I Console

VERTICAL TYPE MACHINING CENTER
AWEA I Console Operation Manual
Machine typeA+/BM/AF/AV/FM ControllerFANUC 18iMB VersionAAEUFI00 Date2009/01/01
AWEA MECHANTRONIC CO.,LTD. 629, Suezhetou Section, Kwanpu Rd., Hsinpu Town, Hsinchu County, Taiwan 305 TEL: 886-3-5885191 FAX: 886-3-5885194
CONTENTS
C O N T E N T S
1. OPERATION MANUAL OF ICONSOLE.................................................................................. 1-1 1.1 OPERATION PROCEDURES OF ICONSOLE ................................................................................. 1-1 1.2 OPERATING INSTRUCTIONS OF I CONSOLE .............................................................................. 1-1 MAIN SCREEN .......................................................................................................................... 2-2 2.1 SOFT KEYS OF MAIN SCREEN .................................................................................................. 2-2 2.2 ITEMS ON MAIN SCREEN ......................................................................................................... 2-3 TOOL LIST ................................................................................................................................. 3-5 3.1 SOFT KEYS OF TOOL LIST ........................................................................................................ 3-5 3.2 ITEMS ON TOOL LIST SCREEN .................................................................................................. 3-6 3.3 OPERATION ............................................................................................................................ 3-6 3.3.1 Select pocket ................................................................................................................. 3-7 3.3.2 Change tool number in magazine pockets .................................................................... 3-7 3.3.3 Change tool number on spindle .................................................................................... 3-7 3.3.4 Re-initializing tool table ............................................................................................... 3-7 WORKPIECE COORDINATE ................................................................................................... 4-8 4.1 SOFT KEYS OF WORKPIECE COORDINATE ................................................................................ 4-8 4.2 SIMPLE WORKPIECE COORDINATE MEASUREMENT .................................................................. 4-9 4.3 SOFTKEYS OF SIMPLE WORKPIECE COORDINATE MEASUREMENT .......................................... 4-10 4.4 ITEMS ON SIMPLE WORKPIECE COORDINATE MEASUREMENT SCREEN ....................................4-11 4.5 PROCEDURES OF WORKPIECE COORDINATE SETTING..............................................................4-11 4.6 ADVANCED WORKPIECE COORDINATE MEASUREMENT ......................................................... 4-12 4.7 SOFTKEYS OF ADVANCED WORKPIECE MEASUREMENT ......................................................... 4-13 4.8 ITEMS ON ADVANCED WORKPIECE MEASUREMENT SCREEN .................................................. 4-14 4.9 ADVANCED CIRCULAR WORKPIECE MEASUREMENT .............................................................. 4-14 4.10 SOFTKEYS OF ADVANCED CIRCULAR WORKPIECE MEASUREMENT ........................................ 4-15 4.11 PROCEDURES FOR ADVANCED CIRCULAR WORKPIECES MEASUREMENT ................................ 4-16 4.12 ADVANCED SQUARE WORKPIECES MEASUREMENT ............................................................... 4-17 4.13 SOFTKEY OF ADVANCED RECTANGLE WORKPIECES MEASUREMENT ...................................... 4-18 4.14 PROCEDURES FOR OPERATION OF ADVANCED RECTANGLE WORKPIECES MEASUREMENT ...... 4-19 4.15 TOOL LENGTH MEASUREMENT ............................................................................................. 4-19 4.16 SOFTKEY OF TOOL LENGTH MEASUREMENT .......................................................................... 4-20 4.17 ITEMS ON TOOL LENGTH MEASUREMENT .............................................................................. 4-20 4.18 PROCEDURES FOR TOOL LENGTH MEASUREMENT ................................................................. 4-21 M-CODE ................................................................................................................................... 5-22 5.1 SOFTKEY OF M-CODE .......................................................................................................... 5-22 5.2 M-CODE ON SCREEN ............................................................................................................ 5-23 ALARM..................................................................................................................................... 6-24 6.1 SOFTKEY OF ALARM ............................................................................................................. 6-24 6.2 PROCEDURES OF ALARM ....................................................................................................... 6-25 CALCULATOR......................................................................................................................... 7-26 7.1 SOFTKEY OF CALCULATOR ................................................................................................... 7-26 7.2 DISPLAY ITEMS .................................................................................................................... 7-27 7.3 CALCULATION ...................................................................................................................... 7-27 CUTTING PARAMETER OPTIMIZATION............................................................................ 8-28 8.1 SOFTKEY OF OPTIMIZE PARAM .............................................................................................. 8-28 8.2 ITEMS ON OPTIMIZE PARAM SCREEN ..................................................................................... 8-29 8.3 OPERATION PROCEDURES FOR OPTIMIZE PARAM ................................................................... 8-29 8.4 OPTIMUM PARAM ................................................................................................................. 8-30
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3.
4.
5.
6.
7.
8.
CONTENTS 8.5 MAXIMUM PERMISSIBLE TOLERANCE ................................................................................... 8-30 8.6 90 DEGREE CORNER .............................................................................................................. 8-30 8.7 CONTOUR ERROR ................................................................................................................. 8-32 8.8 WORKPIECE WEIGHT ............................................................................................................ 8-33 8.9 QUANTIFICATION OF ACCELERATION ADJUSTMENT ............................................................... 8-33 8.10 PROGRAM COMMAND ........................................................................................................... 8-34 8.11 DIAGNOSE FOR ABNORMAL SITUATIONS ............................................................................... 8-34 8.11.1 Feed speed cannot be increased .................................................................................. 8-34 8.11.2 Abnormal surface of the mold .................................................................................... 8-35 9. THERMAL COMPENSATION SYSTEM ............................................................................... 9-41 9.1 SOFTKEY OF THERMAL COMPENSATION ................................................................................ 9-41 9.2 ITEMS ON THERMAL COMPENSATION SCREEN ....................................................................... 9-42 9.3 PROCEDURES FOR THERMAL COMPENSATION ....................................................................... 9-42 10. ADAPTIVE FEED RATE CONTROL (AFC) .......................................................................... 10-2 10.1 INTRODUCTION .................................................................................................................... 10-2 10.2 AFC PRINCIPLE .................................................................................................................... 10-2 10.3 CONTROL LINE ..................................................................................................................... 10-3 10.4 SYSTEM RESPONSE ............................................................................................................... 10-3 10.5 EMERGENCY PROTECTION .................................................................................................... 10-4 10.6 ADAPTIVE FEED CONTROL .................................................................................................... 10-4 10.7 OPERATION .......................................................................................................................... 10-6 10.8 OPERATION PROCEDURE OF AFC SCREEN............................................................................. 10-6 10.9 OPERATION PROCEDURE OF G CODE .................................................................................... 10-7 10.10 ALARM............................................................................................................................. 10-8 11. VERSION...................................................................................................................................11-9 11.1 SOFTKEY OF VERSION ............................................................................................................11-9 11.2 ITEMS ON VERSION SCREEN .................................................................................................11-10
II
CONTENTS
C h a r t
Ta b l e
o f
C o n t e n t s
Figure 1 Flow Chart of iConsole ........................................................................................ 1-1 Figure 2 i Console Main Screen ..................................................................................... 2-2 Figure 3 i Console Screen of Tool List ............................................................................ 3-5 Figure 4 i Console Screen of Measurement Selection.................................................... 4-8 Figure 5 i Console Screen of Workpiece Coordinate Setting Selection ........................... 4-9 Figure 6 i Console Screen of Basic Workpiece Measurement......................................... 4-9 Figure 7 Simple workpiece measurement Points of Measurement ............................... 4-12 Figure 8 i Console Selection of Advanced Workpiece Measurement............................ 4-13 Figure 9 i Console Screen of Circular Workpiece Measurement ................................... 4-14 Figure 10 i Console Screen of Circular Workpiece Measurement Calculation............... 4-15 Figure 11 i Console Screen of Rectangle Workpieces Measurement ........................... 4-17 Figure 12 i Console Calculation Screen of Rectangle Workpieces Measurement ......... 4-17 Figure 13 i Console Tool Length Measurement ............................................................ 4-19 Figure 14 i Console M-Code......................................................................................... 5-22 Figure 15 Alarm Screen.................................................................................................... 6-24 Figure 16 i Console Calculator ..................................................................................... 7-26 Figure 17 Optimize Parameter ......................................................................................... 8-28 Figure 18 Definition of 90 degree corner ......................................................................... 8-30 Figure 19 The best way for keeping speed and shortest time in the corner..................... 8-31 Figure 20 Car race roads, same as path tolerance of machining .................................... 8-31 Figure 21 AWEA Optimize Param.................................................................................... 8-32 Figure 22 Definition of contour error ................................................................................ 8-32 Figure 23 Saw shape path with very short distance corners............................................ 8-34 Figure 24 Simulation for cutting result with bad program (Should be a smooth surface) . 8-35 Figure 25 Cutting result with bad program (Should be a smooth surface) ....................... 8-36 Figure 26 Simulation for cutting result with bad program (Should be a smooth surface) 8-36 Figure 27 Cutting result with bad program (Should be a smooth surface) ....................... 8-37 Figure 28 Simulation for cutting result with bad program (Should be a smooth surface) . 8-37 Figure 29 Cutting result with bad program (Should be a smooth surface) ....................... 8-38 Figure 30 Simulation for cutting result with bad program (Should be a smooth curve surface) 8-38 Figure 31 Cutting result with bad program (Should be a smooth curve surface).......... 8-39 Figure 32 Simulation for cutting result with bad program (Should be a smooth curve surface)........................................................................................................................ 8-39 Figure 33 Cutting result with bad program (Should be a smooth curve surface) ............. 8-40 Figure 34 Thermal Comp................................................................................................. 9-41 Figure 35 Control of rough cutting ................................................................................... 10-2 Figure 36 Figure of PID Control Principle ........................................................................ 10-3 Figure 37 Adaptive Feed Control ..................................................................................... 10-4 Figure 38 Functional List ................................................................................................. 10-5 Figure 39 Softkey List ...................................................................................................... 10-6 Figure 40 Status of dynamic information system ............................................................. 10-6 Figure 41 Alarm List......................................................................................................... 10-8 Figure 42 Version Screen ................................................................................................ 11-9
III
Operation Manual of i Console
1. Operation Manual of iConsole

1.1 Operation procedures of iConsole
Main Screen
Tool# List
WP offset
M-Code DOC M-Code
Alarm DOC
Calculator
CNC Param (Option)
Thermal Comp. (Option)
AFC (Option)
Version
WORK.P
TOOL.L
SIMPLE
COMP.
CIRCLE
SQUARE Figure 1 Flow Chart of iConsole
1-1
1.2 Operating instructions of i Console

1. Select function in I Console, please start from MAIN page. 2. Press screen. to return to previous page, refer to figure 1-1 flow chart of i Console
3. Press will return to main screen directly. 4. Press cursor keys on the FANUC OP panel to move cursor up, down, left, right. 5. Press page down and page up on the FANUC OP panel to change page. 6. Two ways to input data (1) use keys on FANUC OP panel to input data (2) use corresponding soft keys under the screen to input data.
1-1
2. Main Screen
Figure
2 i Console Main Screen
2.1 Soft keys of main screen

Softkey Function Remark
Switch screen to tool page
Switch screen to workpiece coordinate
Switch screen to M-Code
Switch screen to alarm elimination

2-2
Operation Manual of i Console Switch screen to Calculator
Switch screen to cutting parameter optimization Switch screen to spindle thermal compensation display Switch screen to Adaptive feed-rate control interface
Optional package
Optional package
Optional package
Switch screen to display version information
2.2 Items on main screen

Display items <ABSOLUTE > <MACHINE> <DIST TO-GO> <MODAL> F (Uppercase) S (Uppercase) <MOTOR LOAD> <SPD LOAD > M Function Display absolute coordinate (metric system /imperial system) Display mechanical coordinate Display residual distance to go Display G-CODE status Display actual feed rate Display actual spindle rate Display motor load of axis (%, Rated) Display Spindle motor load (%, Rated) Display M-code status (M03, M04, M19, M5)
2-3
Operation Manual of i Console COOLANT SPD ROT <TOOL TABLE > SPD TL # MAZ POT # Display Coolant status Display Spindle status (M03, M04, M19, M5) Display tool list Display current spindle tool number Display current middle tool pocket of tool magazine Display current middle tool number of tool magazine Display current right side tool pocket of tool magazine Display current right side of tool number of tool magazine Display current left side tool pocket of tool magazine Display current left side tool number of tool magazine Time of power on Total process time Time for this process Total # workpiece machine Workpiece NO.
MAZ TL #
RIGHT POT #
RIGHT TL #
LEFT POT#
LEFT TL # Power on Run Time Cycle Time Tot. Parts Parts O#### N#####
Program # to be executed Line number of the program
2-4
3. Tool List
This screen provides an interface for operators to manage the tool number in magazine and spindle. Press on softkey in main screen to enter Tool List screen.
Figure
3 i Console Screen of Tool List
3.1 Soft keys of tool list

Softkey Function Select a tool by entering the corresponding pocket #
Enable tool # to be changed
3-5
Rearrange tool # in ascending order.
Move the cursor to the spindle tool # field
Execute tool # change
Back to previous page
Switch to main screen
3.2 Items on tool list screen
Display items MAG .1 POT. NO TOOL. NO -D. SPINDLE TOOL NO.
Function Display tool capacity of the magazine Display tool pocket number Display tool number corresponding to the pocket Tool radius Display current spindle tool number
3.3 Operation
The followings are detail operating procedures of the screen.
3-6
3.3.1 Select pocket

1. Enter the pocket # by using the numerical pad on FANUC OP Panel 2. Press to move the cursor to the position of assigned tool pocket.
3.3.2 Change tool number in magazine pockets

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

1. Press 2. Enter the Tool # by using the numerical pad on FANUC OP Panel 3. Press to execute the command
3.3.4 Re-initializing tool table

Tool number can be rearranged in ascending order by the following procedures. After executing the procedures, tool number will be the same as the pocket number. 1. Press , 2. Press Input on FANUC OP Panel
3-7
4. Workpiece Coordinate
This screen provides an interface for both workpiece coordinate and tool length measurement. Press on softkey in main screen to enter Tool List screen.
Figure
4 i Console Screen of Measurement Selection
4.1 Soft keys of workpiece coordinate

Softkey Function
Switch screen to selection of work coordinate measurement
Switch screen to tool length measurement
4-8
4.2 Simple workpiece coordinate measurement
Press on press on
softkey in Workpiece Coordinate to enter Selection screen. Then, softkey to enter Simple Workpiece Coordinate Measurement
Figure
5 i Console Screen of Workpiece Coordinate Setting Selection
Figure
6 i Console Screen of Basic Workpiece Measurement

4-9
Operation Manual of i Console This screen provides a simple interface for locating the center point of a circular or rectangular workpiece.
4.3 Softkeys of simple workpiece coordinate measurement

Softkey Function
Selection of X axial direction
Selection of Y axial direction
Selection of Z axial direction
Initial point of the measurement. Center point between initial point and end point will be the workpiece reference point End point of the measurement. Center point between initial point and end point will be the workpiece reference point
4-10
4.4 Items on simple workpiece coordinate measurement screen

Display items <MECHANICAL COORDINATE > < RELATIVE COORDINATE > < EXT > Function Display mechanical coordinate
Display relative coordinate Display external offset coordinate value Display origin point of workpiece coordinates Valid values are from G54 ~ G59
(G##)
4.5 Procedures of workpiece coordinate setting

For a square workpiece as shown in Figure carried out. 7, the following procedure should be
1. Input workpiece coordinate number (select from G 54 ~ G 59 group) by using FANUC OP Panel. Ex. G54 G + 5 + 4 + Input 2. Install a edge finder onto the spindle 3. Press down softkey. 4. Move the edge finder along X axis until it touches the workpiece, as shown in Figure 7, initial point of X 5. Press down softkey.
At this time X axis of workpiece coordinate origin will be highlighted. X axis workpiece coordinate origin will be displaying (the present position [absolute] + initial position [absolute]) / 2. X axis relative coordinate will be displaying the difference between present position and initial position. 6. Move the edge finder along X axis until it touches the opposite side of the workpiece, as shown in Figure 7, end point of X 7. Press softkey
At this time, the X axis of workpiece coordinate origin has been set at the midpoint between initial point of X and end point of X as shown in Figure 7 8. Press down softkey. 9. Move the edge finder along Y axis until it touches the workpiece, as shown in Figure 7, initial point of Y
4-11
Operation Manual of i Console 10. Press down softkey.
At this time Y axis of workpiece coordinate origin will be highlighted. Y axis workpiece coordinate origin will be displaying (the present position [absolute] + initial position [absolute]) / 2. Y axis relative coordinate will be displaying the difference between present position and initial position. 11. Move the edge finder along Y axis until it touches the opposite side of the workpiece, as shown in Figure 7, end point of Y 12. Press softkey
At this time, the Y axis of workpiece coordinate origin has been set at the midpoint between initial point of Y and end point of Y as shown in Figure 7
Initial point of Y
Initial point of X
End point of X
X
Work piece reference point
End point of Y
Figure
7 Simple workpiece measurement Points of Measurement
4.6 Advanced workpiece coordinate measurement
Press on
softkey in Workpiece Coordinate to enter Selection screen. Then,
press on softkey to enter Advanced Workpiece Coordinate Measurement This screen provides interfaces for : 1. Locating the center point of a circular workpiece by 3 measurement points 2. Locating the center point of a rectangular workpiece and compensating for the misalignment of the workpiece by 5 measurement points.
4-12
Figure
8 i Console Selection of Advanced Workpiece Measurement
4.7 Softkeys of advanced workpiece measurement

Softkey Function
Selection of workpiece number
Setting radius of edge finder
Input workpiece number or radius of edge finder
Switch screen to circle workpieces measurement
4-13
Switch screen to rectangle workpieces measurement
4.8 Items on advanced workpiece measurement screen

Display items WORKPIECE MEASURE SELECT Select assigned workpieces# Function
WORK SELECT FINDER.RADS
Select measured workpieces type Radius of edge finder
4.9 Advanced circular workpiece measurement
Figure
9 i Console Screen of Circular Workpiece Measurement
4-14
Figure
10 i Console Screen of Circular Workpiece Measurement Calculation
4.10 Softkeys of advanced circular workpiece measurement

Softkey Function
Input A, B, C
Execution of circle workpieces measurement calculation
Calculation of circular workpieces of central point
4-15
Index of workpieces#
Input value of workpiece coordinate
4.11 Procedures for advanced circular workpieces measurement

1. Input coordinates of workpiece group number (1~6) on the panel, press panel. 2. After pressing , setting radius of edge finder, then press of the panel. of the
3. Select screen of circular workpieces measurement 4. Measure calculation. 5. After pressing
of the panel. for
these three points in orders, then press
, the reference point of circular workpiece will be gotten. Check which will input the value of
number of the workpiece is correct, and pressing OFFSET to workpiece coordinate.
4-16
4.12 Advanced square workpieces measurement
Figure
11 i Console Screen of Rectangle Workpieces Measurement
Figure
12 i Console Calculation Screen of Rectangle Workpieces Measurement
4-17
4.13 Softkey of advanced rectangle workpieces measurement
Softkey
Function
Input A, B, C, D, E
To execute calculation of rectangle workpieces measurement
To calculate central point and tilting angle
Index of workpieces #
Input coordinates
Display angle
4-18
4.14 Procedures for operation of advanced rectangle workpieces measurement

1. Input coordinate of workpiece group number (1~6) on the panel, press panel. 2. After pressing , setting radius of edge finder, then press of the panel. of the
3. Select screen of Rectangle workpiece measurement 4. Measure calculation. 5. After pressing
of the panel. for
these five points in orders, then press
, the reference point of Rectangle workpiece will be gotten. which will input the value
Check number of workpiece is correct, and pressing of OFFSET to workpiece coordinate.
4.15 Tool length measurement
Figure
13 i Console Tool Length Measurement
4-19
4.16 Softkey of tool length measurement

Softkey Function
Index of tool#
Input altitude of Z axis set point station
Present position - height of Z axis set point station
Input added attitude by manual
Input measured attitude by manual
4.17 Items on tool length measurement

Display items NO. GEOMETRY WEAR G43 H MACHINE
Function Tool # Tool length Tool wear Value of tool length compensation Mechanical coordinates
4-20
Operation Manual of i Console HM.INP Setting altitude of Z axis
4.18 Procedures for tool length measurement

1. Press INPUT key or soft key to input data.
2. First, input altitude of Z axis set point station then press . 3. Moves the spindle toward the Z- direction till tool tip touch the station, and press .
4. Press to add length value by manual if it is necessary, if the customer pads height of measured workpiece then input the value of padding height. 5. The column of shape will display the distance from tool tip to the top of workpiece, and then input the values to the column of G43 H.
4-21
5. M-Code
Figure
14 i Console M-Code
5.1 Softkey of M-Code

Softkey Function
M code description.
5-22
5.2 M-Code on Screen

This screen is for user of M-CODE. Use (Page Up / Page Down key) to turn pages.
5-23
6. Alarm
Figure 15 Alarm Screen
6.1 Softkey of alarm

Softkey Function
Alarm index
6-24
6.2 Procedures of alarm

When alarm occurs, input alarm number from screen then press (AL index) to check the alarm of possible reasons. From screen, to see the axial traveling message of 1,001, 1,001 have represented the alarm number, but afterwards in addition alarm message of axial traveling. The column of ALARM and SOLVE which describe the possible reason of alarm created, the axes traveling of Alarm 1,001 that the possible reason is X8.0 = 0 either X8.1 = 0 or X8.2 = 0.
6-25
7. Calculator
Figure
16 i Console Calculator
7.1 Softkey of Calculator

Softkey Function
Addition,1
Subtraction ,1
Multiplication,1
7-26
Division,1
SIN(45),45
COS(45),45
TAN(45),45
Radical sign operation, 10 ,10
To execute operation
Clear
7.2 Display Items

The input value by green color to demonstrate upper left side of calculator graphical representation The operation result by yellow big typeface to above demonstrate of calculator graphical representation.
7.3 Calculation
This calculator without calculating multiplication and division function first, then after addition and subtraction, only use for the basic calculation.
7-27
8. Cutting Parameter Optimization
Figure
17 Optimize Parameter
8.1 Softkey of optimize param

Softkey Function
Set the current setting and servo parameter will be written to NC controller automatically.
Reset the parameter to default value and write to NC controller.
GUI interface description
8-28
CNC Parameter version
Switch to Main page
8.2 Items on optimize param screen

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

1. Use UP/DOWN key to selectACCELERATION OVERRIDE (Cutting mode), ALLOWABLE DEVIATION (Tolerance), WORKPIECE WEIGHT 2. Use RIGHT/LEFT key to select cutting mode grade. 3. Input tolerance value with unit um. Push INPUT key to write the data to CNC.
8-29
Operation Manual of i Console 4. Input workpiece weight value with unit Kilogram. Push INPUT key to write the data to CNC. 5. With setting all parameters above, push soft key and parameters will work after that. Message PRESS [SET PARAM] TO APPLY CHANGES! will soft key alert when the settings have been changed again. Please push and new settings will work. 6. To initial or quit the function, push soft key. 7. Soft key and should be used in MDI mode or Emergency STOP status. The alarm messages PLEASE SWITCH TO MDI MODE! and PLEASE PRESS DOWN EMERGENCY BUTTON! will show when the SET/RESET is pressed in the wrong mode.
8.4 Optimum param

OPTIMIZE PARAM with the GUI interface that can help user to understand the effect of parameter setting. This function can help the machine being more efficient and good performance.
8.5 Maximum permissible tolerance

When the structure of the machine is not changed, position error can not be prevented with increasing the speed. OPTIMIZE PARAM provide user to set maximum tolerance for the contour. There are two types of toleranceOne is 90 degree corner and the other is contour error.
8.6 90 degree corner
Real path Corner error Command path
Figure
18 Definition of 90 degree corner
For example, suppose NC cutting path as race car road and spindle as race car. When the car passes by the corner, in order to keep the speed of inside and outside the corner the car cannot go the 90 degree path. The better way is going with a curve path. If the corner speed is increased, the radius of curve is increased also. Same concept is applied in FANUC controller, so the corner error should be taken into consideration in parameter setting.
8-30
Figure
19 The best way for keeping speed and shortest time in the corner
There are many kinds of race car such as F1, Touring, Rally, Modified truck. With the same 90 degree corner and speed, the inner offset (path error) has relations with the performance of race car. That means small car, high rigidness, good grip of ground will have small inner offset. On the contrary big car, low rigidness, low grip of ground will have bigger inner offset. It is impossible to keep 90 degree path with high moving speed. The cutting tolerance is decided by the machine structure. So the parameter setting is depended on the machine structure. Tolerance error is something like the width of the road. If the tolerance is not asked for good, the speed in the corner can be increased. If the tolerance is asked for good, the speed in the corner should be slow down to match the tolerance.
Figure
20 Car race roads, same as path tolerance of machining
In OPTIMIZE PARAM screen, the allowable deviation is provided for user. The control software will calculate the best corner speed by user settings. Before this function is released, the allowable deviation is restricted within 5 to 30um and must be adjusted by many machine types.
8-31
Contour error 90 degree error
Figure
21 AWEA Optimize Param
8.7 Contour error

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

Contour
error
Figure
22 Definition of contour error
8-32
8.8 Workpiece weight

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

In order to provide more selections for the same weight and tolerance, OPTIMIZE PARAM has quantification for acceleration adjust. There are five grades for acceleration. With the increasing of the speed, the vibration will increase and the quality of the surface will become worse. Grade 5 This grade is used for rough machining. With the advance of the tool technology, high feed rate, high speed and low cut of every tooth are used for rough machining. In this machining, the material removal rate is very important. Therefore the stable of feed rate is needed. If feed rate is faster, the material removal rate will become more faster also, which means more efficient. The basic purpose of grade 5 is to keep stable feed rate without considering the surface roughness. Select the maximum tolerance with cutting the 1/3 of material removal part, the feed rate will more higher and stable. Grade 4 This grade is used for semi-machining. The setting for this grade is similar to grade 5, but when the speed is increasing, the vibration is lower than grade 5. Select the maximum tolerance with cutting the 1/3 of material removal part, the feed rate will more higher and stable.
8-33
Operation Manual of i Console Grade 3, 2, 1 is used for fine machining and the tolerance can be 5 ~ 50 um. Grade 3 Die mold for car or low surface roughness quality. Grade 2 For normal dies mold machining. Grade 1 Surface of Plastic mold or high quality of roughness .
8.10 Program command

This function can be active by G code. Format G400W___. M___. E___. W Workpiece weight (kg) M Cutting mode grade1 ~ 5 E Max. tolerance5 ~ 200 (um)
8.11 Diagnose for abnormal situations 8.11.1 Feed speed cannot be increased
Situation In mold cutting with the path which is a little bit like a long straight line, the path speed is very slow and can not arrive the command feed rate(F). Cause The path which is a little bit like a long straight line may be built by saw shape path. This path has many corners with very short distance. See the figure below. The corner may not be seen with eyes. In order to keep the tolerance, the controller should slow down the path speed.
Figure
23 Saw shape path with very short distance corners
Solution Use difference machining methods, path or redesign the CAM program to make the corner to straight line. Try to enter bigger value of the allowable deviation in OPTIMIZE PARAM setting if high precision is not necessary.
8-34
8.11.2 Abnormal surface of the mold

Situation 1 The surface of workpiece has several blocks of abnormal lines Cause The possible reason for the abnormal lines is low precision setting of CAD/CAM transformation. The normal value of precision for plastic mold is <= 5um. Although higher precision may cause more calculation time, the machining time is still the same. Compare with the machining time, the calculation time of CAD/CAM is very short. It is unreasonable to save 2% of CAD/CAM time which will cause bad surface (means more machining time by reworking) instead of high precision setting. With requesting of higher quality for workpiece, the precision of CAD/CAM transformation should be taken into consideration. Some examples for bad transformation of CAD/CAM software
Figure 24 Simulation for cutting result with bad program (Should be a smooth surface)
8-35
Figure
25 Cutting result with bad program (Should be a smooth surface)
Figure
26 Simulation for cutting result with bad program (Should be a smooth surface)
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Figure
27 Cutting result with bad program (Should be a smooth surface)
Figure
28 Simulation for cutting result with bad program (Should be a smooth surface)
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Figure 29 Cutting result with bad program (Should be a smooth surface)
Figure 30 Simulation for cutting result with bad program (Should be a smooth curve surface)
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Figure 31 Cutting result with bad program (Should be a smooth curve surface)
Figure
32 Simulation for cutting result with bad program (Should be a smooth curve surface)
8-39
Figure
33 Cutting result with bad program (Should be a smooth curve surface)
Solution Increase the precision of CAD/CAM transformation and use the simulation function of the software to check the correction of the program. For example, the known software CATIA has a simulation function of cutting to simulate the real path with workpiece. If some bad lines are found in the simulation result, these bad lines will transfer to NC program undoubtedly. Otherwise, some professional software can be used to check NC program, such as MetaCut, AlphaCut, VeriCut. Situation 2 The surface of workpiece has several blocks of abnormal spots in the corner. Cause The abnormal spots in the corner are caused by the phase changing (from positive to negative direction or vice versa). The bad compensation of backlash should be the reason. Solution Check the NC program by the software MetaCut, AlphaCut or VeriCut to confirm the abnormal spots are caused by NC program. Call the service to measure the backlash and compensate it.
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9. Thermal Compensation System
Figure
34 Thermal Comp
9.1 Softkey of thermal compensation

Softkey Function Back to previous
Start thermal compensation
Close thermal compensation
Reset thermal compensation
9-41
9.2 Items on thermal compensation screen

Display items CH 1, 2, 3, 4 DIFF 1, 2, 3, 4 COMP. X Y Z R1100 R1102 R1104 MODE Function Read each temperature from datum of sensor Temperature difference between current time and machine power on Calculate deformation values Write in register of PLC Machine type
9.3 Procedures for thermal compensation

1. Check if the function of thermal compensation is effective from operation screen ( Start / Close 2. soft key is used for the thermal compensation is not compensated well, press reset soft key can recalculate the value of thermal compensation.
9-42
10. Adaptive Feed rate Control (AFC)

10.1 Introduction
Thank you for using AFC function of AWEA. For many years, AWEA has devoted to research and develop many kinds of new functions for the customer needs. This function is built for reducing the time of rough machining and effective increasing the life of cutting tools, which will creates more benefits for the customers. With this idea, AWEA develops Adaptive Feed rate Control (AFC) function, it combines with iConsole and PLC, using the PLC high speed calculation ability and simple operation interface of iConsole. It provides reliable and easy man-machine interface for the customer to reduce the processing time, reduce the time of manually operate, extend the cutting tool life and so on.
10.2 AFC principle

The theory of AFC is detecting the spindle load to control the feedrate on-line. When the spindle load is lower than the target load, the feed rate override will be increased to make feed rate higher. This increasing of override will stop until spindle load is arrived target. When the spindle load is higher than the target, the feed rate override will be decreased very fast until the load is lower to target. See the figure 38. Spindle Load (%)
Spd Load Limit Spd Load Target
Control Line Time Figure 35 Control of rough cutting
From figure 38, there are 3 dashed lines which indicate spindle load limit of (blue), the spindle load target (red) and the control line (yellow). The black straight line is the curve of spindle load controlled. There are three sections of AFC. The first section refers to under the area of control line. The feed rate is not controlled in this section and override can be controlled by switch on the operation panel. The second section refers to the acceleration area. In this area is related with the setting of the Response on the screen. When the Response set faster, the acceleration become higher to reach the target and vice versa. Third section refers to the deceleration area. When the spindle load is higher than upper limit, the override will be decreased quickly that will keep the stable relationship between spindle load and feed rate..
10-2
10.3 Control line

The purpose of initial control line is to divide feed rate override control to manual control/semi-manual control. When the spindle rotates without cutting, the formula set the initial control value automatically, but current feed rate override can be controlled by operator manually. When the spindle is machining, feed rate override is calculated and applied by formula in order to control the spindle load. When AFC function is active, the operator can also use switch of operation panel to adjust feed rate override manually.
10.4 System response

Response setting is used for controlling the acceleration slop of feed rate override. When the response set faster, it means the increasing/decreasing of override amount is bigger for each PLC cycle. The PID close loop control is used for this system. Unlike the open loop system control, the PID control has faster response and let system become more stable. Figure 36 is the PID control principle: ERROR OVERRIDE Target PID Control SYSTEM Y Actual Spindle (Output) Load
Figure
36 Figure of PID Control Principle
The PID controller is composed of proportion (P), integral (I) and differential (D). The proportion is one of the simplest control modes, using the difference between input and output (the error) to adjust the response of proportion then reduce the error. The contribution from the integral term is proportional to both the magnitude of the error and the duration of the error. Summing the instantaneous error over time (integrating the error) gives the accumulated offset that should have been corrected previously. The accumulated error is multiplied by the integral gain and added to the controller output. The integral term (when added to the proportional term) accelerates the movement of the process towards set point and eliminates the residual steady-state error that occurs with a proportional controller only. The derivative term slows the rate of change of the controller output and this effect is the most noticeable close to the controller set point. Hence, derivative control is used to reduce the magnitude of the overshoot produced by the integral component and improve the combined controller-process stability. Based on above reasons, use the PID control will be able to have the faster system response and a better stability.
10-3
10.5 Emergency protection

When cutting the workpiece, the spindle load may increase rapidly then damage the cutting tool or more badly the precision of spindle broken. In order to avoid the above situations, the AFC control has two ways for protection. First, when the spindle load is increasing over upper limit very fast, the formula rapidly reduces the feed rate override, which will reduce spindle load directly. Second, when the spindle load is over upper limit continuously and feed rate override is up to minimum value, the AFC function will alert an alarm and stop the feed rate to protect spindle and tool damaged.
10.6 Adaptive feed control
System information zone
Setting zone Soft key zone Figure 37 Adaptive Feed Control

10-4
Operation Manual of i Console As above figure 37, screen of AFC operation divides into three parts-Setting zone, System information zoneandSoft key zone. The setting zone includes (Target), (MAX/MIN Override) and Response of acceleration and deceleration. The function display as figure 38
Display items
Function This setting is according to the experience of machining and machining conditions, such as tool or workpiece material and feed or spindle speed will be involved. The purpose of target setting is used for increasing the efficiency of machining. Set range5~100% The MAX. Override is used for user to set its value. Set the value bigger will have higher speed for feed rate control. Set range100~150% The min. allowable override is for limiting the override and lets the user assured that the slowest override for machining. Set range40~99%
Target
MAX. OVERRIDE %
MIN. OVERRIDE %
ACCELERSTION%
The acceleration setting is to increase the override response.
Figure
38 Functional List
Softkey
Function Back to previous page
Start
AFC function
Close
AFC function
10-5
Figure
39 Softkey List
The information zone system provides the user to understand present spindle load, feed rate and the current feed override. Moreover the dynamic information is located on lower right side of screen, including upper load limit, target load, current spindle on load and override. The figure 40 is for various functional descriptions. Display items LOAD% FEED-RATE OVERRIDE Function Read recent spindle load from program Read recent feed-rate from program Read recent feed-rate override from program SPD LIMT blue line SPD LOAD TARGET yellow line SPD LOAD red line OVERRIDE white line Figure 40 Status of dynamic information system
10.7 Operation
There are two ways to active AFC function. First, input the value setting of AFC of iConsole and use M200 to active this function (use M201 to cancel). Second, add G500 with parameters in single block and function will be activated after executing this block. M201 is also used for canceling the function. NoticeStart AFC function; please add M200 command before spindle rotation.
10.8 Operation procedure of AFC screen

Setting AFC parameter can be modified on AFC screen of iConsole. The parameter can be adjusted when AFC function is ON, which can help the operator to modify the best adjustment of parameters for different material, workpiece or machining conditions.
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10.9 Operation procedure of G Code

In programming edition, to execute AFC, please following the format as bellow G500 T**. M**. S**. R*. G500G Code functions for AFC. T Using for setting spindle load target, the MAX. allowable target is 100, and the min. allowable target is 5. M Using for setting the MAX. Feed rate override, which range is between 100 ~ 150. S Using for setting MIN. Feed rate override, which range is between 40 ~ 99. R Acceleration responses set. There are three levelslow, medium, and fast, which will be separately indicated by 1, 2, 3. Remark Each parameters must add dot . behind the setting value. Or it will have an alarm or unexpected error.
% O0001; G500T80M140S60R1; ------>Setting AFC parameter (or GUI of I console) M200; --------> Start AFC //Notice! Active AFC function before spindle rotation M3S1000;
Working program
G500T70M120S40R2; ------>Command setting AFC parameter (or GUI of i console) // G500 is for setting G code of AFC parameter // T70 is for fixing value of spindle target loading to 70% // M120 is for fixing the MAX.feed rate to120% // S40 is for fixing the minimum feed rate to 40% // R2 is for fixing system
Working program
M201 -------> Cancel AFC function M30; %
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10.10
Alarm
Alarm code & message 3001 T CODE IS EMPTY 3002 TARGET IS TOO LARGE 3003 TARGET IS TOO SMALL 3004 M CODE IS EMPTY
Methods of eliminate alarm T CODE is empty , please input T CODE Target is too large, max allowable value is 100 Target is too small, min allowable value is 5 M CODE is empty, please input M CODE The Max. override is too large, Max. override allowable value is 150 The Min. override is too large, min. override allowable value is 100 N CODE is empty, please input N CODE The Min. override is too large, min. override allowable value is 99 The Min. override is too small, min. override allowable value is 40 R CODE is empty, please input R CODE RESPONSE setting is error, please reset RESPONSE range is in 1 ~ 3 The reasons of spindle load too high is as bellow: The target is too small The min override is unreasonable
3005 MAX. OVERRIDE IS TOO LARGE
3006 MAX. OVERRIDE IS TOO SMALL
3007 N CODE IS EMPTY
3008 MIN. OVERRIDE IS TOO LARGE
3009 MIN. OVERRIDE IS TOO SMALL
3010 R CODE IS EMPTY
3011 INVAID NUMBER OF RESPONSE
AL2080 SPD LOAD STILL TOO HIGH
Solutions: Readjust target of spindle load Reduce min override Press [CYCLE START] or press [Reset] to eliminate alarm
Figure
41 Alarm List
10-8
11. Version
Machine Type Software Version Contact Us
Website and E-mail
Figure
42 Version Screen
11.1 Softkey of version

Softkey Function
11-9
11.2 Items on version screen

Display items Machine Type Software Version Contact Us Website and E-mail Function Display recent software of corresponding machine Display recent software of published version Address ,Tel. and Fax of AWEA HsinChu ,Taichung Offer AWEA website and e-mail
11-10

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VERTICAL TYPE MACHINING CENTER

AWEA I Console Operation Manual

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

Operation Manual of i Console

1. Operation Manual of iConsole

M-Code DOC M-Code

CNC Param (Option)

Thermal Comp. (Option)

SQUARE Figure 1 Flow Chart of iConsole

Operation Manual of i Console

1.2 Operating instructions of i Console

Operation Manual of i Console

2 i Console Main Screen

2.1 Soft keys of main screen

Switch screen to tool page

Switch screen to workpiece coordinate

Switch screen to M-Code

Switch screen to alarm elimination

Operation Manual of i Console Switch screen to Calculator

Switch screen to display version information

2.2 Items on main screen

Program # to be executed Line number of the program

Operation Manual of i Console

3 i Console Screen of Tool List

3.1 Soft keys of tool list

Enable tool # to be changed

Operation Manual of i Console

Rearrange tool # in ascending order.

Move the cursor to the spindle tool # field

Execute tool # change

Back to previous page

Switch to main screen

3.2 Items on tool list screen

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

Operation Manual of i Console

3.3.1 Select pocket

3.3.2 Change tool number in magazine pockets

3.3.3 Change tool number on spindle

3.3.4 Re-initializing tool table

Operation Manual of i Console

4 i Console Screen of Measurement Selection

4.1 Soft keys of workpiece coordinate

Back to previous page

Switch screen to selection of work coordinate measurement

Switch screen to tool length measurement

Operation Manual of i Console

4.2 Simple workpiece coordinate measurement

5 i Console Screen of Workpiece Coordinate Setting Selection

6 i Console Screen of Basic Workpiece Measurement

4.3 Softkeys of simple workpiece coordinate measurement

Back to previous page

Selection of X axial direction

Selection of Y axial direction

Selection of Z axial direction

Switch to main screen

Operation Manual of i Console

4.4 Items on simple workpiece coordinate measurement screen

4.5 Procedures of workpiece coordinate setting

Operation Manual of i Console 10. Press down softkey.

7 Simple workpiece measurement Points of Measurement

4.6 Advanced workpiece coordinate measurement

softkey in Workpiece Coordinate to enter Selection screen. Then,