Yellow (caution) – The top 6 boxes can be in a yellow state which means we recommend you check them. Pressing OK turns the box from yellow to green.
12.3 Service Codes These are special codes that may be entered into the ProtoTRAK PMX CNC to call up routines used in installation, setting of preferences, machine checkout and service. WARNING! Before using service codes, be aware that some of the routines are very powerful and may change important system settings. Some of the routines cause the servos to come on and move at rapid speed. The Service Codes are divided into logical categories. The table below summarizes the more important ones.
500 X, Y Ball Lock Offsets 501 Set Z Tool Change Height 502 Set Base Tool Height 505 Over-travel Limits 510 Spindle Setup Used to enter the offsets for ball locks A, B and C Used to enter the offset for the tool changer height relative to the Z home position, and to manually move the ATC in and out. Used to set the base tool height relative to the top of the table. Used to setup and troubleshoot software limits. Also used to get machine off a limit switch when over-traveled.
Service Code 339 - This service code, when set to YES, can also be used to have the head go to a different height before and after a tool change. To set the height you want, go to PART/FIX MGMT and press the Z safety button to set this value. Please be aware that the machine will still need to come down to the tool change height to change tools, so you may need to add a position move to move the X and Y axis to a safe position. 121 Southwestern Industries, Inc.
13.0 Run Mode 13.1 Run Mode Screen Press MODE and select the RUN soft key. Below is a description of what is displayed on the RUN screen. There are 4 windows at the top of the screen that display the following: RUN: displays that you are in RUN mode P/N: displays the part number that is running TIME: displays the total time it takes to cycle through the program. INCH: displays whether you are in inch or mm mode. Items in the main screen: ATC Pos.
Repeat: if a repeat event is in the event counter, this will show which repeat number, for example, if you program a drill with 5 repeats, this will show which repeat of the event that is being machined. Shift: when machining multiple parts using the shift in the PART/FIX MGMT screen, this will show which part is being machined. Position: displays the absolute or incremental X, Y, Z coordinates of the machine.
which program you wish to start in. Hit the SELECT soft key and the screen will change back to the RUN screen. The conversation line will prompt "Input Event #." Input the number of the first event you wish to run, and press SET. If the START EVNT # is a Repeat or Rotate, the conversation line will prompt "Starting Repeat Number" asking which repeat or pass you wish to start. 13.
13.5 Program Run Messages While in Run Mode, the PMX CNC will tell you in clear and concise prompts exactly what to do to run the program. These messages will appear in a green box in the middle of the screen. Any Event Comments you entered during programming will appear on the Data Input Line (See section 7.3.2 to use Event Comments). Once the program starts, a Run Time Clock will appear to the right of the status line at the top of the screen.
14.0 Program In/Out Mode From the Select Mode screen, press the PROG IN/OUT softkey. The first screen you see will ask: "LIST SUPPORTED PROGRAMS ONLY?" With a highlighted YES or NO. Supported programs are part programs that can run on the ProtoTRAK PMX CNC. You do not have to answer this question every time you are at this screen. Simply press the softkey for the operation you want. Select YES to only display the file extensions that the ProtoTRAK supports, such as PT4, PT7, CAM, etc.
File extensions are part of filenames that help describe the file. They appear after the filename and are composed of three letters following a period. For example, .doc is the extension that appears after a file name for a file stored using Microsoft Word™. Usually, but not always, the file name indicates what program was used to create the file. Sometimes this is not the case. Some programs, like those found in early models of CNC, do not attach a file extension to a file name at all.
TRANSFER: to transfer a program from the Staged mode to the Current mode, including notes and pictures. This will also update the Tool Management with any changes made from Staged mode. 14.2 Basic Navigation of Program In/Out Mode Screens The screens in the Program In/Out Mode do not have the normal ProtoTRAK look and feel because they are derived from the Windows operating system. Most functions may be performed using a mouse or keyboard.
When a program file name is highlighted, press the LOOK hard key to see a graphical representation of the part program. The graphics are not a precise representation of the tool path, but should be very handy in helping to identify a file before opening. In addition to the basic parts of the screen described above, two additional parts of the screen appear in the open operation: File Name: - Displays the name of the file that is highlighted from the list.
Creating a Master Program After pressing the CREATE MASTER softkey, you will be prompted to select up to 4 files that you wish to work with. Use the arrow keys to move the highlight around, and then press the SELECT button to add the file. In the lower display window, you will see the list of files that are to be combined, as shown above. Once you have selected all the files you wish to work with, press the COMPLETE softkey, and you will automatically be taken to the Tool Recon page. See Section 11.
14.4 Saving Programs To save a program file to a storage location, press the SAVE softkey from the Program In/Out Mode screen. Find the drive and folder you want to save the program file in using the softkeys as described above in the section on basic navigation. The Save Screen Two additional parts of the screen appear once the SAVE softkey is pressed: File Name: displays the name of the file that is in current memory. SAVE AS: lists the formats for which the file may be saved. The default is .PT7.
Once the save operation is finished, you will see the file name added to the files in the listing area. Note – the ProtoTRAK PMX will not allow you to save to the C drive since it is reserved for the XP operating system and ProtoTRAK software. The LPM does come with a USB storage device that is found on the computer module in the electrical cabinet. It will be called drive D. You can also add additional USB storage devices to the USB ports found on the right side of the control pendant.
PASTE FILE: Writes a copy of the file to the location shown in the Look In box. RETURN: Returns to the Program In/Out Mode screen. When the pasting operation is finished, you will see the file name added to the listing area. 14.6 Deleting Programs Programs in current memory are removed from current memory in Edit Mode. See Section 10.3 To remove a program file from a storage location, press the DELETE softkey from the Program In/Out Mode screen. Use the navigation procedure described in Section 14.
Renaming a file. Press the HELP hard key to call up the alpha keys Additional parts of the screen appear once the RENAME softkey is pressed: New Name: When a file or folder is highlighted, the name will appear here. When the TAB, the RENAME FILE or RENAME FOLDER softkey is pressed, the highlight will move here and you will then be able to write in a new name. New Extension: A new extension can be given to the file picking from the ones available.
14.8 Backing Up In order to protect your important programs, it is a good idea to back them up regularly. That way, if your media device ever becomes unusable, you will not have to re-write the program. To back up your files, press the BACK UP softkey from the Program In/Out Mode screen. Backing up. The top part of the screen shows all the items in Drive F. The bottom part shows the items that have been picked for backing up The basic procedure for backing up is: 1.
Note: It is good practice to back up files to a different drive, rather than to a different folder on the same drive. For example, if you keep your programs on the USB flash drive, it is a good idea to back them up to another computer. That way, if the USB flash drive becomes unusable, you will have the part programs somewhere else so that you can reload them when the problem with the flash drive is resolved. 14.
Use the Open As box to tell the ProtoTRAK PMX CNC what kind of file it is Use the Open As box to tell the ProtoTRAK PMX CNC what format the file is in so that it knows how to convert it to the ProtoTRAK PMX CNC format. In the image above, the ProtoTRAK PMX CNC could guess that the file to be converted was from a previous version of ProtoTRAK because of its file extension (.mx3).
Use the Save As box to tell the ProtoTRAK PMX CNC what kind of file you want the current program (in the .PT4 format) to be converted into. In the image above the file name 102209 is being saved on drive G as a .mx3 file. Note that although the program or part name as shown in the status line is HOUSING014, the file name given for converting the file conforms to the .mx3 format – fewer than eight characters long and consisting of numbers. 14.
14.10.1 File Formats The ProtoTRAK PMX CNC can store and retrieve the following ProtoTRAK and TRAK CNC file formats. Previous ProtoTRAK and TRAK CNC file formats: ProtoTRAK M3 .mx3 ProtoTRAK MX3 .mx3 ProtoTRAK MX3E .mx3 TRAK AGE3 .mx3 TRAK QMV .mx3 ProtoTRAK SM ProtoTRAK VM ProtoTRAK SMX .pt4 .pt4 .pt4 14.10.2 Opening .MX3 and .PT4 files on a ProtoTRAK PMX CNC Programs written on previous generation ProtoTRAK and TRAK CNC’s may be opened and run on the ProtoTRAK PMX CNC.
or %RPM the ProtoTRAK or TRAK CNC Tool Path Programming Only Part Geometry programming is supported on the ProtoTRAK or TRAK CNC. This routine does not exist in the ProtoTRAK or TRAK CNC. Zig-Zag Entry Mode Ramps Event Comments Thread Mill Tool Table Info Irregular Profile Face Mill Event comments are not supported on the ProtoTRAK or TRAK CNC. This routine does not exist in the ProtoTRAK or TRAK CNC. The part programs for ProtoTRAK or TRAK CNC do not contain tool table information.
G01 Linear Interpolation G01 X0.0 Y0.0 Z-1. F15. G02 Circular Interpolation (Clockwise) Circular Interpolation (Counter-clockwise) G02 X1. Y2. I0. J2. G03 (see note below) G03 X2. Z0. I2. K0.
G85 G86 G89 Boring cycle G85 X0. Y0. Z-1 R.1 F15. Boring canned cycle with retract G86 X0. Y0. Z-2. R.1 B35. Q.020 B = Angle of boring head. P300 F15. Q = Retract distance, away from B. Boring cycle, dwell at bottom G89 X0. Y0. Z-1 R.1 P800 F15. P = dwell time in milliseconds G90 G91 Absolute Mode Incremental Mode G90 G91 Default G98 Use previous Z position as Rapid plane Use R value as Rapid plane.
14.11.
Mm: min -9999.99 to max +9999.999 Integer values MUST be followed by decimal. Ok to truncate 02.0000 into 2.0 Linear moves: G01 are formatted the same as rapid moves. Arcs: Arc centers are specified by the address I, J and K for the X, Y and Z axes. The number following the I, J and K are incrementally referenced from the starting point of the arc. Radius values are not allowed. Tool Numbers and Tool Changes: the format of the tool number is from T1 to T99. The M06 command initiates a tool change.
3. An effective revision control. Having a single shared folder on the network enables you to have a single location with all the latest versions of the programs. Of course, the above functions are possible without a network by shuttling floppy disks around. The reason to have a network is that it saves time. Once it is set up, you can do repetitive functions without much work.
An ideal setup would be to purchase a router and have it connected directly to the ProtoTRAK control, and have it handle communications between it and your desktop computer. Several ProtoTRAKs can be hooked up simultaneously with minimal effort.
2. Create a Workgroup name for your computer. For instructions on how to do this, go to Windows™ Help and search for the topic “Workgroup Names”. If there is a workgroup name already, write it down. We will make the ProtoTRAK match the existing name in the next steps below. 3. Share a part of your computer. This will allow the ProtoTRAK to look into the drives or folders you share. For instructions on how to do this, go to Windows™ Help and search for the topic “Sharing” or “How to Share a Folder”.
8. Enter a workgroup. This workgroup must match the name of the workgroup on your desktop computer. Assigning a workgroup name for your computer is discussed above. If you have not selected a workgroup for your computer we suggest “shop” or “toolroom”. 9. Keep clicking OK until you get back to the Select a Mode screen. 10. You may be prompted to restart the computer during this process. If so, click on YES to reboot the computer, and the changes should take effect after reboot. 14.12.
3. In the Drive box, type in an available drive letter. In our example, Drive Z is available (and more likely will be available for you as well). Type in the letters “Z:” You must type in both the “Z” and the “:”. See image below. 4. In the Folder box, Browse for the folder on your PC that you shared, from Section 14.12.2, step 3. When you click browse, you may have to go through a few layers of file hierarchy before you find the folder you shared.
14.12.4 General Information For Advanced Networks The ProtoTRAK PMX CNC is a PC, but for setting up a network it is more useful to think of it as a device such as a printer. While the ProtoTRAK has many similarities to a desktop computer, it is different in that the use of the computer’s resources have been optimized for running part programs and the resulting motor / sensor feedback in real time.
therefore will figure out the tool path for you, the process of converting a three-axis program gives the ProtoTRAK a tool position problem that it cannot resolve without a lot more data from you. The other reason is that the output from a CAM systems for 3-axis shapes is in the form of thousands and thousands of straight-line G01 moves that would convert into the equal number of ProtoTRAK Mill events. This is hardly a manageable program.
Tool Numbers and Tool Changes: the format of the tool number is from T1 to T99. During program run, the ProtoTRAK will rapid to home for a tool change and pause for the tool to be loaded manually and the operator to press GO. Feed Rates: the ProtoTRAK is programmed in inches (or mm) per minute using the 'F' address. Spindle Speed: Defined by the ‘S’ address, followed by the speed in Revolutions Per Minute. File Name: use the .
G89 Boring cycle, dwell at bottom G89 X0. Y0. Z-1 R.1 P800 F15. P = dwell time in milliseconds 14.13.3 Supported Addresses CAM information is communicated through the use of ADDRESS – WORD pairs. For example in the line “N01G0X1.Y2.” N, G, X, and Y are addresses. The other information (01, 1, and 2) are Data Words. The line starts with the Address = N and the data word = 01. The N address is defined as meaning “LINE NUMBER”, therefore N01 means Line # 1, and so on.
D. signed coordinate word, denoted 1. format: negative number: - positive number: + or 2. range: metric: -99999.999 to 99999.999 inch: -9999.9999 to 9999.9999 E. tool function, denoted 1. format : dd (use 2-digit only) 2. leading 0 suppression 3. range: 1 to 99 F. miscellaneous or M codes function number, denoted 1. format: dd 2. leading 0 suppression 3. range: 1 to 99 G. feedrate values, denoted 1. format: metric: ddddd inch: ddd.dd 2.
All other M codes will be ignored. Notes: 1. Place M Codes on same line as movement G Code. 2. One M Code per block. 3. All values are in Absolute, except for I, J, and K values. 155 Southwestern Industries, Inc.
15.0 4th Axis Option The 4th axis option can be retro-fitted onto your ProtoTRAK LPM machine at any time after its initial purchase. Once the option is purchased and physically installed, you can activate it on your software screen by following the instructions below: From the main MODE screen, go to: MACHINE SETUP SERV CODES A CODE 318 You will enter a screen that should look like the one above.
MACHINE SETUP 4TH AXIS ON 15.1 4th Axis Specifications The following are the specifications for the 4th axis unit. Spindle Diameter Chuck Diameter Overall Height of 4th Axis Centerline Height of Spindle Minimum Resolution of System Maximum RPM Repeatability Indexing Accuracy 4th Axis Weight 4th Axis Keyway Size Max distance between 4th axis with chuck (without chuck) & tailstock with center 15.2 201RB Model 7.874” or 200 mm 7.874” or 200 mm 11.811” or 300 mm 5.315” or 135 mm 0.
The 4th axis is referred to as the A axis, and is measured in degrees. On the DRO screen, it will read from 0.000 degrees to +359.999 degrees. However, when programming, you can refer to negative values, and you can use values of greater than 360 degrees. Take a look below at figure 15.2.3. Suppose that A is our starting point, and that A equals +30 degrees ABS. If B was our desired endpoint, then there are actually 4 different ways to program this.
Figure 15.2.5 15.2.2 Feedrate Feedrate for the 4th axis is always defined in inches per minute. When feeding along the A axis, the system will reference from the centerline of the 4th axis. If 20 inches per minute is defined, the system will look at the distance from the current Z axis (tip of the tool, so tool offset needs to be set properly) to the centerline of the 4th axis, and will automatically calculate how fast to turn the A axis in order to achieve the desired feedrate at the tip of the tool.
15.3 DRO Mode When the 4th axis option is turned on, you will see an extra line for the A axis on the main readout. In addition, each of the selections in the DRO page will now have an option for the A axis. 15.3.1 JOG To JOG the 4th axis, simply press the EHW button on the Run Panel, and press the 4th button. The electronic handwheel will now jog the 4th axis in either direction. The resolutions for the JOG speed are as follows: .0001” -> .001 degree per click .0010” -> .010 degree per click .0100” -> .
15.3.4 SET A Press this button to set you A axis to a temporary abs value. Like the other axis, this is only for the ABS reference, and does not affect your part’s abs 0 location. 15.3.5 REF 4th Axis Press REF, and then 4TH AXIS to reference from the 4th axis. The reference points referenced here are defined in service code 506. The X represents the distance to the faceplate of the 4th axis. The Y and Z axis reference the center line of the 4th axis rotation.
15.4.1 POSN A END – specifies the value, in degrees, where the 4th axis will rapid to. 15.4.2 MILL 4 AXIS The 4th axis mill event allows you to feed up to all three axis simultaneously, from any X,Z,A beginning point to any X,Z,A ending point. The Y axis is assumed to be at centerline of your part. The Z axis will be the distance from the center of your part, so think of it in terms of radius. Note that there is no cutter compensation available for 4th axis mill events.
A BEGIN – Specifies the beginning angle of the mill event. A END – Specifies the ending angle of the mill event. XAZ FEEDRATE – Specifies the feedrate of the tip of the tool, in relation to the surface of the workpiece. The feedrate will only be accurate if the part is properly set in the Part/Fixture Mgmt page (see section 15.5.1). 163 Southwestern Industries, Inc.
15.4.3 ENGRAVE 4 AXIS The 4th axis engrave event assumes that you have cylindrical stock, and want to engrave along the surface. X BEGIN – Defines the starting point on the X axis for the text to be engraved. See figure 15.3.3, and note that even though both radial and axial have the same XA starting point, they span across different areas along the X axis. A BEGIN – Defines the angle for the starting point of the text to be engraved. See figure 15.3.
Figure 15.4.3 15.4.4 AUX Event Two new AUX event options will become available when you have turned on Fourth Axis Request in the header event. Select 7 for Auto Clamp OFF and select 8 for Auto Clamp ON. By default the 4th axis will automatically clamp the A axis in place when it is holding position and will automatically unclamp the axis when an A axis move is commanded. It should be noted that there is a slight delay when the unit is going from a 165 Southwestern Industries, Inc.
clamped to unclamp state. This means if you have a connective move from let’s say the X axis to the A axis, you are going to want to program an Aux 7 prior to the X axis event so the unit will not clamp and hence delay slightly before moving into the A axis move. The auto-clamping feature is useful when you are simply indexing the 4th axis from one A position to another. We also recommend you program an Aux 7 when you are going to be doing engraving or contouring type work so the 4th axis will not clamp.
15.5 15.5.1 PROG SETUP Modes PART/FIX MGMT Screen There are a few new features available on this screen when the 4th axis option is enabled. Fixture Location – The user can now select the 4th axis as a reference point from which his offsets will be saved. The X axis is referenced from the face of the 4th axis, the Y and Z axis are both relative to the center of rotation about the 4th axis. The A axis will be referenced from its machine home position.
Figure 15.5.1.1 If you were to take the solid part pictured above and mount it into the 4th axis jaws, you would more than likely tram in the flat side with an indicator assuming that you wanted to machine relative to that surface. The A offset will compensate for the distance between where the A Home position is and where you want your ABS A Zero to be. Figure 15.5.1.2 Say for example that after tramming in the flat surface, the DRO for the A axis read 315.54 degrees (360 – 44.46 = 315.54).
offset, so that when the program is commanded to position to ABS Zero, it will move to that spot that you defined. As a rule of thumb, if you are going to be working on round stock as shown above, you should make it so that Y ABS zero and Z ABS zero remains at the centerline of your part. For our 4th axis engraving and 4th axis mill events, this is a must. Therefore, every Z value that is to be programmed, will be referring to the radius of the part.
15.6.2 4TH AXIS ON / OFF This soft key enables and disables the use of the 4th axis servo, as well as the programming options available to the user. When turning on the 4th axis, you will need to home the machine again so that the 4th axis gets homed as well. If the 4th axis option is turned off, you will get a prompt stating that you will lose your current program in memory. 15.
15.8 4th Axis Setup Notes 1. Please see section 8 of the LPM service manual for important tips for taking the 4th axis unit on and off of the machine when not in use. The 4th axis unit and ball lock plate weighs about 250 lbs so please use a lift to remove the unit from the machine. This plate can be removed by sliding it onto a LPM fixture cart. The 4th axis unit also comes with an eyebolt that can be used for lifting purposes.
Southwestern Industries, Inc TRAK Warranty Policy Warranty TRAK products are warranted to the original purchaser to be free from defects in work-manship and materials for the following periods: Product New TRAK/ProtoTRAK Any EXCHANGE Unit Warranty Period Materials Factory Labor 1 Year 1 Year 90 Days 90 Days The warranty period starts on the date of the invoice to the original purchaser from Southwestern Industries, Inc. (SWI) or their authorized distributor.
