SmartShop MT WinCNC. SUPPLEMENTS to WinCNC Operations Manual

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1 SmartShop MT WinCNC SUPPLEMENTS to WinCNC Operations Manual Overview and specification sheet Page 3 Optiscout Vision System Page 10 Operating the EOT-2 Oscillating Tangential Module Page 21 Operating the TCM-3 Tangential Cutting Module Page 32 Automatic Tool Changer Operations Manual Page 45 Machines Equipped with a Rotary Axis Page 52

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3 MT WITH WINCNC AND VISION SYSTEM(OPTISCOUT) Overview and specification sheet TABLE OF CONTENTS WinCNC Controller... 1 Optiscout... 2 Optiscout Brief Overview... 2 Features... 2 Optiscout further Breakdown... 2 Types of RegMarks available... 4 Machine Specifications... 5 Available Tools and attachments... 5 Tangential Heads... 5 PC specifications... 6 Compatible file formats with Optiscout... 6 Sources... 7 WINCNC CONTROLLER What is WinCNC? Windows PC based controller for CNC machines. Highlights WinCNC provides a customizable easy-to-use interface for any operation [4]. WinCNC uses a large look-ahead buffer, reading thousands of lines ahead while running GCode files. Reading ahead allows WinCNC to accelerate or decelerate through many small arc or line segments producing smoother motion and faster completion times [4].

4 OPTISCOUT OPTISCOUT BRIEF OVERVIEW What is Optiscout? Modular finishing software suite for multi-functional cutters in industrial environments contour-exactly digital cutting and milling. What is used for? Compensates for data inaccuracy during the printing process. Brief overview of how it works? Optiscout locates the position of OptiScout-video marks located on the work piece, using a camera that is mounted on the tool head. Optiscout then uses a correction algorithm to compare the current positions of the reference marks to the original positions of the marks in the primary job. FEATURES Workflow Optimization Automatic interfaces to Design and RIP software Compatible RIP software packages: Caldera, PosterPrint, TexPrint, Colorgate, Wasatch, PosterJet, CADlink, MasterRip (IGEPA), ONYX, EFI, Prepare-it Video Mark and Object Recognition Optiscout has the option to use different types of reference marks: o circles, corners, crop marks, symmetrical objects, edges, and user defined Recognizes different types of materials. Figure 1. Work Flow Diagram Barcode import Files can be read by a barcode reader and linked with pre-defined output files[1]. Macro Editor Automated processes can be made. OPTISCOUT FURTHER BREAKDOWN

5 Figure 2. Can be found on the optiscout website[1]

6 TYPES OF REGMARKS AVAILABLE

7 Figure 3. Can be found on the optiscout website MACHINE SPECIFICATIONS Max Rapid Speed - Currently 1500 inches/min, Note relative to each application. Max Feed Rate - Currently 900 inches/min, Note relative to each application. AVAILABLE TOOLS AND ATTACHMENTS On the tool head, Our machine is designed to have up to 2 tangential heads, 1 camera, and a spindle. Can also have touch probe, and ATC. TANGENTIAL HEADS ECOCAM TCM-4 - Tangential cutting module o foils and flocking material, not limited to. ECOCAM EOT-3 - Oscillating tool o cardboard, sealing materials, foils, corrugated cardboard, carbon fiber prepreg material, leather, rigid foam, not limited to. ECOCAM TCT-1 - Tangential creasing tool o cardboard, paperboard, corrugated cardboard, polypropylene

8 PC SPECIFICATIONS Processor: Intel(R) Core(TM) i GHz RAM: 4.00GB System type: 64-bit Operating System Windows 7 Home Premium COMPATIBLE FILE FORMATS WITH OPTISCOUT Description Adobe illustrator Adobe Photoshop 3.0 Bitmap CMX CUT Import DXF Import EuroCUT 1.5 JOB GIF Bitmap Grafityp Logo Files HPGL Import JPEG/LEAD JPEG Bitmap Job Files Job Template Kodak Photo CD OXX import Onyx import optiscout exchange Format PDF Import Paintbrush Portable Network Graphics TARGA Bitmap TIFF Bitmap Text Files File extension.ai,.eps.psd.bmp,.pcx,.jpg,.tif,.tiff,.gif,.png.cmx.cut.dxf.job.gif.gtp.plt,.hpg,.hpgl.cmp.jpg.job.jtp.pcd.oxx.xml.oxf.pdf.pcx.png.tga.tif,.tiff.txt

9 URW Signus Ikarus Vector2 Files WMF/EMF-Meta File Windows Bitmap Zuend ZCC import.ik.evj.wmf,.emf.bmp.zcc SOURCES [1] "OptiScout." OptiScout: Modular Optical Recognition Software for Industrial Usage in Outline-exactly Digital Finishing Processes. N.p., n.d. Web. 15 Oct < [2] Optiscout Production 7 Manual [3] ECOCAM. Tangential cutting module TCM-3. User manual. [4] "MicroSystems World CNC - PC Based CNC Controller". "Home" N.p., n.d. Web. 15 Oct < [5] "ECOCAM CNC - Precision Made in Germany." N.p., n.d. Web. 15 Oct <

10 Optiscout Vision System Operations Manual 2015 Optiscout Vision System Operations Manual Supplement to the Wincnc operations manual 9/1/2015 Laguna Tools

11 Chapter: Optiscout Overview and Work Flow Optiscout Vision System Operations Manual 2015 TABLE OF CONTENTS Optiscout Overview and Work Flow Design Artwork... 3 Artwork Layer Generate Cut-Contour and Registration Marks... 4 Cutpath Layer... 4 Regmark Layer Print Artwork Import File into Optiscout Selecting Tools and Output Parameters... 7 Selecting a Tool and Material... 7 Editing Output Parameters Secure Material onto Table Setting the Tool Length Offset... 9 Router... 9 Tangential Module Outputting Code Locate First Reference Mark

12 Chapter: Optiscout Overview and Work Flow Optiscout Vision System Operations Manual 2015 OPTISCOUT OVERVIEW A ND WORK FLOW The purpose of Optiscout is to compensate for deviations that arise during the preparation process. Below is a work flow diagram that captures the steps required to utilize the Optiscout system. The following sections outline each step in more detail. Figure 1. Vision system work flow diagram. 1. DESIGN ARTWORK The suggested design software for use with Optiscout are the following. Illustrator CorelDRAW Optiscout Design For this walkthrough, Adobe Illustrator will be used to demonstrate the necessary steps to using your vision system. Keep in mind that the design software will vary, but the concepts remain the same. ARTWORK LAYER The first step is to create the artwork layer. This layer will contain all the graphics that will be printed but not to be cut or routed. As shown in the figure below. 3

13 Chapter: 2. Generate Cut-Contour and Registration Marks Optiscout Vision System Operations Manual 2015 Figure 2. Artwork designed in Adobe Illustrator. 2. GENERATE CUT-CONTOUR AND REGISTRATION MARKS CUTPATH LAYER As the name suggest the cutpath is the layer that the CNC machine will trace over with either a tangential knife or router bit. There can be as many cutpath layers as the project demands. Each cutpath layer can then be assigned a specific tool. In order for a quick transition into Optiscout software the layers need specific names. REGMARK LAYER Registration marks, video marks, regmarks, jog marks are all synonymous terms. These terms refer to reference markers that the camera will locate and use to rotate and scale the output objects. The criteria for the registrations marks are the following. The layer needs to be called "regmarks" case sensitive. At least 3 marks should be present. The size of the marks needs to be 0.25 or inches. Circles should be black when on white substrate. A contrasting color on colored substrate. Marks need to lie within attainable range of the camera. 4

14 Chapter: 2. Generate Cut-Contour and Registration Marks Optiscout Vision System Operations Manual 2015 The placement of regmarks should result in a large triangle which covers the object to be compensated. See figure below for an example. Use more regmarks for more accuracy. Figure 3. (Left) Good coverage, (Right) Poor coverage of the graphic's area. Figure 4. Example cutpath and regmark layers, artwork layer turned off. 5

15 Chapter: 3. Print Artwork Optiscout Vision System Operations Manual PRINT ARTWORK Export the artwork and regmark layer to your RIP software for printing. Note: Make sure that the dimensions of the file will not be changed in the RIP software. 4. IMPORT FILE INTO OPTISCOUT Start Optiscout. Click on the "File import" button located in the macros tab. Select the Illustrator file. Figure 5. Screen shot when Optiscout is first opened. 6

16 Chapter: 5. Selecting Tools and Output Parameters Optiscout Vision System Operations Manual SELECTING TOOLS AND OUTPUT PARAMETERS SELECTING A TOOL AND MATERIAL For each cutpath layer a tool will need to be selected. Each machine may vary but the common tools available are the Tangential Knife, Oscillating Saw, Crease Wheel, Router. Figure 6. For each cutpath a tool and material must be selected. 7

17 Chapter: 6. Secure Material onto Table Optiscout Vision System Operations Manual 2015 EDITING OUTPUT PARAMETERS To edit a tools output parameters such as feed rate and cutting depth, click on the settings button shown in figure 8 below. Figure 7. Output parameters dialog box for the tangential knife. Figure 8. Highlighting the output settings button. 6. SECURE MATERIAL ONTO TABLE This step is dependent on the users application and techniques. For this demonstration the tangential cutting module is being used so cutting mat will be placed down onto the table and a sheet of styrene will placed on top. 8

18 Chapter: 7. Setting the Tool Length Offset Optiscout Vision System Operations Manual SETTING THE TOOL LENGTH OFFSET ROUTER A tool length offset must be stored prior to executing output code for the router. When the router is called, a T1 command is executed. This tool call will activate the last stored tool length offset. Secure a router bit into the spindle. Lower the bit to where Z0 will be. Normally this will be the top of the material, but there are exceptions. Enter the command M37Z0H1 or press the "MeasureToolLength" button. This will store the tool length offset into memory. See figure 9. TANGENTIAL MODULE As with the router a tool length offset must be set prior to executing code for a tangential module. This subsection applies to the oscillating knife and crease wheel as well. Verify the linear slide has been extended. Lower the Z-axis until the desired cutting height is reached. Press the respective tool measure button. See the figure below. Figure 9. Overview of controller interface and storing tool length offsets. 9

19 Chapter: 8. Outputting Code Optiscout Vision System Operations Manual OUTPUTTING CODE Press the output to device button located in the macros tab. Adjust any relative parameters such as the park position. Figure 10. Screen shot highlighting the output parameter dialog box. Once the output button is pressed the camera will lower to the stored camera height and rapid to a starting location. It will then idle and wait for the user to manually jog the camera over the first marker. See next section. 10

20 Chapter: 9. Locate First Reference Mark Optiscout Vision System Operations Manual LOCATE FIRST REFERENCE MARK Using the keyboard hot keys, manually jog the camera over the first reference mark. Once visible in the Optiscout software, press the target button. This will start the scanning process. Each dot will be visited by the camera unless redundancy is detected. Once complete, Optiscout will output code to the controller, which will begin executing. Figure 11. Locating the first reference mark. 11

21 Operating the EOT-2 Oscillating Tangential Module 2015 Operating the EOT-2 Oscillating Tangential Module Supplement to the WinCNC Operations Manual 5/12/2015 Laguna Tools 1

22 Chapter: Electric oscillating tangential tool (EOT-2) Operating the EOT-2 Oscillating Tangential Module 2015 TABLE OF CONTENTS Electric oscillating tangential tool (EOT-2)... 3 EOT-2 Overview and Work flow... 3 EOT-2 Blade Selection and Blade Change... 3 Installing Blade... 4 Homing the C-Axis... 5 Turning Oscillation ON and OFF... 6 EOT-2 Setting Knife Length (Tool length offset)... 7 Steps to store a tool length measure... 7 EOT-2 Setting Work Coordinates... 8 Steps to set work coordinates... 9 Loading A Program and Executing Code Preliminary Checks Post Processor Advanced Settings Adjusting Lift

23 Chapter: Electric oscillating tangential tool (EOT-2) Operating the EOT-2 Oscillating Tangential Module 2015 ELECTRIC OSCILLATING TANGENTIAL TOOL (EOT-2) EOT-2 OVERVIEW AND WORK FLOW The EOT-2 is a processing unit for CNC-machines that is generally designed to cut various materials such as cardboard, sealing material, foils, corrugated cardboard, carbon fiber prepreg material, leather, rigid foam and many others. Nevertheless it s finally up to the user to test the cut ability of respective materials. Below is a work flow diagram that captures the steps required to execute a program. The following sections outline each step in more detail. Figure 1. Oscillating tangential (EOT-2) work flow diagram EOT-2 BLADE SELECTION AND BLADE CHANGE When selecting a blade it is important to consider material thickness and tensile strength. Different carbide metal blades with a shank diameter of 6mm are available for various cutting applications. The table below presents a selection of the most commonly used blades. 3

24 Chapter: Electric oscillating tangential tool (EOT-2) Operating the EOT-2 Oscillating Tangential Module 2015 Table 1. Carbide blades. Blade ID E12 E18 E25 E28 E30 E50 E70 E85 E87 E92 Cutting Edge Length of Cutting Edge Total length Typical Applications 2 12 mm 25 mm Universal blade for various materials such as cardboard, gasket material, foam rubber, cork, useable on both sides mm 25 mm Universal blade for various materials such as cardboard, gasket material, foam rubber, cork, one-sided blade for fine lines 1 25 mm 39 mm Universal blade for various materials such as cardboard, gasket material, foam rubber, cork, one-sided blade for fine lines 1 30 mm 45 mm Universal blade for various materials such as cardboard, gasket material, foam rubber, cork, one-sided blade for fine lines mm 25 mm Special blade for TCM module; Wedge blade for normal foils and writings mm 25 mm Special blade for TCM module; Wedge blade for flock textile foils, felt, cardboard 1 8 mm 25 mm Special blade for TCM module; Wedge blade for textile foils, felt, cardboard, rubber 1 50 mm 65 mm Special blade for EOT module; e.g. for soft polyurethane foam panels 1 70mm 83mm Special blade for EOT module; e.g. for soft polyurethane foam panels 1 120mm 133mm Special blade for EOT module; e.g. for soft polyurethane foam panels INSTALLING BLADE 1. To change blades use a 2.5mm hex key to loosen the torque screw. 2. Insert blade with the weldon surface facing the torque screw. 3. Torque down the set screw against the weldon surface. 4

25 Chapter: Electric oscillating tangential tool (EOT-2) Operating the EOT-2 Oscillating Tangential Module 2015 Figure 3. Changing blades on an EOT-2 module. Figure 2. Selecting a blade based on cutting edge length. HOMING THE C-AXIS The C-axis refers to any axis rotating around the Z-axis, such as the TCM-3 and EOT-2 modules. It is necessary to home the C-axis prior to using the modules. This will ensure blade direction is accurate. If the C-axis is not homed, the blade may be in the incorrect position during a cut, most likely leading to a broken blade. The C-axis automatically homes when either modules tool number is called. One of the two modules will home during the overall machine homing sequence, depending on the last state the machine was in. Figure 4. Blade position after homing sequence is complete. 5

26 Chapter: Electric oscillating tangential tool (EOT-2) Operating the EOT-2 Oscillating Tangential Module 2015 TURNING OSCILLATION ON AND OFF Oscillation will be activated when a T32 tool call command is executed. Oscillation can also be manually activated through the controller interface. Figure 5. Controller overview of EOT-2 controls. 6

27 Chapter: Electric oscillating tangential tool (EOT-2) Operating the EOT-2 Oscillating Tangential Module 2015 EOT-2 SETTING KNIFE LENGTH (TOOL LENGTH OFFSET) The purpose of setting a tool length offset is to store a point in the Z-axis in which the knife will lower to prior to cutting. The buttons "MeasKnife" and "MeasSaw" are used to store this value. When a tool length offset is active there will be a blue next to the corresponding axis. G43 mode will also be active. STEPS TO STORE A TOOL LENGTH MEASURE 1. Select the EOT-2 tool by executing a tool call command. For the EOT-2 module the tool command is T The EOT-2 module will extend and all other modules will retract 1.2. Blue boxes will appear next to the X, Y, and Z axes The head will shift along the X-axis the corresponding offset. 2. Lower the oscillating blade down until it will cut through a sheet of paper. This will ensure the blade is low enough to cut all the way through a material, with minimal wear to the cutting mat. 3. Once desired height is obtained press the "MeasSaw" button as show in the figure below. A Blue box will appear next to the Z-Axis. This represents the stored tool length offset. Figure 6. Methodology to setting tool length for the EOT-2 module. 7

28 Chapter: Electric oscillating tangential tool (EOT-2) Operating the EOT-2 Oscillating Tangential Module 2015 Figure 7. Controller overview with respect to the EOT-2 module. EOT-2 SETTING WORK COORDINATES Work coordinates refer to the point in the XY plane that represents the origin of the work piece. Typically the X=0, Y=0 location is the bottom left hand corner of the material. This point is DEPENDENT on where it is declared in the CAD software. For clarification, the X and Y work coordinates may be referred to by a multitude of names. For instance, work coordinates, XY origin, XY Datum position, local zeros, G54, temporary home, G92, etc., are all synonymous. 8

29 Chapter: Electric oscillating tangential tool (EOT-2) Operating the EOT-2 Oscillating Tangential Module 2015 STEPS TO SET WORK COORDINATES 1. Manually jog the tool head until the knife point is at the desired XY origin point. 2. Press the "Set XY" button. Green boxes will appear next to the X and Y axes. Figure 8. Positioning the EOT-2 module to set local coordinates. Figure 9. Controller overview of setting and removing local coordinates. 9

30 Chapter: Electric oscillating tangential tool (EOT-2) Operating the EOT-2 Oscillating Tangential Module 2015 LOADING A PROGRAM AND EXECUTING CODE Once the previously discussed steps are completed G-code can then be executed. Import a program file using the drop down menu File --> Open. Select the desired file. The program can be previewed in the viewer window by clicking the View button on the tool bar. Execute the program by clicking on the green start button or pressing "Enter" on the keyboard. The file path must be in the command line in order for the program to execute. PRELIMINARY CHECKS The cutting blades are tungsten carbide, which means they stay sharper longer. But carbide is also brittle, and can break easily if stress is applied in the wrong place. That is why doing a test cut in the air is an important optional preliminary step to avoid breaking a blade. Things to look for are Positions in the cutpath where the blade makes sharp turns without lifting. Cutting edge of the blade not facing the correct direction. Cutting speed. To Execute a cut in the air Partly lower the knife so that there is ample clearance for the knife to safely execute the program without crashing into any obstructions. Press the "MeasKnife" or "MeasSaw". Load program into wincnc. File --> Open, select program. Click on the "view" icon in the tool bar. This will display the cutpath in the viewer window. Execute the program. POST PROCESSOR The Post Processor will require commands unique to the WinCNC control system. Post processors can be found at the wincnc.net website. See the "CNC swift series with WinCNC Manual" for more details on locating and implementing new post processors. If using the program Aspire made by Vectric, the post processor is WinCNCKnife.pp. 10

31 Chapter: Electric oscillating tangential tool (EOT-2) Operating the EOT-2 Oscillating Tangential Module 2015 ADVANCED SETTINGS ADJUSTING LIFT When cutting material, like 2" foam, it is important to be aware of the lift height. Each time the oscillating blade lifts out of the material it must lift high enough before rotating. This value can also be adjusted directly in the g-code. This value is only declared once at the beginning of the file. Figure 10. Adjusting lift height in Vectric's Aspire. 11

32 Laguna Tools 2015 Operating the TCM-3 Tangential Cutting Module Supplement to the WinCNC Operations Manual 5/19/2015 Laguna Tools Chapter: Tangential Cutting Module (TCM-3) 1

33 Chapter: Tangential Cutting Module (TCM-3) Laguna Tools 2015 TABLE OF CONTENTS Tangential Cutting Module (TCM-3)... 3 Overview and Work Flow (TCM-3)... 3 Sample Project : Introduction... 3 TCM-3 Blade and Spring Selection... 4 Spring Overview... 4 Changing Springs and Fine adjustment... 4 Sample Project : Spring Selection... 5 Blade Selection... 5 Installing A Blade... 6 Sample Project : Blade Selection... 6 Homing the C-Axis... 6 Adjusting Cutting Depth... 7 TCM-3 Setting Knife Length (Tool length offset)... 7 Setting Tool Length Offset... 7 TCM-3 Setting Work CoordinateS... 9 Steps to set work coordinates... 9 Loading A Program and Executing Code Preliminary Checks Post Processor Drawing Tips Advanced Settings Adjusting Lift Angle

34 Chapter: Tangential Cutting Module (TCM-3) Laguna Tools 2015 TANGENTIAL CUTTING MODULE (TCM-3) OVERVIEW AND WORK FLOW (TCM-3) The TCM-3 is a processing unit for CNC-machines that is designed to cut various materials such as foils and flocking materials. Below is a work flow diagram that captures the steps required to execute a program. The following sections outline each step in more detail. Figure 1. Tangential knife (TCM-3) work flow diagram. SAMPLE PROJECT : INTRODUCTION For a sample project, the TCM-3 module and controller will be setup to cut 0.020" styrene. Figure " styrene sample on a SmartShop MT. 3

35 Chapter: Tangential Cutting Module (TCM-3) Laguna Tools 2015 TCM-3 BLADE AND SPRING SELECTION SPRING OVERVIEW The type of the spring set determines the coarse adjustment of the pressing force. The fine adjustment will be done by the adjustment wheel that changes the pre-load of the springs. If the spring set does not have enough pressing force the blade may be forced up away from the material. Table 1. Available Spring Sets. Spring Set ID S5 S10 S18 S28 Pressing Force 5N/500g 10N/1.000g 18N/1.800g 28N/2.800g Figure 3. Example of available springs. CHANGING SPRINGS AND FINE ADJUSTMENT 1. Use the adjustment wheel to release spring tension. Remove the four torx (T10) screws and front cover. 2. Using a pick tool, remove and replace springs. 3. Reinstall front cover. 4. Use the fine adjustment wheel set desired pressing force. Figure 4. Changing and adjusting springs. 4

36 Chapter: Tangential Cutting Module (TCM-3) Laguna Tools 2015 SAMPLE PROJECT : SPRING SELECTION The material to be cut is 0.020" thick styrene. The strongest spring set S28 will be used because of the high tensile strength of styrene. BLADE SELECTION When selecting a blade it is important to consider material thickness and tensile strength. Different carbide metal blades with a shank diameter of 6mm are available for various cutting applications. The table below presents a selection of the most commonly used blades. Table 2. Carbide blades. Blade ID Cutting Edge Length of Cutting Edge Total length Typical Applications E mm 25 mm Universal blade for various materials such as cardboard, gasket material, foam rubber, cork, useable on both sides E mm 25 mm Universal blade for various materials such as cardboard, gasket material, foam rubber, cork, one-sided blade for fine lines E mm 39 mm Universal blade for various materials such as cardboard, gasket material, foam rubber, cork, one-sided blade for fine lines E mm 45 mm Universal blade for various materials such as cardboard, gasket material, foam rubber, cork, one-sided blade for fine lines E mm 25 mm Special blade for TCM module; Wedge blade for normal foils and writings E mm 25 mm Special blade for TCM module; Wedge blade for flock textile foils, felt, cardboard E mm 25 mm Special blade for TCM module; Wedge blade for textile foils, felt, cardboard, rubber E mm 65 mm Special blade for EOT module; e.g. for soft polyurethane foam panels E mm 83mm Special blade for EOT module; e.g. for soft polyurethane foam panels E mm 133mm Special blade for EOT module; e.g. for soft polyurethane foam panels 5

37 Chapter: Tangential Cutting Module (TCM-3) Laguna Tools 2015 INSTALLING A BLADE 1. Remove the gliding element. 2. Insert blade with the weldon surface facing the set screw. 3. Torque down the 2.5mm set screw against the weldon surface. 4. Reinstall the gliding element. Figure 5. (Right) Changing a blade on the TCM-3 cutting module SAMPLE PROJECT : BLADE SELECTION Either the E12 or E50 blades will be sufficient to cut 0.020" styrene. These blades were chosen because of the thickness of the blade's spine as well as a more robust design. Blades like the E70 and E18 will most be damaged due to a thinner spine near the tip of the blade. Figure 6. Blade examples. HOMING THE C-AXIS The C-axis refers to any axis that rotates around the Z-axis, such as the TCM-3 and EOT-2 modules. It is necessary to home the C-axis prior to using the modules. This will ensure blade direction is accurate. If the C-axis is not homed, the blade may be in the incorrect position during a cut, most likely leading to a broken blade. The C-axis automatically homes when a tool number is called. Depending on the last state the machine was in, one of the two modules will home during the initial homing sequence. Figure 7. Position of blade after successfully homing the C-axis. 6

38 Chapter: Tangential Cutting Module (TCM-3) Laguna Tools 2015 ADJUSTING CUTTING DEPTH Cutting depth is the length of blade protruding past the nylon gliding element. The gliding element also aids in holding down the material as the blade is dragged through. The TCM-3 module can also be used without the gliding element. In this case, only the tool length offset needs to be set. Skip to the following section. 1. Take a small sample of the material and hold it up behind the blade. 2. Loosen the locking nut and adjust the gliding element until the knife tip is just protruding past the material Note. This tutorial assumes that the material is to be cut all the way through. 3. Tighten the locking nut and gliding element against each other without affecting the cutting depth. Figure 8. Setting the cutting depth. 4. The cutting depth can be adjusted precisely if the gliding element is mounted. The cutting depth increases 1.0mm per revolution. In practice it s possible to adjust the depth in increments of mm. TCM-3 SETTING KNIFE LENGTH (TOOL LENGTH OFFSET) The purpose of setting a tool length offset is to store a point in the Z-axis in which the knife will lower to prior to cutting. The buttons "MeasKnife" and "MeasSaw" are used to store this value. When a tool length offset is active there will be a blue next to the corresponding axis. G43 mode will also be active. SETTING TOOL LENGTH OFFSET 1. Select the TCM-3 tool by executing a tool call command. For the TCM-3 module the tool command is T30. The order of events that follow a tool call are outlined below The TCM-3 module will extend and all other modules will retract 1.2. Blue boxes will appear next to the X, Y, and Z axes The head will shift along the X-axis the corresponding offset. 2. Using the manual jog controls in the wincnc interface slowly lower the knife down into the material. See the figures below for reference. 7

39 Chapter: Tangential Cutting Module (TCM-3) Laguna Tools Once the knife has been lowered to the appropriate cutting height. Click "MeasKnife". Figure 9. Controller state after a T30 command. Figure 11. Drag knife extended after T30 command. Figure 10. Demonstrating tool length measure process. 8

40 Chapter: Tangential Cutting Module (TCM-3) Laguna Tools After pressing the "MeasKnife" button, the linear slide will retract and the tool head will return to the Z- home position. TCM-3 SETTING WORK COORDINATES Work coordinates refer to the point in the XY plane that represents the origin of the work piece. Typically the X=0, Y=0 location is the bottom left hand corner of the material. This point is DEPENDENT on where it is declared in the CAD software. For clarification, the X and Y work coordinates may be referred to by a multitude of names. For instance, work coordinates, XY origin, XY Datum position, local zeros, G54, temporary home, G92, etc., are all synonymous. STEPS TO SET WORK COORDINATES 1. Manually jog the tool head until the knife point is at the desired XY origin point. 2. Press the "Set XY" button. Green boxes will appear next to the X and Y axes. Figure 12. Positioning the cutting module to set local coordinates. 9

41 Chapter: Tangential Cutting Module (TCM-3) Laguna Tools 2015 Figure 13. Controller overview of setting and removing local coordinates. LOADING A PROGRAM AND EXECUTING CODE Once the previously discussed steps are completed G-code can then be executed. Import a program file using the drop down menu File --> Open. Select the desired file. The program can be previewed in the viewer window by clicking the View button on the tool bar. Execute the program by clicking on the green start button or pressing "Enter" on the keyboard. The file path must be in the command line in order for the program to execute. 10

42 Chapter: Tangential Cutting Module (TCM-3) Laguna Tools 2015 PRELIMINARY CHECKS The cutting blades are tungsten carbide, which means they stay sharper longer. But carbide is also brittle, and can break if stress is applied in the wrong place. That is why doing a test cut in the air is an important optional preliminary step to avoid breaking a blade. Things to look for are Positions in the cutpath where the blade makes sharp turns without lifting. Cutting edge of the blade not facing the correct direction. Cutting speed. To Execute a cut in the air Partially lower the knife so that there is ample clearance for the knife to safely execute the program without crashing into any obstructions. Press the "MeasKnife" or "MeasSaw". Load program into wincnc. File --> Open, select program. Click on the "view" icon in the tool bar. This will display the cutpath in the viewer window. Execute the program. POST PROCESSOR The Post Processor will require commands unique to the WinCNC control system. Post processors can be found at the wincnc.net website. See the "CNC swift series with WinCNC Manual" for more details on locating and implementing new post processors. If using the program Aspire made by Vectric, the post processor is WinCNCKnife.pp. 11

43 Chapter: Tangential Cutting Module (TCM-3) Laguna Tools 2015 DRAWING TIPS When using the tangential cutting modules it is important to be aware of the angles and arcs used in the graphics. In the graphic below there are both acute angles as well as curves. Figure 14. Example graphic highlighting cutting module behavior. 12

44 Chapter: Tangential Cutting Module (TCM-3) Laguna Tools 2015 ADVANCED SETTINGS ADJUSTING LIFT ANGLE The default lift angle is set at 20. This means that the tangential module will lift away from the material before rotating in a location where the angle of change is greater than 20. Increasing this value will decrease the number of lifts, but increase the risk of damaging a blade. Decreasing this value will increase the number of lifts, but reduce the risk of blade or material damage. Figure 15. Location of the lift angle parameter. 13

45 Automatic Tool Changer Operations Manual For machines equipped with a WinCNC controller 8/1/2015 Laguna Tools

46 Table of Contents Tool Changer Overview... 3 Manually Changing Tools... 3 Executing Tool Call Commands... 3 Quick Start Guide for Generating Programs with Tool Calls... 4 Storing Tool Locations... 7 What happens during a tool change?... 7

47 TOOL CHANGER OVERVIEW The automatic tool changer (ATC) adds another layer of automation to the CNC machine. The advantages of an automatic tool changer are as follows: ATC increases the machine's productivity. Helps to minimize total machining time. Increases the flexibility of the CNC machine. Improves tool carrying capacity of the CNC machine. MANUALLY CHANGING TOOLS Each machine equipped with an ATC will have a means to chuck or release a tool in the spindle manually. This is useful when the project only requires one tool and does not use the ATC. Laguna Tools offers a variety of spindle options, but each spindle compatible with an ATC will have a button that releases a chucked tool. The button will be located on the spindle or on the CNC machine near the spindle. In the picture on the right, the release button is on the front of the spindle. Figure 1. Tool gripper release button. EXECUTING TOOL CALL COMMANDS Tool changes can also be made by executing tool call commands in the command line of the controller interface. The number of tools each ATC can support will vary between machines. The most common is an eight slot tool rack. If the machine has eight tools, then each tool can be called by executing the command "T#" where the # represents a numerical digit from 0-8. Changing tools only requires executing a tool call command.

48 Prior to executing a tool change make sure any blades have been removed from the TCM-3 and EOT-2 modules. Long blades may collide with tool rack during tool changes. Enter the command "T#" where the # symbol represent a number 1-8. For example, the command "T8" will cause the spindle to grab tool 8. If there is a tool in the spindle when executing the "T8" command, the tool presently in the spindle will be parked first. Tool Commands T0 T1-T8 Description Unloads Tool. Changes tool, activates last stored tool measure. Figure 2. Screen capture demonstrating ATC fundamentals. QUICK START GUIDE FOR GENERATING PROGRAMS WITH TOOL CALLS

49 For a simple demonstration three concentric circles were drawn. Each circle has been assigned a different tool to cut along the perimeter of each circle. In figure 3 below is a screen shot of the Aspire software after creating three separate toolpaths, each using a different tool. Figure 3. Demonstrating multiple toolpaths using different tooling. Figure 4. Snapshot of the tool info menu, highlighting the tool number parameter.

50 With all toolpaths selected, save the toolpath list after selecting the WinCNC ATC(*.tap) post processor.

51 STORING TOOL LOCATIONS It is possible that a location will need to be reset. To view and edit a tool location, follow the path Settings Tool Positions. This opens the tool positions dialog box. WHAT HAPPENS DURING A TOOL CHANGE? The flow diagram below captures the order of events that occur when a tool command is executed.

52 Operations Manual for Machines Equipped with a Rotary Axis Supplement to the WinCNC Operations Manual 6/1/2015 Laguna Tools

53 TABLE OF CONTENTS Overview... 3 Safety Warning... 3 Preliminary Checks... 4 Verify The A-axis is Parallel with the Y-axis... 4 Controller Overview... 5 Manual Jog Controls... 5 A-Axis Work Coordinates... 6 From Aspire to Cutting Tutorial... 7 Step 1. Creating a New Wrapped Project in Aspire... 7 Step 2. Design... 8 Step 3. Toolpath the Project... 8 Step 4. Mount the Work Piece into the Chuck... 9 Step 5. Setting the Work Coordinates... 9 Setting Z0 Plane with the Center Line of the A-Axis... Error! Bookmark not defined. Setting the X and Y Work Zeros... Error! Bookmark not defined. Steps 6 and 7. Load and Run Program... 9

54 OVERVIEW The terms rotational axis, rotary axis, 4th axis, and A-axis are synonymous. All these terms refer to a rotary axis that has been integrated with a CNC machine. The rotary axis is similar to a lathe or rotary table such that it rotates the work piece on its axis. But the 4th axis allows for more functionality beyond continuous machining. It can perform indexing, as well as wrapping. The figure on the right is a CNC machine equipped with a 4th axis. Figure 1. Rotary axis overview. SAFETY WARNING It is imperative that the T-handle chuck key is never left in the turner. Injury to the user and damage to the machine can occur. Figure 2. WARNING.

55 PRELIMINARY CHECKS If the chuck and tail stock are not permanently fixed onto the CNC machine, it is important to verify that the 4th axis is aligned to the machine. VERIFY THE A-AXIS IS PARALLEL WITH THE Y-AXIS Whether the rotary axis is placed along the X-axis or Y-axis it is important to verify that the center line of the rotary axis is parallel with the respective axis. In the figure below the rotary axis has been aligned to the Y-axis. There are multiple techniques to verify whether or not the two axes are parallel. One suggestion is to mount a dial indicator onto the spindle or Z plate. Run the dial indicator along the work piece. Adjust the tail stock and chuck to correct for any deviation. Of course, this is only one possibility, you are encouraged to develop your own techniques that suits your work flow. Figure 3. 4th axis alignment.

56 CONTROLLER OVERVIEW Machines equipped with a 4th axis have an additional set of controls and functionality. MANUAL JOG CONTROLS Manually rotating the A-axis can be done by first selecting a continuous or incremental setting. Then either the A-axis manual jog buttons on the control screen can be pressed or the keyboard hotkeys. The hotkeys to manually rotate the A-axis are the "Home" and "End" keys. Figure 4. Controller interface overview, highlighting additional 4th axis controls.

57 A-AXIS WORK COORDINATES It will be necessary to specify a work zero for the A-axis when aligning a new stock. To declare a new A0 position press the "SetA" button. As shown in the command history window below a "G92A" command is executed. Figure 5. How to create and remove work coordinates for the A-axis.

58 FROM ASPIRE TO CUTTING TUTORIAL This section captures the workflow for milling with the 4th axis. This tutorial will walk you through how to create a new wrapped project using the CAM software Aspire. And how to toolpath that project as well as preparing the CNC machine for 4th axis machining. Keep in mind that this is not the only methodology for a project. It depends on how the project is defined in the CAD software. For example, some variances will be the starting location and the position of the Z0 plane. Figure 6. Workflow for 4th axis machining. STEP 1. CREATING A NEW WRAPPED PROJECT IN ASPIRE Open Aspire. Follow the path Gadgets Wrapping Wrapped Job Setup. Enter in the dimensions of the cylinder blank. For consistency and accuracy, the center of cylinder should be selected as the Z0 plane. Figure 7. Path to create a wrapped project in Aspire. Figure 8.Window to set job dimensions.

59 There are a few reasons to use the Center of the Cylinder, and they are listed below. o When rounding a blank, the surface is actually the surface of finished cylinder not the surface of the blank. o There could be irregularities in the work piece o The work piece could be mounted with a small amount of error. STEP 2. DESIGN Vectric, who is the developer of Aspire, provides tutorials and documentation on their website. It is an excellent resource if you are new to Aspire. STEP 3. TOOLPATH THE PROJECT If you are creating a cylinder blank follow the toolpath o Gadgets --> Wrapping --> Create Rounding Toolpath If you are toolpathing your design, then you create a toolpath the same way as a 2D-Drawing. Once the toolpath is created, select which toolpath(s) to output. Select the WinCNC Rotary Post Processor. Then click Save Toolspath(s). Transfer the output file to the machine's PC. Figure 7. Snapshot of Aspire's toolpath tab.

60 STEP 4. SETTING THE Z0 PLANE WITH THE CENTER LINE OF THE A-AXIS Carefully align the bottom of the router bit with the point of the tail stock as shown in figure 10. Press the "SetZ" button. This will establish the Z0 coordinate plane as the center line of the cylinder as was declared in Aspire. Figure 8. Locating the Z0 plane. STEP 5. MOUNT THE WORK PIECE INTO THE CHUCK The goal is to align the center line of the work piece with the centerline of the A-axis. It may take some ingenuity if the work piece is irregular. STEP 6. SETTING THE X & Y WORK COORDINATES Work coordinates need to be established prior to executing code. This applies to each axis. Mark the center of the material. Navigate the router bit and center it over the mark. Store this X and Y position by pressing the "SetXY" button. STEPS 7 AND 8. LOAD AND RUN PROGRAM Load program into the controller using the path File --> Open Run program. Figure 9. Aligning the spindle to the center of the material.