FastPIPE/FRAMEFRAME) Manual english V1... · 2018. 7. 22. · FASTCAM.EXE or SETUP.EXE and run it to start the installation process manually. Select Simplifed Chinese or English based

FastPIPE/FRAME Reference Manual

FastPIPE/FRAME

Reference Manual

For Windows


SOFTWARE INSTALLATION GUIDE .........................................................................7

Installation .................................................................................................................................... 7

Installation Menu and Software Structure .................................................................................. 10

Installation notes ........................................................................................................................ 12

Unistalling .................................................................................................................................. 14

FASTPIPE ........................................................................................................................17

GETTING STARTED .....................................................................................................18

What is FastPIPE ....................................................................................................................... 18

Prerequisites ............................................................................................................................... 18

Central Control ........................................................................................................................... 19

Component Windows – Common Features ............................................................................... 20

THE COMPONENTS LIBRARY ..................................................................................21

Main Only .................................................................................................................................. 22

Branch Only ............................................................................................................................... 23

Main and Branch ........................................................................................................................ 23

TrussPanels ............................................................................................................................. 24

M Branch............................................................................................................................................... 24

N is the classical Pratt truss layout. Assembly of diagonal members followed by vertical members is simple. The converse can be problematical . ........................................................... 25 W Truss ................................................................................................................................................. 25 M Truss ................................................................................................................................................. 25 X Truss .................................................................................................................................................. 25 K Truss .................................................................................................................................................. 25

3-D Structure .............................................................................................................................. 25

Model A ................................................................................................................................................ 25 Model B................................................................................................................................................. 25 Model C................................................................................................................................................. 26 Model D ................................................................................................................................................ 26 Model E ................................................................................................................................................. 26 Model F ................................................................................................................................................. 26 Model G ................................................................................................................................................ 26

Set-In and Set-On Options ......................................................................................................... 26

Set-In .................................................................................................................................................... 26 Set-On ................................................................................................................................................... 27

Branch ‘Ending’ Options ........................................................................................................... 27


Near End .............................................................................................................................................. 27 Far End ................................................................................................................................................ 27

Mix and Match Options ............................................................................................................. 28

Joint Details ............................................................................................................................... 30

General ................................................................................................................................................. 33 Combination Butt-Fillet (Combo B/F) .............................................................................................. 33 Fixed-Butt ............................................................................................................................................ 34

Display ....................................................................................................................................... 35

Part(s) in 3D ......................................................................................................................................... 36 Wrap-arounds ..................................................................................................................................... 37 NC Patterns ......................................................................................................................................... 39

Output ........................................................................................................................................ 41

Machines .................................................................................................................................... 43

Pathing ....................................................................................................................................... 49

Path Transitions.......................................................................................................................... 51

Configuration ............................................................................................................................. 54

The General tab ................................................................................................................................... 55 The 2D Display tab ............................................................................................................................... 56 The 3D Display tab ............................................................................................................................... 57 The Output Defaults tab ........................................................................................................................ 58 The Wrap-Arounds tab .......................................................................................................................... 59

Help ............................................................................................................................................ 61

COMPONENTS ...............................................................................................................61

Chop-Chop ................................................................................................................................. 62

Example 1：Cutting Pipe End and Nesting .................................................................................... 62

Elbow ......................................................................................................................................... 66

Example 2：Elbow .............................................................................................................................. 66

Y-Piece ....................................................................................................................................... 70

Example 3：Y – Piece ....................................................................................................................... 71

Silhouette ................................................................................................................................... 75

Example 4: Silhouette Cutting ......................................................................................................... 77

Example 5：Text silhouette on Pipe ................................................................................................ 83

R-Branch .................................................................................................................................... 86

Example 6：Array holes in R branch ........................................................................................... 88

F-Branch .................................................................................................................................... 91

Example 7：F-Branch usage ............................................................................................................ 92


C-Branch .................................................................................................................................... 94

Example 8：C branch with slot ..................................................................................................... 95

E-BranchIP ................................................................................................................................. 98

Example 9：welding 3 intersecting pipes ...................................................................................... 100

P-Branch .................................................................................................................................. 102

Arrayed Penetrations ................................................................................................................ 104

Example 10：Generate multiple branch pipes at different positions. ....................................... 105

Truss panel ............................................................................................................................... 110

M branch ............................................................................................................................................. 110 N Type pipe frame .............................................................................................................................. 114 W Type pipe frame. ............................................................................................................................ 118 Practical example 1: a warehouse roof’s load-bearing beam structure ............................................... 118 M Type pipe frame .............................................................................................................................. 123 Example 14: Another type of ware house load supporting beam structure. ........................................ 123 Example 15: Working with Pipes from CAD Drawings.. ................................................................... 127 X Type pipe frame ............................................................................................................................. 131 K Type pipe frame. ............................................................................................................................. 135 Model D .............................................................................................................................................. 149 Model E ............................................................................................................................................... 153 Example 22: cutting pipes in different planes. .................................................................................... 153 Example 23: cutting construction drawing. ........................................................................................ 157

TROUBLESHOOTING ................................................................................................164

Problem .................................................................................................................................... 164

Problem .................................................................................................................................... 164

FASTFRAME .................................................................................................................165

FEATURES SUMMARY AND CONCEPTS .............................................................165

Wrap-around templates ........................................................................................................ 166

Cutting List .............................................................................................................................. 166

Cutting Parameters ............................................................................................................... 166

History ...................................................................................................................................... 167

What’s New ? ........................................................................................................................... 168

Connectivity and Setting Out ................................................................................................... 169

‘Feasible’ Members ............................................................................................................................. 169 Chords ................................................................................................................................................. 171 Redundant Specification, and Minimal Framework ............................................................................ 173 Member Axes ...................................................................................................................................... 174


Intersection Point (IP) Movement ....................................................................................................... 175

Data Entry ................................................................................................................................ 177

Node Coordinates and Assembly Sequence … ................................................................................... 177 Member Details and Connectivity … .................................................................................................. 178 Chords … ............................................................................................................................................ 181 Other Data ........................................................................................................................................... 182

Data Checking .......................................................................................................................... 183

LEVEL 1 CHECKING ..................................................................................................184

‘Ignored’ data ...................................................................................................................................... 185 ‘Obvious’ Connectivity errors ............................................................................................................. 185

DATA INSUFFICIENCY .............................................................................................186

LEVEL 2 CHECKING ..................................................................................................186

Member (M) is Main at Node (N). This node must be MidNode in MemberList ............................... 186

Solutions (Methods and Scope) ............................................................................................... 188

Wrap-around Templates ...................................................................................................................... 188 Cutting List ......................................................................................................................................... 191 Three-Dimensional Node Views ......................................................................................................... 192

User Verification and Checking ............................................................................................... 200

Output ...................................................................................................................................... 200

Output ................................................................................................................................................. 202

Configuration ........................................................................................................................... 202

General / Dimensions .......................................................................................................................... 203 Template Display ................................................................................................................................ 203 3D Display .......................................................................................................................................... 204 Output Defaults ................................................................................................................................... 204

List of program files ........................................................................................................ 204

FASTFRAME SAMPLE ...............................................................................................204

SIMPLE TRUSS ............................................................................................................204

MORE COMPLEX TRUSS ..........................................................................................209

Example1: Xuzhou, Beijing-Shanghai Railway Station Platform Structure. 3D structural

drawing created using AutoCAD ............................................................................................. 216

Example 2 : 2010 Chang Zhou Logisitics ( the 16th) Chang Zhou Sporting Complex Project

.................................................................................................................................................. 221

ADDENDA......................................................................................................................238


Appendix A – The FastFRAME.xml Data File ....................................................................... 238

CONTACT INFORMATION .......................................................................................245

World Wide Offices ................................................................................................................. 245

Software Support...................................................................................................................... 245


Software Installation Guide

Installation

Installation is very simple for all FastCAM software, and this is no different for

FastPIPE/FastFRAME. There are generally two media that FastCAM install come in,

one is from an installation CD, or an installation file to be run on the computer.

To begin, start the computer, and logged into the Operation System (Windows)

with an administrator account.

NOTE: Before Installing FastPIPE/FRAME, confirm that all other programs have

been closed.

FastPIPE/FastFRAME is only for running under Microsoft Windows Operating

System.

For the installation CD scenario, insert the CD into the CD/DVD Drive. The

installation CD will run automatically and launch the FastCAM installer. Follow the

instructions on installation menu (choose a language, choose to install). If the

CD/DVD Drive does not allow the autoplay feature, then explore the CD and find

FASTCAM.EXE or SETUP.EXE and run it to start the installation process manually.

Select Simplifed Chinese or English based on your preference, and it will move to

the next screen shown below.


Click on Install FastPIPE to enter the installations interface

(if the install is an installation package on file, run the SETUP.EXE file

directly)

Either of the above will take you to the next screen.

Click on NEXT to proceed to the next screen


Read the License agreement fully, and select to accept the agreement and

continue with the installation. If you do not agree with the agreement select not to

accept, and the installation will end.

After a moment, the installation shown modules being install, eventually, it will

arrive at the screen below


It is possible choose No, I will restart my computer later, and for the next screen

choose Finish to complete the installation.

Note: Choose Yes will allow the Operating System to restart and complete

registrations of keys into the windows registry.

After the installation is complete, new shortcuts will be placed on your Desktop

and Program list under the Start button. As the shortcut names suggests, they will

respectively launch FastPIPE, FastFRAME, PipeSplice, or a tutorial file.

NOTE: on completing the installation, please insert the FastCAM USB Dongle into

a USB port on your computer. Wait for Windows to complete automatic driver

installation for the dongles before starting FastPIPE, FastFRAME or PipeSplice.

Installation Menu and Software Structure

After installing the software, In the Local Hard Disk‟s Program Files Folder,

there will be two new subfolders, FastPIPE and FastFRAME.


List of items in FastFRAME folder

List of items in FastPIPE folder


*.Chm, *.PDF, *.PPS are help files

*.dll, *.tlb are library files for software operation

*.bat, *.exe are batch files to launch softwares

*.cfg, *.xml are setting files for software configurations

*.reg files are for Windows Registry.

Installation notes

After completing the installation, if there are errors trying run FastPIPE or

FastFRAME, then follow the checklist below to verify that the operating systems

has the critical items registered correctly.

1. Find the file regpipe.bat in the FastPIPE folder and the FastFRAME folder

(there one in eash folder). Run each of these files once (double left click on

the file).

2. FastFRAME‟s FRAME.DLL file is designed for AutoCAD 2006, if FRAME

command does not function in AutoCAD, find the file frame.reg in the

FastFRAME folder and run this file once (double left click on the file).

3. .NET framework is required. .NET framework is included in the setup and is

typically run automatically. A copy of .NET framework install can be found

on the installation media, in the install\FastFRAME folder.

4. In the folder C:\WINDOWS\SYSTEM32, find the file Postpipe.DLL. Right

click on this file, and select “open”. Follow the diagrams below to use

regsvr32.exe to open Postpipe.DLL


Select Open, In the popup menu select Select Program option and then click on ok.

In the new dialog follow the images below to select regsvr32.exe

Look in the directory C:\Window\System32, and find the regsvr32.exe application,

click on the regsvr32.exe file, then click on open in the bottom right of the dialog.

A message will appear to indicate the file has been successfully registered. Click on


the ok button to proceed.

Unistalling

Uesr can go through the control Panel and select add/remove programs to

uninstall FastFRAME software.


In the pop-up dialog, Select Remove. The uninstallation process will take a moment to complete.


In the Last Dialogue it will ask if the computer should be restarted. This is optional. Click on finish after making a choice. The FastPIPE and FastFRAME folders will remain in C:\Program Files\ after unsintallation. These can be manually deleted.


FastPIPE


Getting Started

What is FastPIPE

FastPIPE (FP) is an integrated set of procedures for producing Wrap-around

Templets and / or NC Programs for profiling pipe ends and penetrations.

Two editions are available

Standard Edition : Wrap-arounds only Standard Plus NC Edition : Wrap-arounds Plus NC Programs

The original v1.x had a limited component library, output was confined to

wrap-arounds, and some non-bevelled NC output could be obtained via FastCAM

in restricted circumstances The present v2.x has a much expanded component library and has dropped the NC

output via FastCAM option. Six different types of bevelling and non-bevelling pipe profiling Machine are

directly supported in v2.x. These are shown diagrammatically in Figure 1. See

Machines for further detail.

Prerequisites

The title bar of the Central Control form identifies which Edition is active, Standard

or Standard Plus NC. It may also indicate that this is a Demonstration Copy in

which case no output is issued or issuable, and no Key is required. A non-demonstration copy of FP will not run unless and until the Key provided with

the software is installed in either the printer parallel port or a USB port, as

applicable. FP shares with its companion product FastFRAME a common data file containing

pipe material and size data, plus definition of the pipe profiling Machine

capabilities. The name of this file is FastFRAME.XML. It must be present in the FP Folder. It is user-editable as described in Appendix A. A start-up file is normally provided with the FP software, but may require

completion by the user before all FP facilities are fully available and enabled. In particular, if no Machine has yet been defined, or Machine data is in error, then

Lists of standard pipes may not be available to select from, requiring sizes

to be entered manually No NC Programs can be produced. No NC Programs can be produced.

Software supplied as a Plus NC Edition will revert to Standard Edition. See Troubleshooting and Installation for further assistance.


Central Control

FP uses a „multiple document interface‟ similar to MS Word, save that in this case

a „document‟ is a FP „Component.‟ A „Component‟ may be considered as either a physical pipe part or assembly of

such parts, or the window (see below) in which that physical entity is defined,

depending on the context of the discussion. The FP central control form contains a Menu and subsidiary Toolbar containing

most commonly used menu functions. A „work space‟ occupies the remainder of

the form. The Components Library is normally shown in the work space on start up. If not in

view and required at any time, the central control menu File - New will fetch it. A Component is „opened‟ either by

opening a previously saved data file for that Component, selecting one from the Components Library.

To open a previously saved data file, (a number of which are provided with the

initial installation), select menu File – Open (or the appropriate Toolbar button),

and select files having the FP standard .FPD (FastPipeData) extension To make a selection from the Components Library, single click the component and

press OK, or simply double-click the component. Pressing the Cancel button will hide the Components Library. Many different Components, or different instances of any one Component, may be

open simultaneously, each in its own window. To switch between them, select the Window menu, which will list all currently open

Component windows. Click the required Component. The Window menu list contains three item of information ...

The current system Window number The Component Name, as shown on the Component Library. The Sequence Number in which Components were opened since FP was last

started The first will change as Components are opened and closed. The second and third will remain static, and are the more useful for navigation. Components may also be minimized and maximized, and their icons arranged

according to other Windows menu options Cascade, Tile, and Arrange Icons. The central control menu Edit, Display and Output functions apply to the

Component that is currently maximized in the workspace, or otherwise selected

from a cascaded or tiled view of all windows. The central control form title bar also indicates which window is currently


maximized.

Component Windows – Common Features

Each Component (window) is presented in a Tabbed format ...

The Component tab defines fixed FP system information concerning the

component, and is an expansion of data contained in the Component

Library. None of this data is user-editable, and is for information only. The Job tab provides a facility to optionally document data for the current

instance of this Component. The current File name (if any) is also shown. The Data tab is where all data is entered and manipulated.

Which tab is in view when a window is opened can be set under the central control

Configuration menu – FP Options. See Configuration for details. The Data tab contains the following data elements

Main (and Branch) Pipe button(s), raising a dialog from which pipe class,

material specification and size may be selected from the list in the

FastFRAME.XML file (see Appendix A) Non-listed sizes can be entered directly, or listed data may be selected and edited

over. This is the user‟s responsibility. For a Component in which both Main and Branch must be specified, the class and

material specification, and / or when appropriate the diameter and thickness, may

be set identically for both main and branch from either button press. Most Components allow pipe wall thickness to be changed to 0, for a variety of

reasons explained elsewhere, but a blank thickness field will be rejected to ensure

that 0 is intended and not that thickness has simply been overlooked.

A Setting Out box containing (in most cases) a diagrammatic

representation of the Component, and (always) provision for entering

parameters defining it. Data is simply typed into the boxes provided. A yellow background indicates that

the data is outside its permissible range. A red background indicates bad data (eg

letters where numbers are intended) Otherwise the data is acceptable. No data

can be processed until all data is acceptable. Option buttons and check boxes may also be present.

A schematic view of the data which changes dynamically with the data. This view is representational only, to assist with data entry. Provided data is OK, a more precise 3D view may be seen by left clicking the

schematic (or using menu Display or the toolbar button). A right click will show

wrap-around templet(s), while a middle button mouse click (or either left or right

button with any of Shift, Control or Alt keys depressed) will show the NC Program

as a developed pattern. See Display for specifics of viewing.

Note(s) Note(s) are shown below the schematic, and generally indicate required lengths of


workpieces in the machine. If too long, the note will show in red. Other hints may

also appear for various Components.

A Joint Details box, in which details of the weld preparations at the

assembly joint and/or ends are specified in a manner similar to that in the

Setting Out box. See Joint Details for specifics

A Help button, and possibly other buttons depending on the Component. On all Component Data tabs, look for hints that are displayed when the mouse is

held paused over some text boxes, buttons, etc.

The Components Library

Components are named and described in Process Engineering terms of Main and

Branch. Many Components are relevant also to Structural Engineering application in which

Chord may more appropriately replace Main, and Web or Lattice (member) might

replace Branch. (The companion software FastFRAME provides both wrap-around templets and NC

Programs for straight, cranked (and with qualification, curved) members of 3D

space frame structures in which joints („nodes‟) may comprise a main Chord and

up to twelve Branches whose intersection points may be relocated to eliminate or

promote member „overlap‟. It has been used in fabrication of such significant

structures as the Sydney 200 Olympics main stadium.) Graphic artwork is also possible via the Silhouette Component. Components are grouped according to the type of NC Program or Wrap-around


Templet output available from them, which briefly are as follows ...

Main Only

Chop-Chop Chop off lots of bits, chop-chop. Pre-nested straight parts with optionally mitre cut ends, and optional

relative twist between ends. Optional common cutting between parts under restricted conditions. This is a Component of quite general applicability to all areas of application.

Elbow Presented parts of an in-plane gored elbow, with optional end gore

extensions. Optional common cutting between parts under restricted conditions. Combined with parts from Chop Chop, out-of-plane gored elbows are readily

made. This is essentially a Process Component.

Y-piece Presented parts of a Y-piece of quite general in-plane and out-of-plane

setting out This is essentially a Process Component, with occasional Structural

applications. Silhouette

Cuts non-bevelled multiple penetrations defined in a FastCAM file that has

been fully „CAD-Cleaned‟ and pathed. Original source data can be a DXF or IGES or other FastCAM-supported

format file. This Component has limited Structural application, and is more likely to find

application in Process (eg heat exchanger headers, manifolds etc.) and

Artwork areas. The companion product FastCAM is required for this Component to be fully

functional. (See FastCAM website, a link to which is available from the Help

About menu) R-Branch

„R‟ectircular branch from a pipe main. Cuts bevelled single or regularly arrayed penetrations defined by a notional,

possibly actual, branch of „rectircular‟ cross-section, a „rectircle‟ being any

shape derivable by optionally filleting the corners of a rectangle. This includes square, rectangle, obround in either direction, filleted

rectangle and circle, with rotation (twist) around the branch axis. The branch may be inclined at other than square to the main, and may also

be laterally offset. No NC output is issued for the branch, although a


wrap-around is presented to assist with interpretation of the Component

data. It has limited practical utility otherwise. Branch Set-In and Set-On Options are available, together with Mix and

Match Options This Component has limited Structural application, and is more likely to find

application in Process (eg heat exchanger headers, manifolds etc.) and

Artwork areas.

Branch Only

F-Branch Pipe branch from a Flat base, (hence one end mitred) Options for slotting to accommodate reinforcing or splicing plates in either or

both principal planes, plus Mix and Match Options. This is an essentially Structural Component.

C-Branch Pipe branch from a Cylindrical base (ie a pipe). Branch may be laterally offset, but is Set-On only. Options for slotting to accommodate a reinforcing plate in the principal plane,

plus Mix and Match Options. This is an essentially Structural Component.

E-BranchIP Pipe branch from a forged Elbow (toroidal butt weld fitting) Confined to branch InPlane with elbow, but may be offset from

centre-aligned to fully tangential. Branch Set-In and Set-On Options are available, together with Mix and

Match Options The Set-On option is an essentially Structural Component within a Process

application (a structural support to an elbow). The Set-In option finds

application in various chute-work and other applications. E-BranchOP

(To be issued). Similar to E-BranchIP except for allowing Out-of-Plane and

lateral offsets

Main and Branch

P-Branch Pipe branch Penetrating a Pipe main. Branch may be laterally offset. Branch Set-In and Set-On Options are available, together with Mix and

Match Options Includes the „problem‟ case of a set-in branch being the same size as the

main, or with maximum lateral offset. This is essentially a Component with Process applications. (Refer C-Branch


for Structural applications, although P-Branch will do the same without

slotting.)

TrussPanels

This is a set of new procedures that are designed to solve a wide range of „double-ended‟ pipe profiles, again using the power of FastFRAME as with MBranch and following all the same concepts outlined above for MBranch. Double-ended templets can be made from other procedures using the „mix-and-match‟ capabilities that also provide for a relative axial twist between member ends. TrussPanels are confined to plane trusses. Twist between end profiles is thus non-existent, but can be arranged in FastFRAME through editing node coordinates to set the truss into a warped (non-planar) configuration, which may be one of the reasons for requiring twist in the first place in the „mix-and-match‟ system. It is again an effective FastFRAME training tool. The principal differences between MBranch and TrussPanels are

Use of the more direct node coordinate method of setting out in lieu of the need to first

calculate relative angles between members.

The manner in which assembly sequences are specified.

TrussPanels as a set presents a number of standard layouts for simple planar trusses, as follows, described by alphabetical characters that approximately represent the layout of the web members between the top and bottom chord, with no essential connection between the designation and the initial letter of the surname of the engineer often credited with their „invention‟ …

M Branch

This is a new FastPIPE procedure that solves M(ultiple) Branch stub connections using the power of FastFRAME. The main may be cranked, and may be of rectangular cross-section. An in-plane connection plate may be specified.

MBranch is an effective training tool to introduce the user to the power of FastFRAME.

Particular note should be taken of the assembly sequence specifications and how they are ultimately translated into FastFRAME. Users should also be aware that the apparent assembly sequence can be affected by the angles specified to the three branches. If it is desired to change one of the branches from a pipe to an RHS in FastFRAME in order to model a transverse connection plate, that branch should be assembled prior to any branches that will abut it.

N Truss


N is the classical Pratt truss layout. Assembly of diagonal members followed by vertical members is simple. The converse can be problematical .

W Truss

W has no known „inventor‟ – probably just too obvious. Also probably the simplest of all forms to assemble since no sequence is better or worse than its alternative, and ditto for joint strengths.

M Truss

M is the classical Warren truss layout, or a sub-portion of the Petit truss. Assembly issues approximate the N layout if verticals are assemble first, but approximate the W layout id verticals are assembled last.

X Truss

X is often described as the Pratt truss – with counters. Assembly issues as stated above provided the half-diagonals are assembled last, and it‟s difficult to conceive of any sensible alternative possibility.

K Truss

K is usually described simply as a K truss or K-braced tower. Assembly of all verticals prior to diagonals is an obvious choice. The first diagonal assembles easily, the second diagonal with more, but unavoidable, difficulty. Assembly is simpler if verticals are installed progressively after each pair of diagonals. The final basic point to remember is …

Ignore everything said above when the designer insists on using in-plane connection

plates. Unless the joints are designed such that total load is carried through welds

along the sides of slots, so all others are mere seal welds, then it‟s a case of „stub-it,

or else …‟ The W layout may just conceivably escape this generalization, but not

often, and not without a canny and motivated designer on board.

3-D Structure

Model A

A simple construction of 2 Main Pipe intersecting with 1 branch pipe. This structure has the

widest range of application. It allows 2 main pipes in 2 different 2D planes.

Model B


2 main pipes intersecting with 1 branch in same plane.

Model C

2 Main and 2 branches intersecting in same plane

Model D

2 Main and 2 branches intersect.

Model E

2 branches and 2 Main intersecting in different plane. Compare with Model

C, one Mian is not in the same plane.

Model F

Multipul branches intersecting in different plane.。

Model G

Multipul branches intersecting in different plane.

Set-In and Set-On Options

The principal difference between these two options lies in which part is prepared

for welding, and how the other part is cut.

Set-In

The branch is profiled to match the inside diameter of the main, and with no

provision for welding. The main must be penetrated and is prepared for welding, with the weld root

at the branch outside diameter. Some Components, and especially P-Branch, provide for handling some

extreme setting out or „problem‟ cases in which the above definition may

vary. See specific documentation on each Component.


Set-On

The main may or may not be penetrated. When it is, it is profiled to match

the inside diameter of the branch, and with no provision for welding. The branch is prepared for welding, with the weld root at the main outside

diameter. When applicable, this choice is offered and must be made immediately after

selection of the Component from the Components Library. The choice is made before exercising any Branch „Ending‟ Options or Mix and

Match Options

Branch „Ending‟ Options

„Ending‟ is the process of deciding how the branch is to be located on the workpiece

for profiling, and which end of the branch as specified is nearer to the free end of

the workpiece. When applicable, this choice is offered and must be made immediately after Set-In

and Set-On Options when they are relevant, or otherwise immediately after

selection of the Component from the Components Library. Branches as specified in FP have a profiled end where they connect to a main or

base element, plus an assumed square cut at the other end.

Near End

When Near End is chosen, the profiled end of the branch is located nearer

the free end of the workpiece (and hence cut first), with the square cut end

further along the workpiece.

Far End

When Far End is chosen, the cutting sequence is the reverse of the above,

plus a „Twist‟ option is available The Near End option is generally simpler than the Far End option when only a stub


is required, since the Twist option is omitted. In many applications, a pipe may be required to be profiled at each end, without

regard to whether it is a branch or a main. The elements that the pipe under consideration connect between may or may not

lie in a common plane – one end of the pipe may need to be rotated (or „twisted‟)

around its own axis relative to the other end. If somewhere in the length of that pipe there is a square cut butt weld, then only

the overall length is of concern – the twist can be accommodated at the

intermediate joint(s). Then two stub ends can be made without further

consideration once the lengths of each are determined. On the other hand, if the pipe is to be cut as a single length profiled at both ends,

then both the overall length, and the relative twist between ends, are entirely

critical. In order to cut such a pipe, it is necessary to also invoke Mix and Match Options Note : FP does not determine the overall lengths, or the amount of relative twist

required. This is the responsibility of the draftsman detailing the work. (The companion software FastFRAME does determine both total length and

relative twist on the basis of node point locations and intersection point relocation

data as specified by the user of that software, assumed to be advised by the

draftsman who detailed the work.)

Mix and Match Options

Mix and Match Options are available in the Setting Out data entry box of some but

not all Components. They may apply to the Main only, or to the Branch only, or to both. In the case of both, each option is quite separate from and independent of the

other. The option is exercised by entering a required offset dimension and ticking a

checkbox adjacent to the words „Hold this location‟. If the checkbox is unticked, then the offset data, if any, is ignored and the option

is not applied. For the Main ...

When the option is not applied, both square cut ends of the main will be

NC-Programmed together with the penetration(s), all in correct sequence,

and located as close as possible to the free end of the workpiece at X=0 With both ends square cut we have a stub to which Twist is not relevant and

is automatically set to zero. When the option is applied, an NC Program is prepared only for the

penetration(s) and located at the specified offset. Both end cuts are omitted. Twist now is potentially relevant and is applied at the specified value (which

may be zero). Twist has the effect of moving the penetration(s) around the pipe in a


circumferential sense from Top Dead Centre (TDC) For the Branch ...

When the option is not applied, both the profiled end and square cut end will

be NC-Programmed, and located as close as possible to the free end of the

workpiece at X=0 When dealing with the Far End of the branch, (still with the option not

applied), Twist is not relevant in the case of such a stub and is automatically

set to zero. When the option is applied, an NC Program is prepared only for the profiled

end and located at the specified offset. The square cut end is omitted. When dealing with the Far End of the branch, (and still when the option is

applied) Twist is potentially relevant and is applied at the specified value

(which may be zero). When either option is exercised, even though the „length‟ of a branch or main is no

longer represented in its NC Program, sensible setting out data is still required for

lengths of branch and main for purposes of displaying the Component

schematically and in 3D, and for obtaining wrap-arounds. Exercising these options provides for cutting a pipe with different end profiles and

a mixture of penetrations, simply by running NC Programs in sequence …

Near end profile Penetration(s) (in any sequence) Far end profile

The above represents the „Mix‟. There are several critical „Match‟ aspects to using this option ...

The machine and workpiece are referenced for both X and A axes before

cutting the first (Near) end, and these references are not altered until all

cuts have been made and the finished part is separated from the workpiece

at the Far end cut. All NC Programs must share a common X axis reference All NC Programs must share a common A axis reference (Finally and obviously, but easily overlooked), all NC Programs must apply

to at least the same size pipe, regardless of whether it derived from a

branch or a main. (Logically, they should also apply to the same class and

specification of pipe.) A Near end NC Program has a standard A axis reference of zero at Top Dead Centre

(TDC) which is not user-changeable, and a default X axis reference of zero which

is user-changeable. The Near end X axis reference needs to be adjusted by the user to ensure that the

NC Program is located on the free end of the workpiece, but not excessively so. The Near end X axis reference is adjusted by specifying the offset value for FP to

Hold. FP will issue a warning if the offset is insufficient to ensure that all cutting will occur


on the workpiece. The NC Program Display will show the offset location of the Near

end cut, and examination by the user will determine whether or not the end scrap

is excessive. For all Components to be subsequently cut, the Near end X offset must be added

by the user to each Component’s X offset so that the location that FP will Hold is

absolute and measured from the common X=0 starting reference. Twist in subsequent Components is already in absolute terms and does not require

further adjustment. Note : Other forms of Mix and Match that are not formally invoked by FP but can be

applied at user discretion involve using complete parts rather than NC Programs

from different Components. This can be used to effectively make up customized new components, or to solve

special problems associated with Joint Details in extreme setting out cases. Examples :

Combine a part from Chop-Chop with Elbow to make an out-of-plane gored

elbow. Combine parts from Y-Piece and P-Branch

Joint Details

All joint details are based on the angle between planes tangent to each pipe

surface at the requested weld root position. This angle is known as the dihedral angle, , typically as shown in Figure 2,

depicting a branch A set-on to a main B.

The branch weld root location shown as „w‟, is measured radially from the internal


surface. The bold outline of the branch is a cylinder at this location, the internal

and external surfaces of the branch are shown in faint outline. The bold outline of

the main depicts its external surface. In such a set-on detail, the weld groove angle applied to the branch is measured

back from the main tangent plane towards the branch tangent plane, as shown

generally in Figure 3. A set-in detail is simply the converse. The weld groove angle is measured back

from the branch tangent plane towards the main, and applied to the main. In the case of a butt-joint such as in Chop-Chop and Elbow, the main tangent

plane is replaced with the common plane of intersection through the butt. A square

butt such as is provided for at the end of a main or branch for most Components

has a 90o dihedral angle. The weld face angle is always measured from the common plane of intersection,

and is the whole weld groove angle for branch-type joints, and half the total weld

groove angle for butt-type joints. (It is denoted as „g‟ in Figure 3 because of this

association with groove angle.) The bevel angle, , measured from a line perpendicular to the surface, is a

function of both the weld face angle, g, and the dihedral angle, , as shown in

Figure 3 and discussed in more detail under the Fixed-Butt option below. The

„fixed‟ is in reference to the fact that the face angle „g‟ (and hence the weld groove

angle), and the root height w, remain constant around the periphery, whereas in

a general sense the bevel angle will vary. It is appreciated that in cases of extreme geometry such as very acute or obtuse

branches, some technical specifications such as AWS D1.1 require a weld

preparation that the fixed-butt detail is unable to comply with.

边缘详图


Figure 3 also shows the way in which FP deals with an Entry cut, or Lead-in., which

may be specified with Machine parameters in the FastFRAME.xml file (see

Appendix A). Clearly, an entry cut is required whenever an actual bevel ( <> 0)

is to be started if the pierce is to be vertical, which is the FP assumption. The torch

angle transition from the vertical pierce ( =0) to the required at the cut occurs

over the distance of the Entry cut. In the event that any Entry cut length specified is too short and would result in the

pierce interfering with the cut bevel surface, the Entry cut distance is

automatically extended Pierce points are automatically located. There is no provision in the current release

for any form of edge pierce – all pierces are assumed to occur at locations fully

surrounded by sound material. An End Distance may also be specified in the Machine parameters. FP will ensure that the surface cut is at least this distance from a nominal square

cut free end of the workpiece, and also that the underside cut remains in sound

material, again assuming a nominal square cut free end of the workpiece. This matter can be critical for cutting processes / machines which employ

automatic torch height sensing and control, for example. Other details shown in Figure 3 are discussed elsewhere. See Machines and


Pathing. There are three basic Joint Detail options to choose from.

General

The General detail is principally applicable to a non-bevelling Machine, but may

also be chosen for a bevelling machine, in which case the bevel angle, , (Figure 3)

is automatically set to 0. The element (branch or main) to be prepared for welding according to whether it

is Set-In or Set-On, is developed both internally and externally. (This can be seen

clearly in wrap-around templets by solid (external) and dotted (internal) profiles in

the Edge Mark colour.) Cutting is then undertaken (at the relevant Kerf offset only, with no bevel) along

that section of either profile that leaves maximum material in the element, branch

in the case of a Set-On detail, main in the case of a Set-In detail. The other element is also cut without any bevel. The main carrying a Set-On

branch is profiled so that its external surface corresponds with the branch ID. A

Set-In branch is profiled so that its external surface corresponds with the main ID. This is a „safe‟ option, and requires secondary removal of material before the joint

can be assembled, and yet further material removal to form any required weld

groove. However, any joint detail whatsoever that is required may ultimately be formed by

such profile cutting and secondary material removal. This can include extreme geometry cases as referred to above where compliance

with a technical specification such as AWS D1.1 may be required.

Combination Butt-Fillet (Combo B/F)

This is the exact converse of the General detail, in terms of the element to be

prepared for welding. Cutting is undertaken (at the relevant Kerf offset only, with no bevel) along that

section of either profile that leaves minimum material in the element, branch in

the case of a Set-On detail, main in the case of a Set-In detail. The other element is cut identically with the General detail. The main carrying a

Set-On branch is profiled so that its external surface corresponds with the branch

ID. A Set-In branch is profiled so that its external surface corresponds with the

main ID. The Combo B/F detail, like the General detail, is principally applicable to a

non-bevelling Machine, but may also be chosen for a bevelling machine, in which

case the bevel angle, , (Figure 3) is automatically set to 0. It is an „unsafe‟ option. A joint so profiled can be immediately assembled without

the need for secondary material removal. Some sections of the joint will have

external surfaces of both elements meeting, permitting the application of a fillet

weld. Other sections will form a natural open V. However, depending on joint geometry, the V may not be sufficiently wide to form


a butt weld groove and secondary material removal may be necessary on that

account. In other sections, the V may be wider than necessary and may require

filling with weld metal. This detail is commonly used in structural works. (In larger structures with internal

access for welding, an internal butt weld can be substituted for the external fillet

weld, although this is unlikely to be applicable to pipes profiled on most Machines

considered here.) Note that these are effectively „feather edge‟ details that may or may not fully

comply with particular technical specifications.

Fixed-Butt

FP v2.x cuts only a single face bevel, governed by the fact that a Far end cut

separates the part being cut from the remainder of the workpiece, and is, at that

stage, as complete as it can be made. This assumes that the workpiece is

chuck-driven from one end for Machines as indicated in Figure 1.0 While in principle secondary bevels could be cut at Near ends and

Penetrations, there is currently no facility provided for specification of if and

when such secondary bevelling would be applied. One common panacea with a chuck-driven machine is to reverse the

workpiece, which involves a careful transfer of positional reference data. In the event that the workpiece was able to project on either side of a chuck

and the cutting head had access to this area, then multiple face bevelling

would also be possible. Similarly for a machine having underside drive / idle

rollers. Data entry for specification of sufficient data for cutting multiple face weld

preparations may be the subject of a later version of FP The single face bevel requires specification of the weld root height „w‟ and the weld

face angle „g‟ being half or all of the weld groove angle as explained earlier.

Figure 3 shows two basic scenarios for weld root height „w‟ relative to material

thickness „t‟ … w < t/2

The bevel is cut down the actual face of the weld groove at an angle = -

g, thus leaving the surplus material left in the weld root area (if any) to be

removed by secondary means such as manual grinding This is the most common practical scenario with a (default) w=0 „feather

edge‟ preparation being provided, but assumes the weld face angle g is not

left at its default value of 0 (see the w >= t/2 scenario below). In all except very heavy wall applications, the feather edge detail results in

minimal or no secondary grinding. Any question of the need to reverse a

workpiece for second or third face bevelling on the Far end profile is also

obviated. This detail may not be suitable with setting out involving a very acute crotch


angle, or extreme branch lateral offsets where the dihedral angle

approaches 180°. This is true with or without a specified weld face angle, g,

and is more particularly true for machines of Type 2 w >= t/2

The bevel is cut down the common plane face at an angle = - 90°, thus

leaving the surplus material in the weld face area to be removed by such

secondary means as manual grinding. The same result is obtained by leaving the weld face angle, g, at its (default)

value of 0, regardless of the specified root height w. This can be very useful in the case of very heavy wall pipes where a J-prep.,

arc-air gouged after assembly as a secondary process, may be more

cost-effective for welding than flat-sided V preparations. In cases with setting out involving a very acute crotch angle, or extreme

branch lateral offsets where the dihedral angle approaches 180o, it is

strongly recommended that w = t be specified, especially for machines of

Type 2, for reasons discussed in more detail in Pathing. A third possible scenario is …

The P-Branch and E-BranchIP Components provide for some very extreme

setting out to be handled by cutting down the bisector between the two

tangent planes when this is the only way in which certain sections of the path

can be cut. See Components, P-Branch discussion of „problem‟ cases. The end result is that no weld grooves are formed in the joint, and the

branch and main should be capable of assembly immediately following

profiling. The decision to cut in this manner is made automatically by FP. Specification

of g=0 is set by FP and cannot be modified by the user. That data cell is

‘greyed-out’ in this instance. A fourth possible scenario is … = 0 (non-bevelling machines only, and not shown in Figure 3)

The material is cut vertically through the weld root point, leaving either or

both the weld root face and weld groove face (depending on the specified

root height w) to be formed using a secondary process such as manual

grinding. For further discussion of the Fixed-Butt detail, see Pathing.

Display

The purpose of the Display menu functions is to assist the user in verifying that

data has been entered correctly and that output will be as required. Default values of most display parameters and colors discussed below can be

adjusted – see Configuration. There are three Display functions, in each of which …

The display can be closed by pressing the Close button, or the Escape key,


or the middle mouse button. A „zoom window‟ for closer detail is obtained by dragging a rubber-band

box over the display using the mouse left button. Full scale display is returned by a single left click on the display or by

pressing the FullSize button. The display can be printed by pressing the Print button. In the print dialog

so raised … All Pages : prints an entire 3D assembly at full scale, or all 2D patterns

at full scale. Pages From … To : prints an entire 3D assembly at full scale, or 2D

patterns at full scale within the from / to range. Selection : prints only the current display contents at whatever scale

and detail is current In the 2D Pattern displays only, a rubber-band box may also be dragged with the

right mouse button and its dimensions, including its diagonal, are shown in the

Legend box. This is useful for gauging dimensions. The three Display functions are

Part(s) in 3D

A Component may comprise one or more Parts in an Assembly. There is facility to Hide one or more Parts for greater detail or clarity in the Part

which is of primary interest. This display is primarily qualitative and provides for the user to verify such details

as „handing‟ and offset directions. The display is presented in terms of X,Y,Z axes which do NOT necessarily

correspond with Machine X,Y,Z axes, although this does occur in some instances. The Display axes are alternatively thought of as East (X), North (Y) and Up (Z)

The viewing position may be adjusted in several ways

Click an „elevation‟ button.


The Roll Left/Right (longitude) and Roll Towards/Away (latitude) data may

be adjusted by clicking the directional arrow buttons. Step size may be

modified. The axes may be dragged to another position using the mouse left button,

starting in the small axis display box, but then ranging anywhere over the

display window. The standard 3D view is an open wireframe lattice presented isometrically in

default green (near side of an external surface) and blue (near side of an internal

surface) colors. For better visualization it may be recast in red / blue stereoscope,

or be green / blue shaded, or be given perspective, and have its foreground

deleted from in front of a Cut plane. Shading can take significant time and is not always successful, especially with

complex branched assemblies. The Shade request can be cancelled on the dialog

that appears to indicate its progress. Changing the viewpoint a couple of degrees,

and / or hiding one or more parts of an assembly, can often resolve the problem. Shading is considered to be a helpful but non-essential feature of FP. Any

enhanced shading algorithms that may be developed in future will be

automatically available to Licensed FP users who also hold a current Service

Contract with FastCAM Pty. Ltd. Or one of its subsidiaries. The 3D view represents only the outer surfaces of each part, and it may be saved

in 3D DXF format when the Component is output. The Schematic diagram presented adjacent to the Setting out data box for each

Component is essentially a South elevation. If a secondary view is shown in the

Schematic, it is an East elevation presented in standard third angle projection.

Wrap-arounds

Wrap-around templets are presented in 2D terms of longitudinal distance X and

Girth-wise dimension, G (see Figure 1.0). G is equivalent to Angular rotation A° of


the workpiece, also shown, through the relationship G = k*R*A, where R is the

outside Radius of the pipe, and k is a constant (k = 0.01745 = /180) The display scale is indicated in the Legend box. Vertical dimensions and current

cursor position are shown for X (horizontal) and both G and A (vertical) A number of FP-standard Process names and colors are used to depict various

details, which may be selectively hidden for purposes of removing unwanted detail

when plotting. BCut (white)

Solid lines represent the (top or outer) surface final cut edge of a Bevel Cut SCut (red)

Solid lines represent the final cut edge for a Square Cut (ie no bevel) BreakMk (green)

Solid lines represent the „seam‟ or longitudinal edge of the pattern. EdgeMk (blue)

These lines represent the outer (solid) and inner (dashed) edges of the part

where it intersects with its matching part. The implied bevel angle between the two may be considered to represent a

„median dihedral‟ at a non-definable height w somewhere in the range 0 < w

< t. From Figure 2 it should be clear that the actual dihedrals exist at both

inner and outer surfaces, and are generally different. The two lines actually derive from two separate analyses of the same data,

one with w=0 (inner, dashed), the other with w=t (outer, solid) OtherMk (yellow)

These lines are used to show useful reference marks such as Top Dead

Centre (TDC), and centrelines etc. for some details Note : neither BCut nor SCut represent actual cutting tool paths, for which refer to

NC Patterns. The wrap-around is confined vertically to the pipe circumference. When the part

contains a hole, the TDC position may be omitted in favour of Bottom Dead Centre

(BDC) in order to contain the hole entirely within the pattern height. In the companion software FastFRAME, member lengths are fixed by setting out

geometry of the entire frame, there are no holes between member ends, and there

is facility to compress the length of wrap-arounds while retaining true scale on the

end profiles. A cutting list indicates the overall length of each member, and the

wrap-arounds can then be compressed to fit paper size on a printer / plotter. In FP, there is no similar facility, and all wrap-arounds are made at full length of

the part. If required for actual production, (generally when no pipe profiling machine is

available, FP Standard Edition) part length data can be specified to ensure that a

single wrap-around will fit the printer / plotter paper. (This option is not possible in

FastFRAME, which is the reason for its facility as described above.) Alternatively,

the wrap-around output file (see Output) can be plotted over several pages.


NC Patterns

NC patterns are displayed in a similar manner to a wrap-around, representing the

pipe outer surface „unwrapped‟ to a flat plane. The G-A relationship established for the wrap-around holds true for every machine

except Type 6 – see Machines – and the NC pattern for such a machine would be

a complete hash unless specially modified. In this case, however, the pattern is not confined vertically to a single pipe

circumference, but may extend two and a half circumferences above and below

TDC, representing two and a half A axis rotations in either direction. The NC Pattern may be thought of as a „stacked wrap-around‟ in which we are no

longer concerned for penetrations intersecting the longitudinal edges of the

templet. The display scale is indicated in the Legend box. Vertical dimensions and current

cursor position are shown for X (horizontal) and both G and A (vertical) A number of FP-standard Process names and colors are used to depict various

details, which (different from the wrap-around) may not be selectively hidden. BCut (white)

Dashed lines represent the weld root at height w (which may be anywhere

from underside to top surface). The final cut through-thickness surface

should pass through this line Solid lines represent the (top or outer) surface path of the centre of the tool

producing a Bevel Cut SCut (red)

Solid lines represent the surface path of the centre of the tool producing a

Square Cut (ie no bevel) Pierces, which are (non-oblique) point processes, are programmed at the

centre of red circles of 3mm or 1/8” radius. The circle itself is not


programmed, it is used simply to more readily identify pierce points. This process is shown in favour of BCut for all non-bevelling machines, and

for bevelling machines when no bevel is actually cut. BreakMk (green)

Not used EdgeMk (blue)

Not used OtherMk (yellow)

Shows Top Dead Centre (TDC, A=0) of the workpiece. If Mix and Match options have been used, the TDC line will extend over the

machine‟s maximum permissible workpiece length, otherwise it extends

only over the length of the pattern between end cuts. As a general rule, the SCut path will deviate from root path by the kerf radius, and

in the specified kerf offset direction. The BCut path also allows for kerf offset, but depending on the magnitude and

direction of bevel angle , may lie on either side of the root path. As a further general rule, the bevel angle is measured in a plane perpendicular to

the BCut path. One exception to this rule is at transition points where there is a discontinuity in

bevel angle, such as occurs at the intersection of two differently defined cut paths. Example – C-Branch with a reinforcing plate slot cut into a branch end profile,

when there are two re-entrant transitions, and two non-re-entrant transitions. A second exception is in the case of Type 2 machines, with or without any bevel

discontinuity. The BCut path may be seen to cut back over itself in some areas of the profile,

usually in the vicinity of re-entrant transitions. This can also occur when the path

is offset into the concave side of the root path, especially with Type 2 machines in

the vicinity of primarily longitudinal cuts. Such behaviour may be unavoidable, or it may indicate that an inappropriate

Set-In / Set-On choice has been made, or it may indicate that the setting out

geometry is simply too extreme, or that an inappropriate joint detail has been

specified. NC patterns are drawn from the precise X, A data which, on Output, will be

converted to NC code. They are not directly drawn from the NC code itself It is not feasible to represent more than the X, A data in the NC pattern. Absence

of other data defining the bevels can thus make the patterns sometimes difficult to

interpret. NC patterns can also be difficult to interpret correctly without a deeper

understanding of how FP handles transitions. See Pathing and Machines A study of the wrap-around of the same part may shed some light on particular

problems since it is generally much simpler to interpret.


Output

The Output function provides for a variety of different outputs to be obtained for

the Component in the currently active window. Some data from the Component Job tab is copied to the Output form to assist with

recognition and confirmation of the output. Because a multiplicity of files may be output, all output files share a common base

name, which may be specified manually, or selected from an auto-file-naming

facility. If manually specified, the required base name may be entered into or selected

from a drop-down list containing the Component Job tab data copied to the head

of the form. For purposes of examples below, assume a base file name is specified as MFBN

(MyFileBaseName) If automatically assigned, a base name comprising the characters FP_ followed by

three or more letters A to Z starting from AAA is allocated from a register. (The _

is the default file name field separator character which is user-configurable.) The auto file naming facility may be de-activated, and file name field separator

character omitted or modified. See Configuration Files which may be output at Component level are

.FPD (FastPipeData) file Example : output as MBFN.FPD or FP_AAA.FPD It is recommended that this option always be used so that any subsequent

changes to data without corresponding output will not be confused with the

current, which can then always be recreated. The file format is proprietary to FP and is of little use other than to re-open


with FP.

.DXF (DrawingeXchangeFile, as a subset of AutoDesk 3D format,

representing the entire assembly of all parts) Example : output as MBFN.DXF or FP_AAA.DXF This data is primarily of academic interest, but may be used for such

purposes as documentation. The user bears full responsibility for any

changes that may be made to it using any CAD software. Files which may be output at individual Part level have a sequence number

_001, _002 etc. appended, (with the sequence number generally reflecting

the Part Item number within the Assembly as shown on the Display form).

Output options are ..

.CAM (FastCAM standard drawing file for individual part Wrap-around

templet) Example : output as MBFN_001.CAM or FP_AAA_001.CAM This is a FastCAM proprietary file format which is freely available to others on

request, and is far more readable and useable than the .DXF alternative. These files can be read, optionally edited, and plotted by FastCAM. The user

bears full responsibility for any changes that may be made to it using

FastCAM software. FastCAM recognizes the FP-standard Process names BCut, Scut, EdgeMk,

BreakMk and OtherMk discussed in Display, and can also be used to create

flat profile NC programs for wrap-arounds cut from (eg) sheet metal for

repetitive manual marking and cutting tasks Previous FP v1.x options which provided for pipe profile NC code to be

generated from FastCAM as a batch process from within FP have been

abandoned. However, the alternative X-Y or X-A data may still be inserted into the CAM

file – see Configuration. To the extent that FastCAM provides, and continues to provide, limited

support for specific pipe profilers, such X-A output may continue to be used. The X-A output may otherwise be useful to users wishing to develop their

own post-processors for special applications.

.DXF (DrawingeXchangeFile, as a subset of AutoDesk 2D format, for

individual part Wrap-around templet.) Example : output as MBFN_001.DXF or FP_AAA_001.DXF These files can be read, optionally edited, and plotted by FastCAM or by most

CAD software. The user bears full responsibility for any changes that may be

made to it using FastCAM or other software. The FP-standard Process names BCut, Scut, EdgeMk, BreakMk and OtherMk

discussed in Display are assigned to Layer names. No colors are assigned to

any layers or line types.

.NCP (NCProgram, according to data specified for the machine – see


Appendix A) Example : output as MBFN_001.NCP or FP_AAA_001.NCP These are simple ASCII text files ready for transmission to the machine CNC

for execution. Provision of software or other means for transmission of .NCP files is outside

the scope of FP. FastCAM can provide DNC software FastLINK if required and ordered

separately. The form also displays a Parts List with, always by default, all parts listed and

selected for output. The selection may be user-modified in the

MS-Windows-standard manner using the Shift and Control buttons in

conjunction with the mouse to select / de-select various Parts from the

output stream. In the case of a Component such as R-Branch where a Wrap-around for the

Branch element may exist but there is no matching NC Program data

available, FP will simply ignore the request for non-available output.

Machines

Supported machine types are as indicated in Figure 1 and described below. Actual properties of the machine are specified in the FastFRAME.xml file – see

Appendix A. Figure 1.0 defines standard axes and certain assumptions common to all machines

rather than a machine per se.

图 1.0

For the technically minded, the X, Y, Z axes comprise a right-handed orthogonal

set with consistent right handed rotations A, B, C about axes X, Y, Z respectively. For the less technically minded, if the axes X, Y and Z were notionally constructed

from right-hand threaded bars with nuts installed on each, then a positive rotation

of any nut would carry it along its axis in a positive direction. Furthermore, if X


points east and Y points north, then Z must point upwards, not downwards. The line labelled G is not a machine axis as such; it indicates an axis in a

wrap-around templet as discussed elsewhere – see Display – and is used to avoid

confusion with a machine Y axis. In so far as is possible given the different mechanics of various machines, the

standard axes defined above are retained. Features are

An assumed chuck-type drive at one end of a workpiece, denoted the Far

end X,Y,Z axes origin on pipe centreline at the free, or Near, end of the

workpiece Tooling limited to a cutting device, assumed to be a torch or equivalent

(plasma, oxy, etc.) and no NC-programmatic support provided for other

processes such as line marking FP will program movements of the cutting torch or tool in those axes

specified below for each of the machine types, and no other. The chuck-type drive assumption and its practical impacts are discussed

elsewhere in the context of Joint Details. No machine is required by FP to actually

employ a chuck-type drive. The axes names X,Y,Z,A,B,C may be mapped in the FastFRAME.xml file to other

names for purposes of NC output. Since most CNCs contain provision for

re-mapping axes origins and directions and can be configured for compliance with

FP‟s standard, FP currently makes no provision for this. The most important aspect of the axes definition is the X=0 at the free (Near) end

of the workpiece. It is assumed that the machine operator will set the origin at or near the free end

of whatever length workpiece is used or current after progressively cutting parts.

The assumption also has particular relevance to Mix and Match options A distinction is drawn between the axes programmed by FP and the axes that may

be controlled by the CNC. In particular, the axes programmed by FP represent a point on the surface of the

workpiece towards which the centre of the cutting process stream is to be

directed. Depending on the type of process employed, the tool or torch will require to be

positioned some distance along its own centreline axis back away from the

workpiece surface. The machine manufacturer is responsible to manage such tool axial movement in

any manner that ensures compliance with the kerf and feedrate data specified

(see Appendix A), while directing the centre of the process stream towards the

programmed point. Common characteristics of pipes are cross-sectional ovality and lack of

straightness, either of which may cause any point on the pipe to deviate from its

theoretical position when the pipe is rotated.


FP assumes and requires that the machine either prevents such deviation at the

tool position, or senses the deviation and automatically adjusts the tool position to

maintain its correct (programmed) position relative to the pipe. For all except the Type 6 machine, FP programs the tool at the TDC position with

neither Y nor Z being programmed. These two axes, and the aforementioned tool

centreline axis, may or may not be controlled by the CNC depending on the

mechanics of a particular machine. Hence FP refers to machines by Type as defined below, rather than as 4-axis or

5-axis etc. machines. Machine Type 1

See Figure 1.1. This is a non-bevelling machine in which only the X and A axes are

programmed. The tool position is maintained at the TDC position on the workpiece, and

remains vertical at all times.

Figure 1.1

图1.1

Machine Type 2 See Figure 1.2 This is a partially bevelling machine in which only the X, A and B axes are

programmed The tool position is maintained at the TDC position on the workpiece, and can

be tilted through an angle of +/- B from the vertical while remaining in the

vertical XZ plane at all times. (Note that the B tilt in the XZ plane is consistent with the standard definition

for rotation B about Y.) Clearly, such a machine is capable of bevelling along a mostly transverse

path, but is incapable of bevelling along a purely longitudinal path, for which

reason it is described as „partially‟ bevelling. Such a machine is generally suitable for profiling simple ends of pipes, but

handles neither end slots nor penetrations well. It can suffer more problems in pathing through re-entrant corners than

other machine types – see Pathing

Machine Type 1


Machine Type 3 See Figure 1.3 This is a fully bevelling machine in which only the X, A, B and C axes are

programmed The tool position is maintained at the TDC position on the workpiece. It can

be tilted through an angle of +/- B from the vertical in the longitudinal XZ

plane, while also being tilted through an angle +/-C from the vertical in the

transverse YZ plane. (Note that the B tilt in the XZ plane is consistent with the standard definition

for rotation B about Y. The C tilt, however, has new deviated from the

standard definition, and is now consistent with a right handed rotation about

X)

图 1.3


programmed The tool position is maintained at the TDC position on the workpiece. It can

be tilted through an angle of +/- B from the vertical in a vertical plane, which

plane can be rotated +/-C about the vertical Z axis.

Machine Type 2

Machine Type 3


(Note that the rotation C complies with the standard definition. B tilt in the

vertical plane is consistent with the standard definition for rotation B about Y

when C=0)


programmed, and is a curtailed version of the Type 4 machine. The tool position is maintained at the TDC position on the workpiece. It can

be tilted through an angle of + B only (no –B) from the vertical in a vertical

plane, which plane can be rotated +/-C about the vertical Z axis. (Note that the rotation C complies with the standard definition. B tilt in the

vertical plane is consistent with the standard definition for rotation B about Y

when C=0) Such a machine suffers from the need to perform a 180° „pirouette‟

whenever the bevel angle changes sign. (It will be noted that, in Figure 3,

is defined in right-handed rotational sense about the path travel vector.

The bevel angle normally changes sign at least twice in any closed path.)

Machine Type 6 See Figure 1.6

Machine Type 4


This is a fully bevelling machine in which only the X, Y, Z, A and B axes are

programmed. Different from all other types, the tool position is no longer maintained at the

TDC position on the workpiece. It can be tilted through an angle of +/- B

from the vertical in a vertical plane which is maintained parallel with the XZ

plane but displaced laterally by +/-Y. Lateral displacement of the tool from TDC in the +/-Y direction then

necessitates its lowering in a –Z direction in order to follow the surface, and

conversely raising in the +Z direction in any traverse back to TDC. Simultaneous axes movements are far more complex with this type of

machine than with any of the others. As noted in Display, the usual G-A

relationship that holds true for all other machine types requires special

modification for this type of machine in order for its NC patterns to be

correctly represented. The bevel limit along a longitudinal path is a function of the diameter /

thickness ratio of the pipe as well as of the machines ability to traverse

across +/- one pipe radius and down from TDC by almost one radius

As with the Type 2 machine, NC patterns can be difficult to interpret,

especially in areas where the path is primarily longitudinal in the vicinity of

re-entrant corners or concave path segments.

Miscellanea

Feedrates and kerf radii specified in the FastFRAME.xml file (Appendix A) are a

function of effective thickness (taken along the line of the bevel cut). Feedrate is a single and optional figure which, if specified, is issued in the NC

program with every data block, and can apply to whatever the machine designer

requires that it apply to without FP needing to know exactly to what it may apply.

Machine Type 6


It need not even be an actual feedrate, but subsidiary data for the CNC to respond

to. Most CNCs provide for circular interpolation of tool movement in any of the XY, YZ

or ZX planes, but not between any combination of linear and rotational axes. Theoretically, circular interpolation would be possible between X and A through

the G-A relationship discussed elsewhere. This could feasibly be implemented for

a Type 1 machine, but for all other machine types such implementation is less

feasible because of the simultaneous changes required in other axes. Therefore NC programs output from FP are confined to step-wise linear

movements in X-A(G) and assumes linear interpolation only in all axes. It is furthermore assumed that a small surface movement in X-A(G) may be

required in order for such interpolation to occur in the other axes. That is, the

machine could cut a conical crater with apex at the underside surface, but not with

apex at the outer surface. The minimum linear movement programmed by FP is currently taken as the

Minimum Significant Dimension as defined in Configuration rather than (at this

stage) the FastFRAME.xml file. These issues have a bearing on the process known as Pathing discussed

elsewhere.

Pathing

This Topic extends previous discussion on Joint Details, particularly the Fixed-Butt

detail. The term „pathing‟ is used to describe the process undertaken by FP to determine

the path of intersection of the tool centreline axis with the pipe surface,

plus all relevant machine axis settings according to machine Type,

that will cause the through-thickness cut surface to contain all root path sample

points. With reference to Figure 3 (see Joint Details), the first part of the pathing process

is undertaken in the X-G plane with points labelled 1 and 2 representing sample

points on the root path at height w from the inner pipe surface. At all such points,

the path tangent vector slope, , and bevel angle, , in a plane perpendicular to

the tangent and to the X-G plane, are determined by FP from the users setting out

and joint detail data. In the second part of the pathing process, G is mapped to the machine A axis (plus

Y and Z for Type 6 machines only), and is mapped to machine B and / or C axes

(together with Y and Z in the case of a Type 6 machine) Machine properties (Appendix A) are used to determine both the bevel offset,

(represented by the intermediate points 1‟ and 2‟), to which is then added the kerf

offset, (represented by the points 1‟‟ and 2‟‟ on the final outer surface tool path) Most machines have physical limits to their movements, and in particular to their


tool B and C rotations or tilts, which provide components of the bevel angle, . FP

ascertains the maximum possible bevel angle that the machine can cut at a given

tangent vector slope, and such limits become quite obvious in many tool paths. The relevance of the root path is immediately apparent. FP may be forced by

machine limits to cut less than the required , but can never over cut in the sense

of removing too much material from the weld root area of the bevel – at the root

sample points. (Note that the kerf offset, which is a function of the true length of

the bevel face through the thickness, is deferred until after the bevel angle limit

has been set.) The true root path is represented in Figure 3 by the dotted line passing through

sample points 1 and 2, which are determined at 5° intervals around the pipe girth,

while as noted in Machines, FP assumes only machine linear interpolation in all

axes. The dashed line between points 1 and 2 represents the linearized root path. Clearly, there is some error (shown as „e‟) inherent in this process. Between root

path sample points, over cutting at the weld root will occur on a convex path, and

under cutting on a concave portion of the path. In practical terms, this error is insignificant, and could be reduced only by using a

greater number of sample points. For example, it can be shown that for path convexity / concavity applicable to a

610mm (24”) OD pipe mitre cut at 45°, use of 5° increments results in an error, e,

of approximately 0.15mm (0.006”) Unavoidable error in cut edge position at inner and outer surfaces arising from a

machine’s inability to provide the angle requested by the user is generally more

significant. Such error, when significant to the user, can be modified by the user

through his choice of w for the Joint Detail. Pathing as described above functions well in most single-profile-path applications

with practical setting out and practical Joint Details for most machines. In cases of very extreme setting out, resulting in highly concave portions of the

tool path, a tendency toward the behaviour exhibited at transitions as discussed

further below may be observed when unfavourable Joint Details are specified. Cusps may start to form in the tool path, and may extend into loops with the path

crossing back over itself. This is a consequence of the geometry as specified by the

user, and to a lesser extent, to the linearization of the tool path. In the event that the machine had circular interpolation capabilities in all planes

and axes, such behaviour would be more easily avoided, and FP explicitly assumes

that no machine has such capabilities. Such behaviour along the tool path would be exacerbated by any attempt to

minimise the sample point linearization error discussed above through using

smaller sample point intervals The only action that could be taken by FP to avoid or eliminate such behaviour

would be to „short cut‟ problem areas, leaving them to be rectified manually by a

secondary process such as grinding. The FP philosophy is to remove as much material as possible consistent with


machine limitations and the user‟s specified requirements so as to minimize the

need for later grinding. Hence no „avoiding action‟ is currently taken by FP other

than to avoid a zero-length path segment. The Type 2 machine, whose path is also shown in Figure 3, can present additional

problems in sections of a path which are close to longitudinal (typically in

penetrations), which can be overcome by appropriate Joint Detail specification.

Path Transitions

When a path comprises portions of intersecting profiles, or otherwise contains a

discontinuity in bevel angle such as may occur with some penetrations when a

corner is formed, the question arises of how to cut the bevel transitions through

the corner.

There are two types of corner, protruding and re-entrant, as shown in Figure 4. Bevels could be cut around a protruding corner using a „loop-around‟ style of

transition such as shown in Figure 5, but no such option exists at a re-entrant

corner.

图 4 corner

图 5 loop-around - only 'A'


An alternative to the „loop-around‟ would be to simply cut beyond each corner and

re-pierce for the start of the next path segment. Any such scheme is generally

possible at the Near end of the workpiece, but can present problems with

premature separation of the part from the Far end. Since FP is equally committed to cutting both end profiles and penetrations, (and

end profiles may also contain re-entrant corners, as when slotted for a reinforcing

plate), a solution is required to the re-entrant corner situation. The solution adopted by FP, which is equally applicable to both protruding and

re-entrant corners, is the „scuplted‟ corner, as shown in Figure 6 (for machines of

Types 3 to 6) and Figure 7 (for machines of Type 2). Both Figures are drawn for

protruding corners on a „kerf offset (scrap side) to right‟ assumption, or for

re-entrant corners on a „kerf offset (scrap side) to left‟ assumption.


图 6雕刻的突出角

The dashed lines intersecting at point „i‟ represent the root path. The solid lines

containing points 1‟ and 2‟ represent the outer surface path after offsetting for

bevel angle, but prior to kerf offset. The point 3‟ exists at the intersection of offset

paths through 1‟ and 2‟. The arrows through points 1‟, 3‟ and 2‟ represent the path


tangent vectors, , at these points, ie, they are the instantaneous cutting

directions. Typically, the final edge is cut through points in sequence 1‟-3‟-2‟, with either or

both 1‟ and 2‟ being omitted when not in correct sequence, or when the path

distance 1‟-3‟ or 3‟-2‟ would be too small – see Machines and Configuration

(minimum significant dimension) Several features of the sculpted corner detail are …

relatively high rate of change of both and in the immediate vicinity of

the corner ditto in the approach to the corner when 1‟ is omitted ditto in the departure from the corner when 2‟ is omitted. generally greater at 3‟ than at either 1‟ or 2‟, hence an increased kerf

offset, plus a greater risk of machine limit conflict. Generally, the surface path will not cut over itself, except in the case of acute

re-entrant corners when combined with small root height w and an unfavourable

resulting from the weld face angle, g, specified in Joint Details. Note however, that if the root height w is adjusted in the Joint Detail for purposes

of eliminating outer surface path crossings, then it is almost inevitable that such

crossing will simply be transferred to the inner surface of the pipe. Whereas in the case of the highly concave portion of a non-transitionany path, the

path linearization was a contributing factor to path cross-overs, in this case this is

not so. Any path cross-overs are entirely a consequence of user-specified

requirements and machine limitations. The only means of avoiding path cross-overs now would be to „short-cut‟ the

re-entrant corner which must then be completed manually. Practical experience indicates that the often-anticipated loss of cutting process at

a path cross-over in fact is rare, and if it occurs is more likely to be attributable to

rapid change in bevel being required over a short outer surface path interval. Such

situations may be largely unavoidable, but FP attempts to minimize them. A user-configurable „short-cut‟ option may be considered in a future release of FP.

Configuration

In addition to the FastFRAME.xml file described in Appendix A which specifies

details of your machine and contains lists of standard products, there are a

number of FP features that may be modified under the Configuration menu. The Language submenu allows FP to switch between various languages. The FP Options submenu raises a tabbed-style form with various settings that may

be modified and acted upon according to choice of button… Save

Saves the present settings in the configuration file, but does not close the

form Restore


Replaces all current settings with standard FP default settings. Does not

close the form Apply

Applies all current settings and closes the form. Those settings are used until

again changed, or FP terminates. Upon next starting FP, settings are

re-established from the last Saved set of configuration settings. Cancel

Closes the form. Any changes made since last Saved are abandoned. Help

Opens this document. The first time FP is started after installation, a warning will be issued to advise that

the configuration file has not been found. This is normal. Open this form, review

the settings and Save them, then Apply.

The five tabs are …

The General tab

Units are defined in the FastFRAME.xml file and may not be modified directly from

FP.


Units may be metric (mm) or inch. The form shows which are current, and the

derived units for each system. In the metric system, data computed by FP is displayed to a precision of 0 decimal

places (ie to the nearest whole mm), but user data may be entered to any desired

precision. Inch data computed by FP is displayed to a precision of 3 decimal places, but user

data may be entered as decimal numbers to any required precision, or as

fractional inches to a precision no less than 1/64”. The data format is (eg) 1‟6 7/8 or 18 7/8 , both of which are equivalent to 18.875.

Use only an apostrophe to denote ft. and follow immediately with the inches (no

space). Separate the whole and fractional inch component with a single space

only. NC program data is carried at full precision available and output to the precision

defined for the machine in the FastFRAME.xml file. Two critical dimension need to be specified. These are, with values ..

Dimension Min Max Default

Minimum Significant

Dimension 0.01mm or

0.0004” 0.5mm or 0.02” 0.1mm or 0.004”

General Dimensional

Tolerance (min.significant

dim.) 5mm or 0.2” 1mm or 0.04”

The minimum significant dimension should generally be set to not less than a

typical NC resolution of 0.1mm (0.004”), and as large as acceptably possible. It

acts as an effective zero when FP needs to decide various issues, and currently

defines the minimum acceptable linear movement for the machine – see

Machines. The general dimensional tolerance also aids FP in decision making on various

matters. It is also used when fairing wrap-around data, as discussed below under

the Wrap-Arounds tab. Each Component window contains a Component tab, a Job tab and a Data tab. The

two boxes labelled „Open New Window on …‟ and „Re-open Window on …‟ allow the

user to determine the most convenient way of operating. The default is Data Tab

in each case. The Show Toolbar (default is yes, show it) allows the user to omit the main toolbar

below the central control menu and thereby provide a slightly larger work space.

FP mau need to be terminated and re-started before a change here will become

fully effective. The FastCAM Path should be specified in order for the Silhouette Component to be

useful. The ? button allows browsing to locate the FastCAM5.exe file if it is

installed.

The 2D Display tab


FP standard Process Names are defined and described. Colors used in display of

both Wrap-around and NC templets (patterns) may be adjusted to individual taste

and / or Color / B-W printer requirements from a pallette of 16 numbered basic

colors. Defaults are BCut : white(15), SCut : red(12), BreakMk : green(10), EdgeMk :

blue(9), OtherMk : yellow(14) over a Background : black(0)

The 3D Display tab

The boxes labelled Mono and Stereo refer to the alternative viewing styles rather

than the number of colors selected, and show the current color selections. The pallette is much broader than for the 2D templets to facilitate individual

adjustment for optimum stereoscopic effect.


To change color, click on the relevant color sample in either the Mono or Stereo

boxes, then use the slide controls in the Color Adjust box to adjust the

Red/Green/Blue mixture of the color. If an Axes Color sample is selected, the Color Adjust box will show an option to set

axes color same as background, which will effectively prevent the axes from being

displayed. Default color schemes are Mono : green external, blue internal generators / surfaces, white axes over a grey

background Stereo (Through the use of 3D glasses): red left / blue right (lenses), white axes

over a black background The fourth box on this tab is labelled Default View. The default is a standard

isometric view from the „south-east‟ quadrant in the upper hemisphere, with

(loosely) X being associated with „east‟, Y with „north‟ and Z with „up‟. The numbers

are (again loosely) degrees of latitude and longitude. The schematics on all Component Data tabs view most naturally in „South

Elevation‟ in which we would set „Roll Left/Right‟ at 270 and „Roll Away/Back‟ at

zero. Rather than belabour the point about how this system is actually defined, what the

numbers mean, and whether the assembly moves relative to the viewer or vice

versa, the following is recommended

Find a „comfortable‟ default viewing position and system using the Display

form, then copy its settings to the configuration. (This will most probably

be the „South Elevation‟ if not the default provided.) Consider the directional arrows alongside the Roll Left/Right and Roll

Away/Back data entry boxes on the Display form as moving the closer side

of the assembly relative to the viewer.

The Output Defaults tab


Enables the user to specify which files (as described under Output) are selected by

default, so as to expedite the Output process. The default selections may be

modified at any time prior to commitment when Output is being prepared. There is provision for future implementation of a Production Log which is disabled

in the current version 2.x release.

The Wrap-Arounds tab

There are 3 different subject covered under this tab, Fairing, Cut Path direction,

and data style included in FastCAM output. None of these has any impact on production of NC programs – they are all


associated with the wrap-around templets. Fairing is the term used to describe the consolidation of

individual straight line entities drawn between points on a process path into

a single straight line when departure of any point from the faired straight

line is within the general dimensional tolerance specified on the General

tab, individual points on a process path which do not lie in a straight line (within

the specified tolerance) but may lie within specified tolerance on a common

arc having regard to both arc radius and centre point location. The fairing concept is occasionally useful for both data consolidation and

„smoothing‟ of cut paths for both plotting and display purposes. It may also be

switched off, which is generally recommended. The facility is provided solely

because it is demanded by many users. Cut Path Direction and X-Y / X-A options are similarly included for the benefit of

users desirous of writing their own NC post-processor routines from CAM or DXF

output file, but wish to avoid the mathematical machinations of path direction

reversal and the simple G-A (or Y-A in the present context) relationship discussed

elsewhere. Fairing, when selected as other than ‘Omit’, is only ever applied to plottable X-G

(X-Y) wrap-arounds. It is never applied to X-A output, and never to NC Patterns.

Also see Machines and Pathing.

Pipeconfig settings:


Help

The Help menu contains 3 submenu items …

A Contents listing leading to this file Provision of email support, as described further below About FP… which shows the FP License Number and provides a link to the

FastCAM web site. The email support system provides for the user to email FastCAM with any

problems or queries (assuming, of course, that the computer is connected to an

email facility). The FastFRAME.xml file and other configuration files are automatically attached to

the email to help FastCAM support staff in resolving any technical difficulties. Any relevant .FSD file(s) should be specifically attached In the event that a machine cuts some details in an unexpected manner, please

read other sections of this Manual, in particular Display and Pathing, before

concluding that the machine behaviour is truly not to be expected. There are numerous situations where FP can be confronted with a practically

impossible task and does the best it can. This is particularly so in the case of

heavily bevelled re-entrant corners.

Components

This Section of the Manual defines specific technical details, data limits, etc. for

each of the Components listed below whose broad descriptions and areas of

application are described in The Components Library. With all Components, FP aims to provide the maximum flexibility to the user in

setting-out parameters and choice of Joint Detail. FP does not claim or seek to represent that all Joint Details or setting out that may

be specified are necessarily practical or viable – many combinations will clearly not

be.


It is the user’s responsibility to make practical choices between competing

alternatives, and to verify that the result is satisfactory before proceeding to cut

materials. The Components are …

Chop-Chop

The maximum number of parts that may be nested is determined from the

maximum useable workpiece length specified for the machine and the part length

requested. Common Cut Rules

The Common Cut option is available only to the Standard Plus NC Edition The Common Cut option is available only when more than one part is

requested The Common Cut option is available to General and Combo B/F Joint

Details only for pipes having effectively zero specified wall thickness,

otherwise, for thicker walls …. The Common Cut option is available only to the Fixed Butt Joint Detail, and

no weld face angle may be specified.

Example 1：Cutting Pipe End and Nesting

In this example, we have to cut from galvanized round pipes, diameter 198mm, thicknes 8mm, pipe length 5m. We want to cut out 6 pipes,one end with 45°, one end with60°, angles in the same direction, pipe length 1M.

1.Run FastPIPE software, and then select CHOP CHOP to enter options dialog for that model.


Type the information in task tab and input Data as below:

Length: For the length of the pipe to be cut, with 2 options to follow

Centre line: indicates dimension is specified for the centre line of this pipe. (if this is a square cut, this is the same as total length) Total length: indicates the full length of the object (if both ends have been cut at an angle, then this is the furthest distance end to end). Left end cut angle: Indicates angle to be cut on the left end, this can be between 0-75 degree.

Right end cut angle: Indicates angle to be cut on the right end, this can be between 0-75 degree. Twist cut angle: this represent the twist in plane between the angle of the left and right end. Nesting Amount: this represent the quantity required for pipes of the specified dimensions, when this is more than 1, the total length will be shown in an area further down


the screen.

2. Click on the 3D structural diagram, on the middle of the right side of the screen In the upper right location on the display, it is possible to view the diagram in 3D view and U

view (bevel face). It is also possible to change the view angle position of the pipes. Hint: if you want to view a specific area of the diagram, you can click and drag over an area

to zoom in and out.

Click on the close button on lower right location to close the diagram interface.

3. Right click the middle tool bar to show the template of cutting.

This shows each branch pipes cutting template, in the bottom left area each branch pipe can be

selected and observe changes in the diagram. The coordinate displayed here can be use to verify each

brabch pipe’s length.

4. Click on the button on the toolbar to review NC template.


Through this view, you can see the nest result of 6 pipes. And also the NC

Machine will cut exactly the same as what you see here.

Click close button in the bottom right to close.

5. Click on the button on the toolbar to output NC Code.

Select the required items for output and specify the file name, click output now and output NC

code.

Note, if there are some error, it will popup the following message


Elbow

Bend Angle permissible range is 1° minimum to 180° maximum. Subject to total length required for a single Elbow not exceeding the maximum

useable workpiece length specified for the machine, other limits apply as follows Number of Gores permissible range is 2 minimum to 20 maximum, except that if

Bend Angle is greater then or equal to 160°, minimum is 3 gores. Gore extensions are optional, and may not be negative. Common Cut Rules 1. The Common Cut option is available only to the Standard Plus NC Edition 2. The Common Cut option applies only to the mitred cut(s) between gores. 3. The Common Cut option is available to General and Combo B/F Joint Details

only for pipes having effectively zero specified wall thickness, otherwise, for

thicker walls …. 4. The Common Cut option is available only to the Fixed Butt Joint Detail, and no

weld face angle may be specified.

Example 2：Elbow

(Example needs a 5M length bend pipe split into 6 sections to transition a 90 degree bend. The Bend radius is 3050mm. On each end of the pipe 8mm green is required for further welding)

1. Run FastPIPE, select the Elbow module to launch dialog for Elbow.


Fill out the details in the Job tab for records, and then click on the Data Tab and enter the Elbow data.

Bend Angle : 90 degrees Bend Radius: 3050mm Bend segment: 6

(lower) green : 8 Finally (top) green: 8

Select common cut feature

2. Click on the 3D structural diagram, on the middle of the right side of the screen

In the upper right location on the display, it is possible to view the diagram in 3D view and U


to zoom in and out.



3. Right click the middle tool bar to show the template of cutting

This shows each branch pipes cutting pattern, in the bottom left area each branch pipe can be




Click on the close button on lower right location to close the diagram interface

4 Click on the button on the toolbar to review NC Pattern.

Through this view, you can see the nest result of 6 pipes. And also the NC



5.Click on the button on the toolbar to output NC Code.



code.

Y-Piece

Angles between branches are projected angles in the XZ plane, which contains

branches 2 and 3. Permissible range for any angle is 15° minimum to 330°

maximum, subject to the total not exceeding 360°. Note that the angle between

branches 1 and 3 designated (Ref.) is computed automatically from the other two. Branch 1 is constrained to lie in the YZ plane. Its angle from the XZ plane may lie

within +/-165o of 0o, although values outside the range +/-90° are likely to be of

mainly academic interest and may raise some pathing problems. (In such case,

the angles to branches 2 and 3 are better considered to be based on the lower half

of the YZ plane) The specified length of Branch 1 is the true length in the YZ plane, not its projected

length in the XZ plane. All branch lengths are measured from the centre of the common central sphere at

the XYZ origin.


In the event that the angle between branches 2 and 3 is specified as 180o,

P-Branch may be a more appropriate choice of Component since it would eliminate

one crotch weld, and this point is noted. On the other hand, P-Branch in this

configuration will not cut weld faces and the Y-Piece approach may be

cost-effective in an overall sense. More importantly, a combination of parts from both Y-Piece and P-Branch may

comprise an effective solution in certain circumstances. The schematic adjacent to the setting out box is very approximate (especially in its

implied representation of the crotch planes), and intended only to assist the user

in basic data entry and orientation. The 3D view (left click the schematic) is

accurate. For those academically interested (but not pedantically so), the following short

dissertation should help with an understanding of both Y-Piece and P-Branch … When a pair of right circular cones are both tangent to a common central sphere,

their line of intersection is an ellipse lying in a plane which in the present context

will be termed a „crotch plane‟ The centre of the common central sphere lies at the intersection of the cone axes,

and does not, in general, lie in the crotch plane. Furthermore, the crotch plane

does not bisect the angle between the two cone axes. The branch lengths

measured along the centreline axes must clearly be measured from the axes

intersections at the centre of the sphere, and not from the point of intersection of

either axis with the crotch plane. Lack of appreciation of this point has brought many draftsmen and boilermakers

unstuck. Nevertheless, a perfect joint can be formed provided both cones are mitre cut in

the correctly located and oriented (crotch) plane. The cylinder is a special case of right circular cone. In the case where two cylinders

intersect on a common central sphere, the centre of the sphere does in fact lie in

the crotch plane, and the crotch plane does bisect the angle between the cylinder

axes – in this special case. When a third cone is added to the assembly to form a bifurcation or Y-Piece, three

crotch planes are now formed. Any two crotch planes intersect in a common line.

It can be shown that all three crotch planes in fact share a single common line of

intersection, which in general does not pass through the centre of the common

central sphere. A perfect joint can be formed by mitre cutting the end of each branch twice, once

in each of its two crotch planes. In the special case of a bifurcation comprising 3 cylinders, which is the Y-Piece

Component, the common line of intersection does pass through the sphere centre,

which fact may be seen qualitatively at least in the 3D view.

Example 3：Y – Piece

(Requirements are to design a Y-Piece, each Pipe has a length of 1M, the angles


between the 3 pipes are 90°、150° and 20°，of the three, the two branch pipes separated by

90° has a 20 degree slant. The Pipes dimensions are 200mm diameter, 10mm thickness). 1. Run FastPIPE, select Y-Piece model to launch dialogue for Y-Piece

Type the information in task tab and input Data as Y branch.

Note the diagrams shown specifications for 2 different planes. In Plane 1:

Branch 1,2,3 length as: 1M Branch 1 and 2 angle as: 90° Branch 2 and 3 angle as: 150°

In Plane 2: In diagram 2 add an angle: 20

2. Click on the 3D structural diagram, on the middle of the right side of the screen In the upper right location on the display, it is possible to view the diagram in 3D view and U


to zoom in and out.


Click on the close button on lower right location to close the 3D diagram interface．

3. Right click the middle tool bar to show the Wrap-Around of cutting

This shows each branch pipes cutting pattern, in the bottom left area each branch pipe can be





4. Click on the button on the toolbar to review NC Pattern

Through this view, you can see the nest result of ３ pipes. And also the NC


Click close button in the bottom right to close

5. Click on the button on the toolbar to output NC Code


Select the required items for output and specify the file name, click output now and output NC code.

Silhouette

Note : There is no provision for bevel cutting any Silhouette. A Silhouette is the result of cutting entities (lines and arcs) defined in a 2D drawing

that has been wrapped around the pipe. The user is responsible to ensure that the height of the drawing does not exceed

the girth of the selected pipe – the drawing is considered to be wrapped once only. This Component requires that the 2D drawing has been processed through the

companion software FastCAM, (a powerful 2D drawing editor, among other

things), It also requires that drawing entities comprising the Silhouette have been

pre-pathed by FastCAM before being transferred into Silhouette, which then must

re-path them. The reasons for requiring pre-pathing in FastCAM are two-fold. First, to distinguish drawing entities that are required to be cut by Silhouette from

any others (un-pathed) that may continue to exist in the FastCAM drawing

definition, which may itself have originally been prepared as a DXF or similar file in

a separate CAD system


Second, to add any entry cuts that may be required for off-line piercing in

Silhouette and are best defined by the user. (Exit cuts, if included in any path, are

omitted by Silhouette.) The reason for Silhouette needing to re-path the entities lies in the presumed lack

of circular interpolation in all machines. All circles and arcs must be redefined as a

series of straight lines. The basic rules recommended for drawing preparation and pathing in FastCAM are

Any number (except 0) of individually defined open or closed paths may be

defined Minimize the use of straight lines, especially short lines or chains of

contiguous parallel lines which are best replaced with the longest possible

line. (Silhouette will not consolidate such chains, but will cut every line as

presented in so far as it is possible to do so.) Maximize the use of arcs. Do not break down arcs into faceted lines. Do use

FastCAM‟s splining and fairing facilities when appropriate to convert chains

of line entities into arcs. (Silhouette will convert arcs into faceted

approximations in as fine a detail as it can reasonably handle.) Add entries to paths where required.

Closed paths are defined as paths whose end point connects with the end of the

last defined entry entity (if any), otherwise with the start of the first entity defined

for that path. Closed paths thus cut holes, and it expected that entries (if any) will be cut from

the pierce in the scrap internal to the hole. It is the user‟s responsibility to ensure

this is so. Silhouette does not check or modify any entry entities This assumes that the material cut from the hole will become scrap, which need

not necessarily be the case – pre-curved parts could be cut from the wall of the

pipe, which is then scrapped. In such a case, the entry may be placed external to

the part, and the kerf offset applied in the opposite direction. The user is

responsible to ensure that both entries and kerf offsets are correctly specified

when pathing in FastCAM. Any non-closed path is obviously open and will be cut as a slit from pierce at start

of the first entity, whether or not defined as an entry, to end of the last entity. Silhouette assumes without checking that every path is separate and independent

from every other path, and does not check whether or not the tool would be

currently cutting in scrap that is present, or in scrap that has already been parted.

(One of the purposes of pre-pathing in FastCAM is to eliminate such possibilities.) Drawing data can be introduced to Silhouette using either of two methods Method 1 Browse for a FastCAM file (.CAM extension), then open it in the File Open dialog

that is raised when the Browse button was pressed. If the file so opened is a valid FastCAM file and has at least one path and one

pathed entity defined within it, it will automatically replace any current Silhouette

drawing data. If Silhouette then determines on further analysis that the incoming


data is insufficient or is in error, a warning will be issued and no useful data will be

available. Once file data has been read as above and proved acceptable, that data is

embedded in Silhouette, and may be saved with remaining Joint Detail, Pipe and

other data via FP‟s File-Save menu. A FastCAM file in its own right cannot be embedded into Silhouette through

opening it under FPs File-Open menu. Only drawing data embedded in Silhouette

when it was saved may be accessed in this manner. Method 2 Open FastCAM by pressing the FastCAM button. Any drawing data currently

embedded in Silhouette will be passed to FastCAM in a file named

FP_SILHOUETTE_TEMP.CAM in the FP folder, and FastCAM will display that data, if

any. Any data so transferred may be edited, including being cleared and re-drawn,

replaced with data from a DXF file from elsewhere, etc. Any data so edited may, (usually does), need to be re-pathed, and must be

resaved in the file FP_SILHOUETTE_TEMP.CAM in the FP folder. When FastCAM is

closed by the user, those saved changes will be transferred back to Silhouette and

will replace any embedded drawing data that previously existed. If FastCAM is closed without any changes having been saved as above, then the

embedded Silhouette data will remain unchanged regardless of its status. Data re-embedded in this way must be re-saved under the FP File-Save menu. The file FP_SILHOUETTE_TEMP.CAM is a temporary file whose contents will endure

only until the time of its next use.

Example 4: Silhouette Cutting

(As per the diagram, a drawing file is to be added to a PIPE with dimensions 360mm diameter, thickness 7mm. In the drawing, center circle 30mm, above circle at 90 degrees is

80mm, Chamfer Rectangle at 135degrees has a offset to shift it up by 45mm,

Rectangle has length and width, 40mm x 28.51 mm. The chamfer has radius of

8mm, part to part distance between rectangles is 3mm, the upper circle has

vertical offset distance of 30mm, from this vertical line it is 410mm to end of the

pipe. The total cut length is 2410mm.)


Analysis: As per the requirements, the shape is to be cut on the pipe. All the data is taken

from the customers drawing. To begin we will obtain the drawing‟s flat pattern (using AutoCAD to design) 1. Start AutoCAD, copy 2 sets of perpendicular straight lines, using offset move move the x

position by 360mm. Then again move another 510mm from this position

Following specifications, the length of the pipe calculates to 1131.12mm ( the diameter for the pipe is very close to 3.142). The following is then calculated: length at 90° is 282.78 (pi / 4), length at 45° is 141.39. Following the drawing arrives at the diagram below


Save this file．

2. Open FastCAM software, Read in the previously saved drawing file (remove labels and reference lines)

In order to cut these shapes on the pipe, we need to set the entries and exits internal to the shapes. Run FastPATH settings, set to contours, also set internal entry/exit to straight lines 10mm. (this value is based on the hole size and pipe diameter and thickness). Set to break longest entity. Set center pierces as 15.1 to provide best case resolution for small holes. Set the entry position to bottom right


Save FastPATH after completing settings, add a large rectangle that surrounds every

part, this will serve as a plate for pathing purposes


Add NC path. Then remove the large rectangle and save it as a CAM file．

3、Run FastPIPE, select the silhouette module and enter the relevant data

On the right area click on this button, in the popup dialog choose the pathed CAM file we saved in 2

Explanation: when the cam file does not meet the requirements, message will appear to indicate this If the file cannot be added, then the CAM file needs to be checked for correctness

4、 Through this diagram the cutting can be observed for the pipe in 2D. In the bottom right

area hit the check below button, click the button to right to check the shapes for different segments



5、Click on the button on the toolbar to review NC Pattern

Through this view, you can see the result of drawing with wrap around.

Click close button in the bottom right to close




code

Example 5：Text silhouette on Pipe

Text cutting is not only prevalent in 2D cutting, it is also common in pipe cutting. FastPIPE software has the facilities to product pipe text cutting (including the ability to produce a vector drawing). This example is a step by step description of cutting text with FastCAM and FastPIPE.

1、Use FontGEN to create a drawing of the desired Text

Save the file as CAM or DXF

2、Use FastCAM to open this document, and Cad Clean and Compress the text file to improve the quality of the text file for cutting


and the block menu for features such as enlarge and rotate block to adjust properties for the text

3、Enter settings for Entry and Exits, and Constructs Menu items such as bridging or

insert gap to create bridges to hold center pieces of the holes in text (e.g to hold the middle the letter A, and the middle 2 sections of the letter B)

4、Use the Generate NC code feature to automatically add paths, but click on cancel when asked to output NC code. This leaves the path information on. E.g. save this as WENZI.CAM


5、Run FastPIP, select Silhouette module, and enter corresponding data into the

data tab Enter accordingly the text distance from the left as 300mm, total pipe length as

1000mm, pipe radius 260mm, thickness 6mm, click on button the right area and select the file (in this e.g. WENZI.CAM) from step 4

6、click ，you will get the cutting template of the texts


7、click output NC Code

R-Branch


This is the only FP Component whose branch may be anything except a pipe, and

whose branch element is not developed to a NC Program. NC output is confined entirely to the main, which may contain multiple

penetrations. See Arrayed Penetrations. The branch, which is of „rectircular‟ cross-section as defined in the Component

Library summary, is dissected into 72 linear intervals of approximately equal

length. There may be up to 3 different interval lengths involved, one length for the shorter

flat sides, one length for the longer flat sides, and one length for facets of the

radiused corners, of the general rectircular cross-section. R-Branch aims to provide maximum flexibility to the user, so permits some fairly

extreme cross-sectional shapes and sizes, as well as some extreme setouts of

branch relative to main. The following „rules‟ and restrictions must however apply. 1. The minimum permissible cross-sectional height or width is twice the wall

thickness of the main 2. The minimum permissible perimeter of the branch is approximately one

tenth of the main OD 3. Small corner radii may be specified for the filleted rectangle option, but

may result in omission of this detail, or use of a single linear entity across

the corner (arc replaced with its chord), depending on the balance of

lengths as described above. 4. The maximum permissible transverse dimension of the branch, after

application of any axial twist specified, equates with the ID of the main, at

which size no lateral offset of the branch axis is permitted. 5. The maximum permissible lateral offset of the branch axis is set to ensure

that no part of the branch cross-section can deviate from the main

centreline by more than the internal radius of the main. 6. Branch angle relative to main may lie in the range 15o to 165o.

There may be occasional difficulty with determining limits for a twisted filleted

rectangle with small corner radii. Initially, R-Branch will acknowledge the

requested radius and may determine that data complies with 4, 5 above. However,


when later converting the cross-sectional shape to 72 linear intervals the corner

may be omitted, and the overall width may then violate rules 4 or 5. In such

borderline cases, it is best to specify no corner radius. The schematic diagram adjacent to the setting out box shows only the enclosing

rectangle of the rectircle, so does not accurately depict compliance with or

violation of rules 4 or 5. Textual information issued in the Notes frame will warn of any such violation. The schematic is intended only to assist the user with „getting oriented‟ while

entering data. This is one component where a stratagem of „creeping up on the

problem‟ can be useful – start small and gradually increase data values until the

desired result is obtained. The 3D view (left click the schematic) will show a more accurate view of the joint

than does the schematic. Under Pathing, differences in treatment of transitional and non-transitional

portions of tool paths were discussed. Transitions in the form of re-entrant corners will occur in R-Branch in the following

situations

Regardless of cross-sectional shape, branch size or lateral offset is at the

rule 4 or 5 limit Regardless of the foregoing, the cross-sectional shape is a rectangle, or

filleted rectangle from which R-Branch has omitted the fillet because its

chord length was too short. Flexibility provided in setting out allows for some very extreme situations to arise. As with all other Components, but perhaps most especially with this one, R-Branch

does not attempt to judge the practicality or otherwise of the user‟s data – it

simply does its best to comply. The user is expected to make a sensible choice of Joint Detail relative to branch

size, shape and setout. For example, expect R-Branch not to sensibly cut large

bevels in holes for small or narrow branches, or through extreme re-entrant

transitions. With or without a formal re-entrant corner, the rectircular path in the wall of the

main can acquire some very concave portions. A „w = t‟ choice of Joint Detail may

be found to be more appropriate here then any other, and particularly for Type 2

machines The lack of facility to specify a branch wall thickness allows R-Branch to handle

various actual cross-sectional shapes that need not be concentric, and need not be

of constant wall thickness. Example : an extruded aluminium rectangular (outside)

profile with an obround hole.

Example 6：Array holes in R branch

1. Run FastPPE from desktop, select R-branch from the desktop to enter the relevant dialogues


Select Set-IN and enter data in the data tab. (Note enter the flat pattern and internal measurement data with your requirements in minds, especially the distance between hole and centre of pipe).

After completing data entry, click on the diagram in bottom right area. Then close the new popup window, click the button for (holes on main pipe), again click on this button to set square holes.


Enter relevant settings into the yellow areas in the dialog Explanation:

Vertical number: represent the quantity for the same drawing to be arrayed vertically on the main pipe. Option 2 seperation angle: The difference between the vertical angle and the shape‟s angle, if it is flat pattern dimensions, to calculate theses data do the following (The vertical of the circles has a distance of (L) x 360) / (Pipe diameter and pi ????) Horizontal number: represent the quantity for the same drawing to be arrayed horizontally on the main pipe. Horizontal Distance: distance between center points of horizontal arrayed items.

As the above diagram the vertical amount is 2, the position difference on the pipe is 80 degrees. ( the flat distance is 159.56mm) horizontal amount is 5, the horizontal distance is 280mm. Click on the menu item, display -> NC sample.


This generate nc code (click on generate on the menu bar)

On the generate menu open the file and on this pipe it will cut 10 of the same holes.

F-Branch

In its most minimal form, F-Branch provides a simple square cut end, which can be

used in Mix and Match options with other Components. „Optional extras‟ are then a mitre cut, plus one or two pairs of slots. The mitre cut derives from the branch angle, which may range from 15° to 165° Slots are presumed to be for the purpose of fitting around one or two reinforcing

plates, and are dimensioned on the same basis as that on which such plates are

normally detailed. No wrap-around or NC program is prepared for the base plane, but a small „patch‟

of the base plane in the immediate vicinity of the branch is shown in the 3D

Display.


Example 7：F-Branch usage

According to the Diagram, a pipe‟s diameter is 160mm, thickness 10mm, length

1000mm, compensation plate‟s height is 80mm. thickness 12mm

1、select F branch

Choose Far in the popup form，click ok

2、According to the above data, the F Branch pipe‟s data has been entered as per the

requirements


When the data have all been entered correctly, in the right area a diagram will be generated, click on the diagram to see a 3D part

On the right area click on the different buttons to get different view of the part, and click on default to see the shape in 3D


3、Click on the button on the toolbar to review NC Pattern.


4、Click on the button on the toolbar to output NC Code

Note: This model can only allow 2 compensation pate, in the shape of a cross

C-Branch


The branch angle may range from 15° to 165°. Branch lateral offset is limited to prevent the outside of the branch projecting

beyond the boundaries defined by the main OD. Slots are presumed to be for the purpose of fitting around an in-plane reinforcing

plate, and are dimensioned on the same basis as that on which such plates are

normally detailed. Slots are not optional. If an unslotted version of the detail is required, it can be

produced using P-Branch. Only a Set-On detail is provided for, since this is essentially a structural detail. A wrap-around is provided for the main and may be used as an aid to marking-out

for assembly. No cutting path is shown on the main wrap-around, and there is no

NC program for profiling a hole in the main.

Example 8：C branch with slot

As the above diagram, there‟s a branch pipe on a main pipe, the angle is 45 degrees. On the branch pipe there is a compensation plate, the data for the main pipe and branch pipe are respectively: diameter: 180mm, 120mm, thickness: 12mm, 8mm, length: 1000mm, the compensation plate thickness is 15mm, height is 100mm


1、Select C Branch

Select Far in the popup form, and click enter.

2、Type the information in task tab and input Data as below

After input the data, in the right hand area will show the diagram. Click it will show

3D parts.


view (bevel face). It is also possible to change the view angle position of the pipes.


Hint: if you want to view a specific area of the diagram, you can click and drag over an area to zoom in

and out.


3、 Click on the button on the toolbar to review NC Pattern

4、Click on the button on the toolbar to output NC Code


Click output now, will popup :

Click output now, will show the post form.

select the path that you want to output, and give the bevel angle that you

want to add as extra. As above, the NC output will only have one end cut.

Note: In this model it is possible to set offset and twist between main pipe and branch pipe

E-BranchIP


The branch of this Component is confined to lie in the centreline plane of the

forged elbow. Branch OD may not exceed Elbow cross-section OD for either a Set-On or Set-In

detail. The default in-plane branch offset of 0 places the branch centreline along the

elbow centreline tangent line. The in-plane offset in the –X direction is specified as a negative amount and may

take the branch centreline as far as the centre of the elbow, but no further. If both elbow and branch pipe are of the same size and wall thickness, then no

in-plane offset in the +X direction is permitted. If the elbow OD is larger than the branch OD, then +X offset is limited to prevent

branch OD lying outside the elbow outer tangent line. Subject to the above limits, a Set-On branch profile can always be developed in

theory for any desired Joint Detail. However, when the branch OD and / or the set

out is at an extreme limit, the dihedral angle is 180o in the areas where the limits

apply. Some difficulty with bevel offset may be experienced in pathing around

these areas, and a „w=t‟ Joint Detail choice may be found to be more appropriate. The Set-In branch profile can always be theoretically developed for any desired

Joint Detail provided the branch OD does not exceed the elbow ID. However for larger branches with OD up to and including elbow OD, the branch

profile solution becomes more problematical. Such „Problem Cases‟ are handled by E-BranchIP in the same manner as described

for P-Branch, even though the E-BranchIP „main‟ is a torus while the P-Branch

main is a cylinder. The existence of a „Problem Case‟ is apparent when E-BranchIP presets the weld

face angle for the Joint Detail to 0, and that data cell is disabled. See P-Branch for further details, discussion and recommendations concerning the

„Problem Case‟ Set-In detail All that differs in principle is the fact that the E-BranchIP „main‟ has no

wrap-around or NC program since FP v2.x has no support for the general robotic


device that would be needed to hole the torus. P-Branch, on the other hand, does

cut the main hole. The 3D display shows a small surface „patch‟ of the torus in the vicinity of the pipe

intersection. Since no hole can be cut in the torus, no hole is depicted.

Example 9：welding 3 intersecting pipes

A petroleum piping manufacturer company needs to process a bend pipe with 3 penetration, the bend has a radius of 800mm, the end of the bend has diameter 300mm, thick 12mm, branch pipe‟s external diameter is 160mm, thickness 10mm, The rest of the data are as per diagram

1、Select E Branch module

Click Far and click enter, and then choose set in, Far get in the data input interface.

2、Type in the data in the E branch as following


Click on the 3D structural diagram, on the middle of the right side of the screen


3. Click on the button on the toolbar to review NC Pattern.



Click output now, will show the post form.



P-Branch

The branch angle may range from 15° to 165°. The main may contain multiple penetrations. See Arrayed Penetrations. Branch lateral offset is limited to prevent the outside of the branch projecting

beyond the boundaries defined by the main OD for both Set-On and Set-In

details. Using |e| to denote the magnitude of the lateral offset in either + or – direction,

Rib, Rob to denote inside and outside radii of the branch, and Rim, Rom to denote

inside and outside radii of the main, then the above limit can be expressed as |e| + Rob <= Rom Provided the lateral offset and branch OD combined are within the main ID area, |e| + Rob <= Rim


then both Set-In and Set-On details are developed normally. However, at the |e| + Rob = Rim limit for a Set-In detail, and bearing in mind that the weld root height w is defined

in the thickness of the main, a „w=0‟ Joint Detail choice involves a dihedral angle

of 180°. This may lead to difficulty in pathing around the re-entrant transitions

that then appear in the main hole. Beyond the above limit, scenarios vary … The Set-On branch profile is developed normally right up to the ultimate limit |e|

+ Rob = Rom, at which point a protruding corner transition appears at the „cheek‟

point on the side of the branch for a „w=t‟ (branch) Joint Detail. For w < t, no

transition appears, although the dihedral angle will be close to 180o, and pathing

may start to show signs of difficulty. The main penetration for a Set-On branch, which is essentially an extension of the

branch bore, presents no problems until |e| + Rib > Rim. Beyond this limit, the hole in the „cheek‟ area would start to cut through the wall of

the main below the intersection. P-Branch then truncates the main hole at vertical

planes tangent to the main inside surface. Because the dihedral angle can be very

high, the resultant bevel angle may exceed the machine capacity, and the actual

hole as profiled may taper and require final grinding to shape. This is particularly

true for a Type 2 machine. The Set-In branch detail presents special problems, hence is designated the

„Problem Case‟, whenever Rim < |e| + Rob <= Rom The problem is visualized most clearly when both branch and main have identical

diameters and thicknesses, (so |e| = 0) in a simple T setout with branch angle at

90o. Bear in mind the definition of the Set-In detail – the branch is profiled without any

weld preparation to sit flush with the inside of the main, while the main is prepared

for welding at the specified face angle back from the branch tangent plane. In a cross-section taken through the crown of the joint where the dihedral angle is

90o, this detail seems quite clear. However, in a cross-section taken through the „cheek‟ area where the setting out

Y axis intersect both the branch and the main, the detail is much less clear. The

dihedral angle here is 180° and the bevel cut through the main wall would be made

in an area that can ultimately only be occupied by the branch. In the extreme, if Joint Details specified w = 0, g = 0, then the cut through the

crown of the main would be vertical (radial), and the cut through the cheek area

would also be vertical, but down a tangent to the inside of the main. It is not uncommon to see weld details for such a joint called up on manufacturing

drawings which are, at best, a hybrid between Set-In and Set-On, not applying

either concept consistently but varying it around the periphery of the joint.


The sharp re-entrant corners in the main penetration are also not considered

favourable to high quality work, and are often shown rounded-off in a free-hand

manner, hence do not comply with any particular mathematical derivation or

development. FP is not structured to handle such variable detail – whatever is done is applied

consistently over the entire joint periphery. The solution adopted by P-Branch, (which also applies in similar circumstances to

E-BranchIP) derives from observations made in Y-Piece concerning the crotch

planes. P-Branch in the sample setout defined above is the direct equivalent of a Y-Piece,

and when both the branch and main are cut along the two common crotch planes

with no weld preparation, they will assemble perfectly. This is the equivalent of cutting the bevel at an angle that bisects the dihedral

angle, omitting any weld face angle, and is the solution offered by FP to solve

„Problem Cases‟ Problem cases exist at any branch angle, and when |e| is non-zero. The same

solution is adopted in all such cases. All weld preparations must then be formed

using a secondary process such as grinding. A Problem Case is indicated when P-Branch presets the Joint Detail weld face angle

to zero and its data cell is disabled. While the solution offered may be less than perfect, neither are any other available

options. Fortunately, there are a number of work-arounds available to the user

ranging between sublime and ridiculous which need not be mentioned here. The most practical of all work-arounds is – don‟t do it! Use the Set-On detail in lieu.

Arrayed Penetrations


The terms „penetration‟ and „hole‟ may be used interchangeably. Component Silhouette defines penetrations in a main. Those penetrations can be

arrayed externally from FP using FastCAM facilities. Any array of penetrations is

treated by FP as a single Silhouette, and the silhouette itself may not be further

arrayed in FP. Components R-Branch and P-Branch which define also penetrations in a main

have an Array option for those penetrations. The single penetration defined with the Component setting out provides an anchor

point, or corner, for a regular array of identical penetrations Columns of penetrations are located around the pipe girth, separated

longitudinally by a specified distance. Odd numbered columns all have equal numbers of penetrations with specified

separation of degrees in sweep around the girth. Even numbered columns may have the same number of penetrations as odd

numbered columns, or one more, or one less. Girth-wise spacing is the same as for

odd numbered columns, but a girth-wise offset may be specified, again in degrees. FP undertakes some basic checking of separations between penetrations, but the

final responsibility for this is left with the user. When the NC Pattern is displayed, both root path and tool surface path, plus pierce

point, etc, are shown for the „anchor‟ penetration. All other penetrations are shown

by their root paths only.

Example 10：Generate multiple branch pipes at different positions.


A liquid manufacture corporation needs to process a batch of pipelines as per the diagram. Main pipe diameter is 200mm, thickness is 12mm, branch pipe‟s diameter is 120mm, thickness is 8mm, main pipe and branch pipe makes 70 degree separation, from one end of the main pipe to the first branch pipe‟s center is 1300mm, each branch pipe‟s center are 1000mm apart. Main pipe length is 5000mm, each branch pipe is 800mm

1、Choose P-branch

In the dialog that appears, select Far, and click enter, choose setin and get in the data form

2、Type the information in task tab and input Data as below


In the upper right location on the display, it is possible to view the diagram in 3D view


3、click array button in form will popup the following form.


According to the above data, enter data as per the requirements

4. Click on the button on the toolbar to review NC Pattern

Click in the bottom right, then will see 4 holes.

5. Click on the button on the toolbar to review wrap around


In the Wrap-Around of cutting, show only one hole.


Click output now, will popup nc output f




Truss panel

M branch

This is a common structure. The supporting pipe can be a round pipe, flat plate, and other long

products.

This structure is quite simple, enter the assembly sequence and each branch pipe’s first intersecting

angle and this structure can be defined

When entering angles, keep in mind positive values are counter clockwise from the origin.

Horizontal to the right is 0 degrees, take this as the origin and add the individual angles to get the

absolute angle from 0 degrees.

Once all the required data are entered, a diagram of the structure is presented on the right of

the screen. Click on it to create a file with this naming structure FPxFF.FFD. This .FFD file is

automatically saved to FastPipe’s Folder. Typcially this is C:\Program Files\FastPIPE.

NOTE: After editing data or defining a new model, the FPxFF.FFD file will be overwritten.

When there’s a need to retain the data in FPxFF.FFD, copies of it should be made elsewhere in your file

system.

In order to generate the NC code for this model, use the item ‘generate pipe nc’ in FRAME.

Example 11: Simple pipe PLATE intersection.

A steel structure company requires a 3 branch pipes to intersect with a rectangular main pipe.

The dimensions are:

Rectangular Mainpipe: 1600x400x20

Branch Pipes lengths : 120x8, 150x10, 130x10.

Angle of intersection for each pipes is 45 degrees apart. Branch pipe of length 150x10 is to be the

central branch pipe.

Analyse: Following the above description. We can use a model within FastPIPE.

1. Run the FastPIPE software, and select 3 branch pipe intersection to launch the corresponding

Dialog.


Fill out the details in the Job tab for records, and then click on the Data Tab and enter the related pipe

data and structural data

For each of OA,OB,OC enter data as 120x8/150x10/130x10 with options RHS (When using round pipe

choose CHS), Enter height and width as 20 and 400

Branch pipe OA 、OB、OC lengths are : 1M

Branch pipe OA and ON angle: 45

Branch pipe OA and OB angle: 90

Branch pipe OD and OC angle: 135

Branch pipe OD and OM angle: 180

OM and ON lengths as 800mm

Assembly sequence CBA is the correct choice for this case.

If this is not variable bevel cutting, then it is not required to set SOMETHING. If this is setting

for variable bevel cutting, it is necessary to select the SOMETHING on the weld preparation position,

as well as the bevel angle


2. Click on the 2D structural diagram, on the middle of the right side of the screen.

3. Run the FastFRAME software. From File, open, in the dialog select FPxFF.FFD file in the

folder C:\Program Files\FastPIPE

4. On the toolbar click on the display nodes (3D) structure.

In the upper right location on the display, it is possible to view the diagram in 3D view and U view

(bevel face). It is also possible to change the view angle position of the pipes.

Hint: if you want to view a specific area of the diagram, you can click and drag over an area to

zoom in and out.


5. Click on the display manual setting button on the tool bar


This shows each branch pipes’cutting diagram(2d), in the bottom left area each branch pipe can be


branch pipe’s length.

In the bottom right area click on the close button to close this dialog 6. Click on the NC model button on the toolbar to review NC model

On the bottom right click on the close button to close this dialog

7.click on the Shortcut button to display a list of NC cutting to see the pipe cutting

information.

8. click the button on the toolbar to generate NC code


Select the required items for output and specify the file name, path ( in this example only nc

output has been selected, other items will not be output), click on output now and a new dialog will

appear. Select the required output for cutting end and pipe bevel angle. Next, click on the output NC

button

N Type pipe frame

This result appears often for many type of supporting structure, and it is a common structure.

The main pipe construction can generally be rectangular pipe and flat plate Practical example 12: cutting a support structure

Practical example 12: cutting a support structure


Displayed in this diagram is a beam support structure. Main pipe is a 260x12, branch pipes are

140x8, where we are required to construct the structure inside the box. The left vertical branch/support

pipe has length 800mm, right vertical branch/support pipe has length 1300mm, the 2 vertical pipes are

1600mm apart.

1、Start FastPIPE software, choose N type support pipe to open the corresponding dialog.




Select the assembly sequence deabh. Given the correct data has been entered, a structural

diagram will be presented in the bottom right area. Click on this diagram to enter structural view

If

If this is not variable bevel cutting, then it is not required to set SOMETHING. If this is setting



2. Run the FastFRAME software. From File, open, in the dialog select FPxFF.FFD file in the folder

C:\ProgramFiles\FastPIPE

3. Click on the shortcut for verify structure to review the status for the entire structure.

4、On the toolbar click on the display nodes (3D) structure.


view (bevel face). It is also possible to change the view angle position of the pipes Hint: if you want to view a specific area of the diagram, you can click and drag over an area to

zoom in and out.







In the bottom right area click on the close button to close this dialog.

6. Click on the NC model button on the toolbar to review NC model



7. click on the Shortcut button to display a list of NC cutting to see the pipe cutting information.


Select the required items for output and specify the file name, path ( in this example only nc output has

been selected, other items will not be output), click on output now and a new dialog will appear. Select

the required output for cutting end and pipe bevel angle. Next, click on the output NC button.

W Type pipe frame.


The main pipe construction can generally be rectangular pipe and flat plate.

Practical example 1: a warehouse roof’s load-bearing beam structure


This diagram shows a warehouse roof’s load-bearing beam structure, main pipe as 260 x 16,

branch pipe as 130 x 12. The two branch pipe’s distance is 2800mm. Main pipe distances is 1000mm

Analysis: Following the diagram, this is a structure the requires only SOMETHING.

Therefore, we can select W type pipe for cutting this item. In W type pipe it defines a branch pipe

sections’ end to end length, as the full distance between a pair of connected branch pipe is 2800mm, 1

pipe’s section length should be 1400mm.

1、Start FastPIPE software, choose W type support pipe to open the corresponding dialog



Assembly sequence CEJ is the correct choice for this case, If this is not variable bevel cutting,

then it is not required to set SOMETHING. If this is setting for variable bevel cutting, it is necessary to


select the SOMETHING on the weld preparation position, as well as the bevel angle If this is not variable bevel cutting, then it is not required to set SOMETHING. If this is setting


as well as the bevel angle.

2、Run the FastFRAME software. From File, open, in the dialog select FPxFF.FFD file in the


3、Click on the shortcut for verify structure to review the status for the entire structure





zoom in and out.







In the bottom right area click on the close button to close this dialog




7. .click on the Shortcut button to display a list of NC cutting to see the pipe cutting information.




the required output for cutting end and pipe bevel angle. Next, click on the output NC button


M Type pipe frame


The main pipe construction can generally be rectangular pipe and flat plate.

Example 14: Another type of ware house load supporting beam structure.

This diagram shows a warehouse roof’s load-bearing beam structure, main pipe as 260 x 16,

branch pipe as 130 x 12. The two branch pipe’s distance is 2800mm

Analysis: Following the diagram, this is a structure the requires only SOMETHING. Therefore,

we can select W type pipe for cutting this item. In W type pipe it defines a branch pipe sections’ end to

end length, as the full distance between a pair of connected branch pipe is 2800mm, 1 pipe’s section

length should be 1400mm.

1、Run the FastPIPE software, and select M branch pipe intersection to launch the

corresponding Dialog.




Assembly sequence CAEBJ is the correct choice for this case, Select the assembly sequence

deabh. Given the correct data has been entered, a structural diagram will be presented in the bottom

right area. Click on this diagram to enter structural view If this is not variable bevel cutting, then it is not required to set SOMETHING. If this is setting






3、Click on the shortcut for verify structure to review the status for the entire structure.





zoom in and out.






branch pipe’s length. In the bottom right area click on the close button to close this dialog,



7. click on the Shortcut button to display a list of NC cutting to see the pipe cutting information.






button

Example 15: Working with Pipes from CAD Drawings..

通 Taking the Data from the drawing, Off the middle of the Main pipe (vertical): W-524(219x8),


the branch pipes (horizontal) are 83x4 (The drawing labels these as W-428/W-431/W-431), the

diagonally pipes are W-105(133X4.5)、W-108(133x4.5)、W-370(102x4.5)，The vertical Branch Pipe

has length 3998mm, diagonal W-108 has length 6278mm.

Analysis: Inspecting the CAD file, this is design and construction drawing for a Pipe structure.

According to this structure, it follows the M type pipe frame structure. Because the diagonal pipe

length is 6278mm, we can calculate the 2 vertical pipe to be made has a distance of 4664mm between

their centre point.

Steps:

1、Start FastPIPE software, choose N type support pipe to open the corresponding dialog



Assembly sequence CAEBJ is the correct choice for this case, Select the assembly sequence

deabh. Given the correct data has been entered, a structural diagram will be presented in the bottom

right area. Click on this diagram to enter structural view、 If this is not variable bevel cutting, then it is not required to set SOMETHING. If this is setting







4、Click on the close button on lower right location to close the diagram interface


view (bevel face). It is also possible to change the view angle position of the pipes.

Hint: if you want to view a specific area of the diagram, you can click and drag over an area to zoom in

and out.



5、 Click on the display manual setting button on the tool bar



branch pipe’s length. In the bottom right area click on the close button to close this dialog

6、 Click on the NC model button on the toolbar to review NC model


7、 click on the Shortcut button to display a list of NC cutting to see the pipe cutting

information.

8、 click the button on the toolbar to generate NC code





X Type pipe frame


The main pipe construction can generally be rectangular pipe and flat plate

Example 16: Holiday House Balcony Fencing

This diagram shows a warehouse roof’s load-bearing beam structure, main pipe as 48x5,

branch pipe as36x3. The two branch pipe’s distance is1100mm

1、Run the FastPIPE software, and select X branch pipe intersection to launch the


corresponding Dialog


data and structural data.

Assembly sequence ADCBEFGHJ is the correct choice for this case, Select the assembly

sequence deabh. Given the correct data has been entered, a structural diagram will be presented in the

bottom right area. Click on this diagram to enter structural view、 If this is not variable bevel cutting, then it is not required to set SOMETHING. If this is setting









view (bevel face). It is also possible to change the view angle position of the pipes. Hint: if you want to view a specific area of the diagram, you can click and drag over an area to

zoom in and out.






branch pipe’s length. In the bottom right area click on the close button to close this dialog.

6、 Click on the NC model button on the toolbar to review NC model.

On the bottom right click on the close button to close this dialog.

7、 click on the Shortcut button to display a list of NC cutting to see the pipe cutting information.

8、 click the button on the toolbar to generate NC code.





button.

K Type pipe frame.

Example 17: Offshore Platform Structure

Displayed in this diagram is a beam support structure. Main pipe is a 360x25, branch pipes are

200x14, where we are required to construct the structure inside the box. The inclined vertical

branch/support pipe has length 800mm, the 2 vertical pipes are 5300mm apart


1、Start FastPIPE software, choose K type support pipe to open the corresponding

dialog.



Assembly sequence npakmb is the correct choice for this case. Select the assembly

sequence deabh. Given the correct data has been entered, a structural diagram will be presented in the

bottom right area. Click on this diagram to enter structural view、 If this is not variable bevel cutting, then it is not required to set SOMETHING. If this is setting










zoom in and out.


5、 Click on the display manual setting button on the tool bar.





In the bottom right area click on the close button to close this dialog,



7、 click on the Shortcut button to display a list of NC cutting to see the pipe cutting

information.






3 dimensional branch pipe structure - Model A

A simple construction of 2 Main Pipe intersecting with 1 branch pipe. This structure has the

widest range of application. It allows 2 main pipes in 2 different 2D planes.

Eample18 : a Simple Branchpipe

1、Start FastPIPE software, choose A type support pipe to open the corresponding dialog.




2、选择要存储的文件的保持路径和文件名后，保存后，系统自动会链接到FastFRAME

软件。

3、On the toolbar click on the display nodes (3D) structure In the upper right location on the display, it is possible to view the diagram in 3D view and U view




zoom in and out.














Model B

This is a relatively common structure model, the difference from Model A is this Model

requires the 2 main pipe to be in the same 2D plane.

Example 19 : Cutting horizontal branch pipes with reverse angles at 2 ends.


A Branch pipe intersects with 2 different Main Pipes. The Main Pipes are not cut, the Branch

Pipe is cut at both ends. The left end intersection is at 60 degrees, the right end is at 45 degrees. The

Main Pipes are: 320x16/380x18/250x10 Branch Pipe length is 2300mm

1. Start FastPIPE software, choose B type support pipe to open the corresponding dialog.

分别在选项框内输入相关管材数据和结构的数据。完成后点输出按钮

2.选择要存储的文件的保持路径和文件名后，保存后，系统自动会链接到FastFRAME

软件。


3. On the toolbar click on the display nodes (3D) structure. In the upper right location on the display, it is possible to view the diagram in 3D view and U view



zoom in and out.






branch pipe’s length. In the bottom right area click on the close button to close this dialog.


(在NC样板图示里，是含有坡口线与切割线的，故而可以呈现出一种立体的切割效果) On the bottom right click on the close button to close this dialog.





the required output for cutting end and pipe bevel angle. Next, click on the output NC button..

Model C

This is also a common pipe structure.2 branch pipe intersecting on a main pipe, the 2 branch

pipes are in the same 2D plane. Example 20: 2 pipes double intersection

2 branch pipe intersects with 2 different main pipes, the main pipes are not cut. 1 branch pipe

is cut at both ends, whilst another branch pipe is considered for intersection between branch pipes, and

is not cut. The branch pipe to be cut has the left end intersecting the main pipe at 60 degrees, with the

other branch pipe at 45 degrees, whilst the right end intersects another main pipe at 60 degrees. The

main pipe’s data are: 320x16,380x18, the branch pipe to be cut has length 2300mm, 230x12. The final

branch pipe is : 200x10

1．Run the FastPIPE software, and select C branch pipe intersection to launch the

corresponding Dialog





软件。





zoom in and out.





branch pipe’s length. In the bottom right area click on the close button to close this dialog







the required output for cutting end and pipe bevel angle. Next, click on the output NC button

Model D

Example 21: 3 pipes intersecting at the same node

In this pipe structure there are 3 branch pipes all intersecting a main pipe in one node. The

branch pipes are respectively, from left to right : 130x8、80x6、130x8. The vertical Main Pipe is of

175x10. The central Branch pipe has length 800mm, and intersects perpendicular to the Main Pipe, the

other two branch pipe each intersects the vertical branch pipe at 45 degrees.


1. Start FastPIPE software, choose D type support pipe to open the corresponding dialog




软件。


3. On the toolbar click on the display nodes (3D) structure



zoom in and out.















Model E

Another common pipe structure, 2 branch pipe intersects on another pipe, the 2 branch pipes

are in different 2D planes

Example 22: cutting pipes in different planes.

On the Main Pipe, 2 branch pipes intersects with it. Each of the branch pipe intersects at

different a plane to the main pipe. The branch pipes and main pipe diameter and thickness are


respectively 130x10、130x10、160x12, the branch pipe length are 1200mm, intersecting at 60 degrees.

1. Start FastPIPE software, choose E type support pipe to open the corresponding dialog.

分别在选项框内输入相关管材数据和结构的数据。完成后点输出按钮(根据图示，在单选项里

选择另外一端为平面切割)


软件。


3. On the toolbar click on the display nodes (3D) structure. In the upper right location on the display, it is possible to view the diagram in 3D view and U view



zoom in and out.













Model F

This is a type of structures 3 pipes with intersections at both ends, a cutting machines ‘s

something


Example 23: cutting construction drawing.

1. Start FastPIPE software, choose F type support pipe to open the corresponding dialog.

根据切割示意图，分别在选项框内输入相关管材数据和结构的数据。完成后点输出按钮

2. 选择要存储的文件的保持路径和文件名后，保存后，系统自动会链接到FastFRAME软

件。





zoom in and out.















Model G

This is model of multiple combinations. Given the correct settings and data, This can the

above model.

Example 24: A drawing of 3 pipes intersecting a main pipe spread along its

perimeter

A harbor equipment manufacturing company is required to process a harbor lifter’s main

support beam. The Main pipe 399x18 the Brach pipes 144x12, the branch pipes intersect along the

perimeter of the main pipe. The middle Branch pipe is perpendicular to the Main pipe. The left and

right branch pipes intersect the Main pipe at angles of 22.5 degrees. The branch pipe lengths are all

2600mm.

1. Start FastPIPE software, choose G type support pipe to open the corresponding dialog.


分别在选项框内输入相关管材数据和结构的数据。完成后点输出按钮

2．选择要存储的文件的保持路径和文件名后，保存后，系统自动会链接到FastFRAME

软件。


3. On the toolbar click on the display nodes (3D) structure. In the upper right location on the display, it is possible to view the diagram in 3D view and U


zoom in and out.






branch pipe’s length. In the bottom right area click on the close button to close this dialog,








Troubleshooting

Problem

When FastPIPE is started, a FastPIPE banner is seen, but then a message

"Operation not permitted by FastLOCK. Please check software versions

with FMS FastCAM" appears and FastPIPE will run no further Solution First check that the hardware lock issued with the software is properly plugged in

to a parallel printer port or USB port, depending on type supplied, then reboot the

computer. If the problem is not resolved, contact FastCAM or the software

supplier.

Problem

The Standard Plus NC Edition was bought, but only the Standard Edition

is indicated in the FastPIPE central control title bar. Solution There is probably an error in the FastFRAME.xml file. Check its contents against

Appendix A and try again. If unsuccessful, contact FastCAM or the software

supplier.

Problem The NC program patterns look weird! Solution Read the sections of this documentation on Machines and Pathing. Try cutting on

some scrap material – the result may not be weird.


FastFRAME

Features Summary and Concepts

FastFRAME solves complex intersections between members of space frameworks. Units of measure may be metric (mm) or imperial (inch or ft.inch).

All members are closed hollow sections and may be circular in cross-section. In certain restricted circumstances

(1), some members may be of rectangular cross-section. Some

members (termed dummies) may also be of nil cross-section dimension, and exist purely to assist in defining the geometric setting out. The framework is defined by a set of nodes (points of NO Displacement), with members connecting generally between them. One of the features of FastFRAME that distinguishes it, and differentiates it from other software, is that it uses 'natural‟ setting out information – node coordinates. It does not need to be told a hard-to-calculate set of angles and offsets – it will tell you what they are! Members may be straight between pairs of nodes, or may be cranked (miter cut and joined) at an intermediate node, or may, with some qualification

(2) be curved to form circular arcs

between the two end nodes and an intermediate node. The assembly sequence of all members at each node is required to be defined, assuming that a certain amount of production planning has already occurred before start of data entry. Intersection points (IP‟s) between the longitudinal axes of members may be relocated away from nodes in order to eliminate, or to promote a desired degree of, overlap between members at nodes.

A variety of weld preparations is available, and may be applied individually to all member ends. The selection of weld preps. includes the butt-fillet combination in which simple radial cutting removes sufficient material to facilitate instant assembly for maximum fabrication productivity. The converse of this may also be selected - radial cutting leaves maximum material thereby necessitating secondary metal removal prior to assembly, but can be adapted to any desired weld detail including full and partial penetration details having variable weld face and groove angle, such as is required by AWS, CIDECT etc. specifications in very acute crotch angle applications.


Finally, there exists a family of details having effectively a constant weld face, varying from zero for full penetration external butt weld, up to a full wall thickness at a rather impractical opposite extreme. A constant groove angle may also be defined. Output is available for most

(3) members of the framework, and is issued in a number of forms

as follows …

Wrap-around templates

These are an outside-up development of the surface of a complete circular cross-section member. They may be plotted using FastCAM

(4) or any suitable CAD program reading

FastFRAME‟s .DXF output, or may be converted to NC code for any of a number of pipe profiling machines supported by FastCAM. FastFRAME provides for full scale and compressed-length templates depending on requirements of the processing / plotting machinery. For cranked members, the template can include the cut at the midnode, when one end will be pre-rotated 180 degrees to facilitate pre-nested cutting prior to joining at the miter.

Cutting List

This appears in tabular (spread-sheet style) format which may be printed, and / or copied to system clipboard, and / or output as a comma-separated-variable (CSV) text file. It contains dimensional, setting out and reference information for the templates.

Cutting Parameters

A variety of parameters are available in a narrative-style text file which may be printed and / or output as a CSV file. The format is KEYWORD, Data [,Ref.Data] for each parameter in a number of cutting paths at each end of each circular cross-section member, thereby facilitating post-processing to a form suitable for automatic or manual data entry to a number of different types of pipe profiling machine. Note that whereas many pipe profiling machines contain „canned‟ cycles for cutting predefined pipe intersections with other pipes or planes, and require the intersections data to be input parametrically as angles and offsets, FastFRAME takes the more natural node setting out data as input, and generates typical parametric data as output. Footnotes : (1) Rectangular cross section members may be Chords or Mains passing through a node, but may not otherwise or also be Branches to or from a node. The sides of rectangular cross-section members are required to lie in a vertical plane, their being no facility to define axial „twist‟. Circular cross-section members may thus be developed against rectangular cross-section members, but the latter are not developed. (2) Members specified to be circular arcs are treated as though they were locally straight in the vicinity of each node. For end profiling after curving (the only practical method) the


approximation is usually reasonable. However, the approximation may be less reasonable when a branch is developed to a curved main, and the user is responsible for this decision. Further, FastFRAME does not check whether or not a sequence of mains comprising a chord are all coplanar. Nor does it check whether all would have the same radius of curvature. (3) No output is issued for any rectangular cross-section member, and no output is issued for mains. To the extent that a Chord comprises a set of overlapping mains (see later), any Chords that are defined (other than circular arcs) are developed in segments between nodes. (4) FastCAM, the software, is a powerful set of facilities for preparing, reading, cleansing, editing, plotting and saving drawing information, defining paths for CNC machine operations, then converting the path information to NC code. Several dozen generic CNC makes and models fitted to a veritable host of different cutting machine manufacturers‟ adaptations of them, are supported. FastCAM Inc. and FastCAM Pty. Ltd., the corporations, author and own suites of software bearing the „Fast‟ designation, and others.

Please be our guests at www.fastcam.com.au

History

The FastFRAME concept was informally developed in the early 1980‟s by the author who was at that time Chief Engineer for a steel fabrication and construction contractor based in Melbourne, Australia. The initial impetus was a contract for construction of the moving roofs of what is now known as Rod Laver Stadium, the well-known host facility for the Australian Tennis Open. Production technique initially used paper wrap-arounds to mark the ends of members which were manually cut in a radial direction. Later, more repetitive, production saw the wrap-arounds fitted to a rotating mandrel coupled via welding manipulation equipment to the workpiece, and a photocell following the template driving the cutting torch longitudinal movement. Circular arch members within the roof were always precurved and manually marked and cut. The first formal FastFRAME software (v1.0) was written in 1988 for Fagan Microprocessor Systems Pty. Ltd., developers and owners of the FastCAM suite of software products. It was confined to all-circular members with all IP‟s at nodes, and ran on a PC under DOS with some fairly severe memory limitations which curtailed the sizes of frameworks which could be handled. Later versions expanded these limits, added the IP move facility, then added rectangular section mains, culminating in v1.3, handling up to 40 nodes and 80 members. FastFRAME v1.x has enjoyed a high degree of success with a number of steelwork detailers and fabricators. Some major Australian structures which have been built with the assistance of FastFRAME are numerous towers, masts and spires on Melbourne buildings, roofs of the Melbourne Cricket Ground Southern Stand and Colonial Stadium, both fixed and movable roofs, plus more recently roofing for the Sydney 2000 Olympic main stadium. Typical componentry in these structures is steel pipe from 2” NPS to 24” NPS, wall thickness up to 1”


or more. On a more micro level, FastFRAME v1.x and FastCAM is used by North American Cutting Systems Inc. of California to prepare NC code for their most recently developed TUBE PRO HD Plasma profiling machine, cutting airframe components for Univair Aircraft Corporation of Colorado. Typical componentry here is 5/8” x .05” wall tubing. The FastFRAME v1.x data file format has loaned itself well to external preparation by detailing offices, and AutoCAD procedures have been written by some users to prepare the data. After development in FastFRAME, the DXF or CAM templates have then been edited for documentation and incorporation of other details such as slots for connection plates.

What’s New ?

FastFRAME v2.0 for Windows retains almost all the features of v1.x, and adds many new ones aimed at improving user-friendliness. A number of old frustrations (that really weren‟t frustrating when we were all accustomed to DOS, but became so as we all adjusted our expectations with Windows), have thereby disappeared at last ! Spread-sheet style editing, including system clipboard cut, paste, copy etc. is now available for the principal data entry tables, plus CSV file importation for individual tables. Framework size is no longer limited to 40 nodes, 80 members. Final size that can be handled is a function of Windows resources limits, and has not yet (December 2000) been ascertained. The limits are believed to be far larger than any practical framework would require, however, it is recommended that individual frames within a structure be compartmentalized as far as possible, principally because of the problem of managing large volumes of data, particularly those associated with node assembly sequences.

The number of branches per node has been increased from 6 to 12 to accommodate odd cases as needed. FastFRAME still retains the original right-handed X=east, Y=north, Z=up axis system, however node coordinates specified in A,B,C columns may be reassigned at any time to + or – any axis. Thus the framework may be rotated within a set of fixed axes, and may also be deliberately (or inadvertently !) opposite handed. New weld prep details are now available, and may be individually applied to each end of every member. Chords definition has been added, together with a „mains generator‟. One of the less friendly aspects of v1.x was the need to multiply define chords as mains without ever defining or developing the chord itself. Chords development was formerly undertaken with PipeRun or Penstock from the FastSHAPES suite of programs. This is no longer necessary, so we have effectively two programs now packaged in one.


(Briefly, a Chord is a member passing continuously through a number of nodes, say A,B,C,D and E. Both v1.x and v2.0 require that mains be defined as A-B-C, B-C-D and C-D-E. These are „developed‟ for purposes of displaying nodes in a 3D view, but are of limited practical use otherwise. FastFRAME v2.0 does not issue output for them, but provided the chord was defined, the mains can be automatically generated. If the chord is not defined as curved, its (straight) segments between nodes will be developed, with miter cut ends as may be required, as in FastSHAPES PipeRun.) The data file format has been modified to make it easier to manage for external data preparation, however, the old v1.x file format is supported for input only. The cutting list format has been modified slightly to reflect the fact that other, more appropriate data is now available in the newly added Cutting Parameter listing. Graphic displays add an optional „Title Bar‟ which can be located by the user, show the node or member name, and the length of the title bar itself. The 3D Node views include optional member names and axes, and are now a shadable monochrome in lieu of the previous technicolor display. Cutaway and perspective views are also provided. Viewpoint adjustment has been simplified, and a „look down member axis‟ or „look on plane of two members‟ setting is now available. Printer Dialog has been added to the Graphics window, and a Print Dialog / Preview facility provided for printing of numeric data and output. An expanded set of Help forms is available from the pull-down Help menu. Watch this space for bulletins on future releases !

Connectivity and Setting Out

„Feasible‟ Members

FastFRAME is best initially thought of as a collection of data sets in which each data set completely describes everything needed to be known to develop both ends of any single member. Please re-read until this statement is clear, logical and remembered. Each data set for any member will thus include the coordinates of the end points (nodes), (and midpoint (midnode) if any), plus the diameter and wall thickness of the member, the weld details required at each end (and middle if cranked), plus finally the OD, location and direction of every member at each of its ends that the member under consideration must connect to. At each end node, there is a „through member‟, or „Main‟ to which all branches from the node potentially attach. The member being considered may attach partially or fully (and in some cases maybe not at all) to the main, and / or to any branch previously assembled to the main.


Clearly, in order to ascertain the geometry of the main, it must be defined by 3 nodes, one at each end and one in the middle which is at the end of the member under consideration. This applies whether the main is straight, or cranked, or curved. (Note that straight is simply a special case of cranked or curved, for which reason the user is asked to specify which of the latter is intended in the event that the 3 nodes are not collinear.) It is also clear that if the main itself should happen, at either or both of its ends, to connect to other mains, it will be a branch at such mains, and will eventually be defined elsewhere as a branch. Alternatively, the main may simply be 2 segments of a chord, and would then later be considered as such. In its present state, the main acts purely as a part of the data set for the member under consideration, and is merely incidental to developing the cut path(s) at the ends of the member under consideration. It is finally clear in considering the collection of all members in a framework whose end(s) may have their cut paths developed (a.k.a.‟feasible‟ members), that the data sets for each of those members would contain much duplication. While the bulk of such duplication can be avoided in the actual FastFRAME data specification, that which is associated with the mains remains necessary. Development of all feasible members is undertaken in a single campaign. Before that campaign commences (at user request), FastFRAME checks the entire collection of data to ensure that every member is either clearly a main only and is fully defined as such, or otherwise has sufficient data to permit its full development. Every member is therefore subjected to a test which effectively asks, „If this were the only member in the framework, is there sufficient data to develop both ends ?‟ Any one failure fails the entire collection of data, and the campaign is aborted. A report is generated, and deficiencies in the data collection must be rectified before all feasible members are developed. At risk of laboring this point, it may be noted that there is occasional frustration with novice users of FastFRAME which stems from lack of appreciation of the above concepts. FastFRAME provides a Verification system which can be invoked at any time, and is independent of the connectivity checking procedure (although a minimal level of checking is done first as described elsewhere). The Verification facility enables viewing of the setout of just those members nominated for assembly at a single nominated node, or of the entire frame. Views show all members as „stick‟ members (longitudinal axis only). Curved members are displayed as a pair of dotted straight lines connecting nodes. (Geometrically, these are chords, not to be confused with the structural chord members mentioned frequently herein.) The Verification facility also permits selection of any individual member for display together with the members nominated for assembly at each end node, which is directly relevant to the issues described above, and should be the principal means of user verification of the data. While these matters appear self-evident in simple cases, they can rapidly become more


complex, especially when we consider the joint issues of assembly sequence and IP movement. The root of much frustration is lack of production planning of assembly sequences in a (sometimes understandable) desire (or direction from the boss) to „just get on with the job!‟ Sorry, this is a problem that cannot be wished away, and must be addressed sooner or later. The sooner the better, obviously. This problem is not unique to FastFRAME – any software that ignores assembly sequence should be treated with deserved contempt. On a more positive note, FastFRAME has been used as a production planning tool to investigate various alternative assembly scenarios using the 3D Node views primarily, but also considering other data such as member lengths that may require shop or field splicing that can also affect feasible assembly sequences, especially when connection plates are inserted between members.

Chords

Next, consider the mains as described above. They will frequently comprise adjacent pairs of segments lieing along a single chord of a truss. (In this context, a chord is a continuous structural member passing through a number of nodes, generally extending over the full length of a frame, and having a structural function equivalent to the flange of a girder. This common engineering term should not be confused with the geometric definition of a chord as a straight line connecting two points on a circle.). Suppose a chord starts at node A and runs through nodes B, C, D to end at node E, then branches from nodes B, C and D will need to nominate mains as A-B-C, B-C-D and C-D-E. Nodes at ends of a chord (A and E in the example above) must either be free nodes (i.e. branch-free), or may be midnodes in yet further mains : for example, there could be a main X-A-Y connecting nodes X, A and Y.


This succession of structural support eventually ends at members which are only mains, either having free nodes at each end, or being redundantly specified segment pairs along a chord. Any member which has main-only status is excluded from the set of feasible members and is not developed. Any chord can only be specified to be cranked or curved (Geom = 1 or 2 respectively, see later), and a chord which is in fact straight is simply a special case or either one. A chord specified with Geom=1 is deemed to be cranked and is developed in segments between nodes, even if there is no miter at some or all nodes) A chord specified with Geom=2 is deemed to be curved and is NOT developed, even if the chord of segments of it are straight or nodes along it collinear. (Neither condition insofar as chords are concerned is checked by FastFRAME) Hence a straight chord is often optionally specified with Geom=2 simply to suppress its development In the example above, suppose the chord A-B-C-D-E is specified as cranked (Geom=1). It will be developed in 4 segments, A-B, B-C,C-D and D-E. The free node „E„ end of the fourth segment will simply be developed at square cut through node E. The „A‟ end of the first segment will also be similarly treated, even though A may not be a free node. However, if member A-B-C is included as a branch (after the main X-A-Y) in the assembly at node A, then A-B-C is a cranked branch and will be developed with intersection at A, miter at B, „free‟ end at C. A complete solution is then obtained by manually extracting segment A-B from the A-B-C branch solution, and segment B-C from the chord solution (necessary only if there is indeed a miter at C)


Redundant Specification, and Minimal Framework

FastFRAME requires that all mains be specified in the Member List data table, whether or not they may also be implied in the optional Chords List data table. In the previous example, mains A-B-C, B-C-D, C-D-E must all appear in the member list, and implied segments B-C, C-D both appear twice. This redundancy is perfectly normal and necessary as previously explained. Note that using the optional Chords List table also provides an option to automatically generate a set of mains data and insert it into the member list (or overwrite any existing entries)

FastFRAME does NOT check whether any two or more nodes may share the same coordinates, and nor does it check whether there is any interference between members other than at the defined intersections at nodes. For example if two members F-G and L-M connecting between nodes as implied were to in fact intersect around their midpoints, FastFRAME would neither know nor care. It is therefore quite possible for the complete collection of all data sets to specify the same intersections several times over (provided unique node and member names are assigned as discussed elsewhere). An example was previously given where A-B-C was both a branch at A and part of a chord A-B-C-D-E. It would also be quite possible to define nodes S,T,U,V,W coincident with X,Y,A,B,C, and members S-U-T and U-V-W coincident with X-A-Y and A-B-C all in the same collection of data, and to see all four members developed.


All that is required by FastFRAME is that there be sufficient data at least one feasible member be defined (other than a chord segment) and developed. The minimal structure is therefore one main and one branch, requiring the existence of four nodes.

Member Axes

Members are, as already stated, connected between nodes. The first-defined node is termed the Near node, the last the Far node, and the intermediate the Mid node. That is, an observer is considered to reside at the near node and to look along the longitudinal „z‟ axis of the member.

A local „x‟ axis for the member is next defined, and will pass through what will become the template „seam‟. For cranked and curved members, the seam is located on the inside of the bend. Once the member has been curved, or miter cut and joined at the crank, if it is laid flat on the floor a try-square mounted to the floor can be presented to the member to contact it tangentially at the seam location. When the member is assembled into the frame, the seam remains on the inside of the bend.


Straight members are considered in-situ in the finally erected frame, and except for members having a vertical axis, the seam is always at Top Dead Center (TDC) of the member, regardless of whether the member slopes uphill or downhill, or lies horizontally. If the „z‟ axis is vertical, either up or down (+/- global Z), the local „x‟ axis and the global X axis correspond so that the seam is always on the East face. The local „y‟ axis is of lesser interest, but for the record is 90 degrees clockwise around „z‟ from „x‟, clockwise as seen by the observer at the near node looking along „z‟

This local axis system is used in the first instance to effect IP movement. It is also the basis for development of wrap-around templates, and for the parametric solutions at the near end of the member. Parametric solutions at the far end of a member are inverted so that it would appear that the near and far nodes had been temporarily exchanged. The reason for this is discussed elsewhere. FastFRAME treats curved members as though they were locally straight at each node, and develops branch ends on this basis, using the tangent to the curve at the node as the direction of the „straight‟ main.

Intersection Point (IP) Movement

As described so far, a node is a point through which a main axis passes, and at which any branch axes either start or end, i.e. all IP‟s coincide at the node coordinates. This can raise undesired characteristics in the intersections of the surfaces of the members, and it is often required to adjust the geometry at the node to achieve the desired result, either a lesser or greater degree of „overlap‟ between members. FastFRAME allows for the axis of any member having branch status to be moved in such a way that its axis intersects the axis of any member previously assembled at the node at a specified axial distance from that prior member‟s own intersection with a yet earlier-assembled member, etc. A positive IP movement occurs along the nominated prior member‟s „z‟ axis in the +ve „z‟ direction, and a negative move in the opposite direction. The movement is defined to start from zero at the prior member‟s own IP.


A maximum of 12 branches may be assembled to any node, (including any nil-cross-section „dummy‟ members defined for the purpose of effecting IP movement), hence there are a maximum of 12 intersection points (IP‟s) associated with any node, all initially having the same coordinates as the node. Dummy members are most commonly used to effect a (usually lateral) IP move when there is no other member already aimed in the desired direction. For fairly obvious reasons, a nil-cross-section „dummy‟ may only ever be a branch, it may never have Main status. Whereas when there are no IP moves to be made, each feasible member can be considered and tested in isolation, the requirement to move any IP requires consideration of the sequence of moves over the entire framework. All first-assembled members at every node must have their IP‟s moved at each end, then all second-assembled members, and so on. This succession of movements cannot be resolved if the connectivity of the members involved is incorrectly specified, and is again heavily dependent on node assembly sequences. FastFRAME has no way of ascertaining in advance whether or not an assembly sequence at one node is consistent with that at another, or whether or not node assembly sequences are consistent with any desired member assembly sequence for the whole framework. All that can be ascertained is whether or not there is „gridlock‟ in attempting to solve all IP moves, which is indicative of the fact but not necessarily the fine detail of any connectivity errors. It is clear that FastFRAME make no provision for moving nodes (these being by definition points of NoDisplacement) from their specified locations. There is provision only to move an IP away from the node. It should also be clear that a member‟s axes continue to pass through any defined midnode of that member, whether that member is cranked or curved, and whether of main, branch or main-only status. The IP‟s of branches connecting to that member‟s midnode may be moved from the node position. It should finally be clear that there is no way of defining an IP different from a node on a member with main-only status. Moving the IP‟s at the ends of cranked members (but with midnodes remaining fixed in space) can affect the miter cut angle at the crank. The radius of curvature of curved members may be altered when end IP‟s are moved. When a curved member end is developed against a straight or cranked member, the locally straight approximation of the curved member is normally adequate for most practical purposes, and IP movement along the prior member axis is not generally a problem. However, when developing the end of any member against a curved member, again treated as locally straight at the node, any IP movement will occur along the tangent and the solution approximation may not remain adequate. Determination of adequacy or otherwise is in the


hands of the user.

Data Entry

All setting out and connectivity data is specified in two or three spread-sheet style tables having spread-sheet style editing facilities (see the pull-down Edit menu). Editing is similar to, but not in all cases identical with, MS Excel. Column widths may be adjusted by dragging vertical separators in the header row and are „remembered‟ between runs. They also affect the printed form layout as described elsewhere.

Node Coordinates and Assembly Sequence …

Every node in the framework must be assigned a unique Windows-filename-compatible Name. (Node names are used to build up Chord segment names – see below – and these (and Member) Names are used as parts of output file names.) Any data row that does not define a non-blank node name is ignored, and blank or ignored rows may appear anywhere in the list. However, when data is submitted for checking, every row is read, and when printed or saved, every row is printed or saved. It is therefore both beneficial and appropriate to delete unused rows, and add or insert (see the pull-down Edit menu) rows as required. Three columns after the node name define the node coordinates. The 3 columns are A, B and C which by default are assigned to global +X(east), +Y(north) and +Z(up). All data in these 3 columns can be reassigned at any time via a command button and pop-up dialog. FastFRAME uses four-byte floating point variables for coordinates and other non-integer data. The accuracy is limited to at least 6 significant digits, 7 at most. Many structures are laid out on a site grid system, and sometimes even on a national grid system whose origin may be extremely remote from the structure. CAD software commonly uses eight-byte floating point numbers accurate to 15 or 16 significant digits. Precision will be lost from data input with more than 6 or 7 significant digits in it decimal representation, and while on the scale of the structure, error in absolute node location may be acceptable, member lengths calculated between nodes as the difference between large numbers are of more serious concern. If importing CAD-sourced data, or manually entering from setting out plans employing a grid system, it is wise to adjust the data to place the global origin close to the geometric center of the structure. If all nodes are within, say, +/- 500m (1640 ft.) of the origin, there should be no cause for concern with accuracy at normal structural tolerances of the order of 2mm or 1/16” The next column is headed Main and may contain the name of the main member at the node. When a main name is specified, FastFRAME will later expect to find the node named on this line to appear as that member‟s midnode in the Member list.


If no main name is specified, the node will be interpreted as a „free‟ node which will simply define the end node of a free-ended branch, or the end node of a main-only member. In the latter case, that member is nominated as the Main for its midnode, not for either of its end nodes. The next twelve columns name the members framing into that node as branches in the sequence in which they will be assembled. If no Main is named, then no branches may be listed. Blank branch names may appear in the list. They are simply ignored. For example, if names are blank in columns headed Br1 and Br2, then names appear under Br3 and Br5, Br4 and Br6 to Br12 remaining blank, then physically the first branch is that named under Br3, and the second under Br5. The reason for this is to simply cut / paste editing of the assembly sequence when experimenting with different possible sequences. If all 12 possible branches exist, this facility is of little use, of course. The last column provides for Remarks and is simply for the user‟s convenience.

Member Details and Connectivity …

Every member in the framework must be assigned a unique Windows-filename-compatible Name. (These are used as parts of output file names.) Any data row that does not define a non-blank member name is ignored, and blank or ignored rows may appear anywhere in the list. However, when data is submitted for checking, every row is read, and when printed or saved, every row is printed or saved. It is therefore both beneficial and appropriate to delete unused rows, and add or insert (see the pull-down Edit menu) rows as required. The Description column is principally for reference and to promote clearer Cutting List documentation. An entry may be edited directly, or may be drawn from the member look-up tables - see below - and inserted automatically. The Type column defines the type of member. Type 0 or blank (default) defines a circular hollow section (CHS), and Type 1 defines a rectangular cross section member (RHS) which in fact need not be hollow. It could also be an H section with plates added locally as required between flange tips. (Other Type numbers are reserved for possible future development.)


Column D defines the OD of a CHS, or the Depth of an RHS. In the latter case, and as covered elsewhere, an RHS must have two opposite sides lieing in parallel vertical planes, and D is the depth of the member in either plane, measure transverse to the member axis. Column „t or B‟ defines the watt thickness „t‟ of a CHS or Breadth B of an RHS, the latter being the horizontally measured separation between the two vertical side walls. Look-up tables are provided for CHS (Type 0) members only, one table for metric (mm) pipes and one for inch series pipes. The appropriate table is consulted according to current Units configuration, and accessed via a command button. A Materials look-up table is also provided, again to assist with member classification and Cutting List presentation. To use the lookup tables, select all rows that will have the same member class and size, then press the PipeList command button. Select the required details, the press OK. The relevant data will be copied / overwritten into all selected rows for Description, D and „t‟ In the case of an RHS, Description must be manually edited. It is also valid to specify a zero D or zero B (but not both, otherwise the member will become a „dummy‟). Column Geom defines the Geometry of the member as follows ... Geom = 0 or blank (default) is a straight member having no midnode (and no midnode may subsequently be specified for it.) Geom = 1 is a straight or cranked member having a midnode (which must subsequently be specified by name). Geom = 1 includes all straight members having Main status in the node assembly sequence list. Geom = 2 is a curved (possibly straight) member also having a midnode (which must subsequently be specified by name)


FastFRAME tests all Geom > 0 members to ascertain whether in fact they may be straight, and responds with appropriate development. Collinear nodes to not raise an error. However, all members are also tested for length, and any having a length between adjacent IP‟s of less than D (CHS) or the larger of D and B (RHS) will raise an error. (in the case of very small members, the IP proximity limit is 10mm or 0.4”) The next three columns define NearNode, MidNode and FarNode by name of node. NearNode and FarNode are mandatory for all member Geom. MidNode is mandatory for Geom > 0, and prohibited for Geom = 0. (The reason for not simply ignoring the latter is that Geom may be incorrectly specified.) The next three columns define the required weld detail at Near, Mid and Far nodes. Permitted types are depicted in the appropriate Help form under the pull-down Help menu. In this case, any detail specified at Midnode for a Geom <> 1 member is ignored, otherwise it may only be a weld detail „w‟ >= 0 type for butt welding at the miter cut crank.


The next two pairs of columns define at near and far nodes the (previously assembled) member along which the IP is to be moved, and the amount of movement. If the member name is unspecified (left blank), or the movement is 0 or unspecified, no movement occurs and the member axis passes through the node setting out coordinate. If the member name is specified, the relevant node assembly list will be checked to confirm that the member has already been assembled, and movement is relative to that members own IP, which may itself have been moved, and so on. The last column provides for Remarks and is simply for the user‟s convenience.

Chords …

This optionally used list pops up in response to pressing the Chords … command button. Any chord in the framework may optionally be defined in this list, and when defined must be assigned a unique Windows-filename-compatible Name. (These are used as parts of output file names for the segments of the chords.)

Any data row that does not define a non-blank member name is ignored, and blank or ignored rows may appear anywhere in the list. However, when data is submitted for checking, every row is read, and when printed or saved, every row is printed or saved. It is therefore both beneficial and appropriate to delete unused rows, and add or insert (see the pull-down Edit menu) rows as required. The first six columns are as for the member list. Column 7, NodeList, contains a comma-separated list of node names in sequence along the chord. (If the Windows configuration defines a character other than the comma as a list separator, this must be used in lieu.)


Node names together with the Chord name are used to build up automatic Segment names for purposes of documentation and output as follows. Suppose the Chord is named NNN and it connect nodes named A,B,C,D. Segment 1 will be named NNN_A_B, Segment 2 will be named NNN_B_C and so on. The three Weld Detail columns are as for members, save that currently the StartWeld and FinisWeld details are disabled and ignored – Chord templates are simply finished off square cut at their end nodes, and Parametric data applies the MidWelds details at ends also. This may be modified in a future release. All Midnodes have the same detail applied. The last column again provides for Remarks and is simply for the user‟s convenience. If the „Mains to MemberList‟ box is checked, then when the form is Oked, main member names are automatically generated as follows, using the above example. The first main from A to B to C will be named NNN_B, and the second from B to C to D will be named NNN_C, and so on.

Other Data

The Job Number can be configured to be mandatorily checked for Windows filename compatibility, and is then offered as a default output filename skeleton, otherwise it is optional and for user reference only. Job Description is simply for user reference. The „Cranked Members ends are to be profiled before / after being joined at crank‟ option implies certain production issues as follows. It applies to feasible members in the member list, not to chord segments. If cranked members were to be cut and joined prior to having their end profiled, they would be similar to curved members in that their lack of straightness would prevent their being cut on a wide range of machine types other than robots able to work around a stationary workpiece. The other option is manual marking off and cutting. Hence both ends of the template would have seams relative to the common seam line on inside of the bend, and the miter cut line on the template would be irrelevant, so is omitted. On the other hand, if both segments of a cranked member were cut by any means prior to joining, the miter cut line is relevant, and the far node end cutting path needs to be rotated 180 degrees around the member axis. Then when the common miter cut is made and the far end segment rotated 180 degrees to assemble the miter joint, the far end cut is restored to correct relative position, and the seam line will now be on the outside of the bend.


The „cut before‟ (default) option should be adopted for any processing on a moving workpiece type of machine. Neither option makes any difference to parametric solutions for the two segments. The „Template Length Full Scale / Truncated to ….‟ Option again implies certain production issues. If templates are to be converted to NC code via FastCAM, then the (default) Full Scale option should be adopted. If templates are to be plotted by any means and used as wrap-arounds for manual or PE cell type machine applications, then truncation to a sensible length appropriate to the plotter should be specified. (Note that if too short a length is specified, cut paths may overlap and thereby defeat the purpose of the template. Every template should be confirmed by viewing prior to output.)

Data Checking

All data is tested before any Verification view requested is presented. Any error in the data is NOT necessarily fatal to obtaining any Verification view – FastFRAME does the best it can with what it has, to assist the user in resolving data specification and entry problems

All data is also tested before any templates can be developed or parametric solutions obtained, and an error anywhere in all data IS fatal to development of any and all templates. Data errors fall into one of several classes, any of which can be the result of typographical error or misunderstanding of connectivity rules, or misapplication of connectivity rules, or simply just bad design of the data by the user. Checking can be undertaken progressively as data is entered or changed. This occurs when


the Autocheck option is On, and can be extremely cumbersome during any bulk change session. It is useful once a full working model has been accomplished and isolated bits of data are just being „fine-tuned‟ The default Checking protocol, and that recommended for use in most situations, is checking on command. This occurs when the Autocheck option is Off, and the user presses the CheckNow command button or selects the Display menu. When data errors exist, certain menu functions are disabled and are not enabled until all data errors have been corrected. The total data structure can become quite complex, as discussed in Connectivity, and checking is undertaken at several Levels as described below. A narrative Errors and Warnings report is available through the command button so labeled for Level 2 and higher checks only.

Level 1 Checking

Level 1 checking is for fundamentals. Color-coded flags are used to indicate problems, and it is expected that the user will be sufficiently aware to rapidly diagnose and correct the problem. Colors used are yellow and red. Whenever a row of a table contains an error, the leftmost (Ref.) column in that row of the table will also be flagged in yellow. (The reason for this is that tables are often wider than the screen, and cells flagging errors may be scrolled off-screen and otherwise overlooked) Uninterpretable data. Data representing a number or a length must be interpreted as such. Appearance of an alpha character in either will raise an error that is flagged in red. (A blank numeric or length field is assigned a value of 0.) When INCH units have been selected, an incorrectly formatted input length will also raise an error flagged in red. Out-Of-Range data. Numeric or Length data may be required to lie within certain bounds. If outside those bounds an error is raised that is flagged in yellow. (A blank numeric or length field is assigned a value of 0.) For example, and as covered elsewhere, Member Type may be only 0 or 1. Geometry may be only 0, 1 or 2. Weld detail types may be only as indicated in the relevant Help form, member sizes D, B or t may be greater than or equal to 0, and there is no upper limit, however it is clear that a circular member requires that D exceed 2*t, and if not, both fields will raise an out-of-range error.


Prohibited data. Certain data may be prohibited in some data fields, and its appearance will raise an error that is flagged in red. For example, node and member names are used in output file names, hence must comply with Windows file naming conventions. Member names must not contain \ / : * ? < > | (It is strongly recommended that use of the period (.) and blank spaces be avoided. FastFRAME will automatically strip any leading or trailing spaces. The Job Number is also used as a data file name for automatically saving data when templates are output, hence it must also comply with file naming rules.)

„Ignored‟ data

When a Member Name is missing from the Name field of the Member List, the entire line of data is ignored. Similarly when a Node Name or Chord Name is missing. These are not errors as such, and will occur at any blank line at the bottom of (or elsewhere in) either List, however, if the omission is inadvertent and other data exists on the line, it may be the source of errors flagged elsewhere.

„Obvious‟ Connectivity errors

These are all flagged in yellow, and include the following … Duplicated Names of nodes, and duplicated Names of members. (It is not prohibited for a member and a node to have identical names, but it is strongly recommended this be avoided. There is, however, sometimes much merit in embodying one within the other) Member(s) named in assembly sequence part of Node List not found as Member Name in Member List. (If any Branch is named, whether correctly or otherwise, in the assembly sequence, a Main is mandatory. If none specified, „Main‟ will be flagged in red) MidNode specified for a Member having Geom=0. MidNode not specified, or not found in Node List, for a Member having Geom > 0 NearNode or FarNode unspecified, or not found in Node List, for any Member. Member named in IP Move part of Member List not found as Name elsewhere in Member List. Member named in IP Move part of Member List found as Name in same row in Member List. IP Move Member unspecified when a Move is specified in the IP Move part of the Member List.


(The converse, member specified but no move specified (implied 0) is OK) A node named in the NodeList column for a chord cannot be found in the Node List table

Data Insufficiency

The minimum possible frame has a 4 nodes and two members, (i.e. 1 main member requiring 3 nodes, plus 1 branch requiring 1 additional node at the free end, the „other‟ end being the main‟s midnode). Anything less raises a Level 1 error (but no color flag) and prohibits any further checking.

Level 2 Checking

Once all color flags have been eliminated from Level 1 checking, more complex connectivity issues are addressed. No further color flags are raised, and any errors are reported in narrative form. Messages that may appear in the report are as follows …

Member (M) is Main at Node (N). This node must be MidNode in MemberList

When any member is named as the Main in the assembly sequence at a node, it assumes Main status and is required to have a midnode, whether or not it may also be a Branch (at yet another Main) Member (M) has Main status. Must not be (zero size) Dummy. Self explanatory. Zero-sized dummies are basically intended to facilitate lateral movement of branch IPs, and a „zero-sized Main‟ is effectively a contradiction in terms. Either the member should not appear as a Main in the assembly sequence at this node, or its size is incorrectly specified. Member (M) has Branch status. It MUST be tubular (Type=0).


Members may assume Main status and/or Branch status, and Main Only status when they have Main status but not Branch status. FastFRAME does not develop the ends of rectangular cross-section members, hence these can never have Branch status Member (M) is Main ONLY. IP's may NOT be moved. Because IPs for any member are movable only along a member which is already assembled at a node, and because a Main is always the first member assembled at any node, it follows that it is not possible to relocate the Nodes (which remain the IPs) of any member which has Main Only status Member (MA) must assemble before (MB) at node (N) for IP move. In the Member List row for Member Name MB, MA is nominated as the member at Near or Far Node N along which to move the IP for MB. FastFRAME checks the assembly sequence for Node N and fails to find either member, or finds them out of sequence. The error could be in either or both lists. Bad Geom. Member (M) There are potentially 12 intersection points at any node, (i.e. 1 IP for each branch), all of which must be calculated in sequence because any one may depend on movement of an earlier-assembled member. As the IP coordinates are calculated, the geometry of all previously assembled members is rechecked for problem setting-out, zero length portions of members in particular. (Note that while it is generally expected that IP Move dimensions will be relatively small (up to about one diameter, approx.), there is no limit imposed by FastFRAME) FastFRAME does, however, expect that the separation between intersection points at ends (or IP‟s and Midnodes) will be not less than the larger size of the member cross-section dimension after all IP movements have been made. An absolute lower limit or 0.4” (10mm) is placed on this dimension. Failure to pass this test will generate this error, which may also appear multiple times because of the multiplicity of IP‟s Mismatched nodes between Members (MB) and (MA) FastFRAME concedes defeat. Something went desperately wrong in the process described above in attempting to relocate the IP for MB along the MA axis. Adjacent Nodes too close along Chords as indicated OR Node named twice in list. This is the only level 2 check undertaken on the Chords List and is fairly self evident. The proximity test nodes defining chord segments is as for other members.


In particular, FastFRAME does NOT check that all nodes of an RHS chord are vertically coplanar – any problem here will raise a succession of Main errors from the member list if Mains are automatically generated. No RHS chords are developed, so no further problem will ever become evident. CHS curved chords are also not developed, and FastFRAME does not undertake any testing of Chord layout – it simply generates mains on request, based on the chord data. Because curved mains are each taken in isolation, any logically overlapping (duplicated) chord segments that do not exactly physically overlap will create physical problems that will NOT be discovered by FastFRAME.

Solutions (Methods and Scope)

FastFRAME‟s solutions are …

Wrap-around Templates

Scope : all feasible members (including chord segments when optionally defined) Method : radial line at 5 degree intervals ………. For any weld detail specified there are 1 or 2 cutting paths required to be determined. Given a maximum of 11 previously assembled branches plus 2 segments of a cranked main, a 12‟th branch can have up to 27 individual cutting paths defined at either end, from which a single cutting path must be determined between intersections of relevant individual paths. The 27‟th path (which is in fact the first to be defined) arises from the possibility that the member may in fact fail to completely intersect any of the main or prior branches. Except as noted further below for RHS mains, FastFRAME prevents any member template extending beyond a cutoff square to the axis through the end IP. It is therefore possible to permit such oddities as branches having diameter larger than the main or prior branches, and branches which partially intersect, partially miss, mains and prior branches. Roughly defined „saddles‟ then appear in the final template. While not necessarily of vast practical merit, this treatment enables solutions to be obtained which can point to errors in the data which would otherwise prevent a solution being obtained and would raise some difficulty in accurately reporting the nature of the error. The penalty, although scarcely an onerous one, in this approach is that it behooves the user to examine carefully each template (and 3D Node view – see below) to confirm that the presented solution is indeed as intended by the user. Effectively we start with up to 27 overlaid patterns each comprising 72 surface generators and 72 cut path entities and finish with a single pattern comprising up to about 100 generators and up to about 100 cut path (straight line) entities at each end. The pattern shows only the cut path entities and the two seam generators. All other generators are omitted from the templates.


Because many NC pipe profiling machines are unable to deal adequately with circular interpolation, cut path entities in V1.x and v2.0 are left as straight lines. As in the companion product FastSHAPES, it would be possible to spline and / or fair the cut paths to a much reduced set of circular arcs and straight lines lieing within a specified tolerance of the „exact‟ solution, and this may possibly be implemented in a later release. Dihedral angle data is also available (internal to FastFRAME‟s information base) for each cut path entity, but as at v2.0 is not implemented in the templates as a basis for bevel cutting. Any Groove Angle data which may have optionally been included in input weld detail data is therefore ignored in FastFRAME v2.0 for purposes of drawing templates, Templates are hence drawn on the basis that all cuts are made in a radial direction only through the wall of the pipe – see the appropriate Help form for details. (Such considerations may ultimately limit the practicality of fairing to arcs as described above.)

„Phantom‟ solutions

One of the substantial difficulties to be overcome in developing the template is dealing with „phantom‟ solutions, and this also impacts on the case of the RHS main which provides a useful demonstration of the difficulty. Refer to the relevant Help form from the pulldown Help menu for pictorial explanations.


The usual stratagem for determining which of up to 27 cut paths to take at any point at a given end of the member is to take that path which removes most scrap from the end of the member, and this works quite satisfactorily for complete intersections of a smaller pipe with several larger, previously assembled straight pipes. However, if the main is an RHS and the member more or less intersects the two nearer faces of the RHS, the stratagem fails. Both faces extend mathematically to infinity, and cutting off the maximum scrap would leave the member intersecting in a line along an edge of the RHS. The extended faces are „phantoms‟. A similar situation can occur with a cranked CHS main. If the member lies in (or close to) the plane of both segments of the main, and intersects the inside of the bend, the stratagem works. However, if the member intersects the outside of the bend, the extended segments of the main become „phantoms‟ which would release too much material using the maximum scrap stratagem. A brief study of the Weld Details Help form will show that weld detail type –2 can also suffer in the same way. We are pleased to advise (quite confidently) that FastFRAME‟s templates do indeed eliminate all phantom solutions when tested over a wide variety of very practical yet very complex frameworks. Nevertheless, nothing is ever cast in stone, and a determined „software-flumoxer‟ may yet succeed in creating a phantom we have yet to discover. FastCAM Inc. has seriously considered offering a substantial prize for the first such phantom. (We jest, of course.) In FastFRAME, when a member „misses‟, either partially or fully, either of the closer physically limited surfaces of the RHS main, the template is „cropped‟ at either plane which is the closer of the two further surfaces extended as necessary to crop the member, and a „saddle‟ is seen in the template. (As noted above, when the main is a CHS, the member is cropped at a plane through the IP and square to the member axis)


One of the stratagems FastFRAME adopts to eliminate phantoms is the end cutoff square to the member axis and through the IP, provided an RHS is not already assembled at the node (i.e. as the main). The cutoff in the latter case is in fact one or two cutoff planes being the „further‟ faces of the RHS. Otherwise, we have a pipe intersecting a pipe, and provided the diameters and offsets are such that there is always a full intersection, the usual case, it is clear that an arbitrary cutoff through the IP never causes any loss of required detail. In the event that a later-assembled pipe has a larger diameter than an earlier-assembled, or it is offset so as to achieve only a partial intersection, then the cutoff through the IP may unavoidably cause some loss of detail.

Cutting List

This contains quantitative data associated with each template, generally as described on the Cutting List and Templates Help form, (which also defines several Cutting Parameters in order to clarify minor difference between the two sets of information). CL.Rad is the radius of curvature on the centerline of a curved (Geom = 2) member. MidCut is the amount of cut at the mitered midnode of a cranked member, this being effective diameter (at weld root, D – 2t + 2w) * Tan(CrankAngle/2) Lnett definition varies slightly for a cranked member … (a) Ends profiled before joining at crank. The template is shown „prenested‟ at the crank, and

the right hand end as drawn (far end) is rotated axially 180 degrees relative to the near end, as explained in detail elsewhere. Then Lnett = -Onear + IP.Lnear + IP.Lfar - Ofar

(b) Ends profiled after joining at crank. The template is shown without the midcut, and the

right hand end as drawn (far end) is not rotated axially relative to the near end. If drawn to full scale (which in this case has little practical merit), Lnett assumes that the member was


made from two separate pieces without the benefit of any nesting at the midcut. In the case, Lnett = -Onear + IP.Lnear + MidCut + IP.Lfar - Ofar

Note that the cutting list can be copied to the system clipboard and pasted to a spread sheet. It can also be printed directly from FastFRAME, and output in .CSV format as well.

Three-Dimensional Node Views

Scope : all except free nodes – i.e. those having no specified Main, and hence no branches. Method : „reconstituted template‟ ……… This method is considered by the author (and numerous users) to provide the ultimate proof of the accuracy of the template. The only (unavoidable) resort to the original setting-out data is in adopting the original member axes. Otherwise the templates for each member framing into a node are „undeveloped‟ and put back into 3-dimensional space in a manner free from input data assumptions, derivations and solutions. It is perhaps best thought of as an alternative simultaneous view of relevant parts of a related set of templates. When viewing any node, bear in mind that the templates exist on the outside surface of each member, and represent (in v2.0 at least) purely radial cutting for which the wall thickness of members needs to be visualized. In particular, and depending on selected weld details, reconstituted templates may be shown well clear of others in some areas of the intersection, and may be shown intersecting in other areas. In yet other areas, they may be show to be nominally just in contact. To facilitate viewing from any desired viewpoint, the position of the observer may be incrementally adjusted in vertical and horizontal „great circles‟ around the node, with the observer‟s body always lieing in a vertical plane. Global X,Y,Z axes are indicated in a mini-viewport as well as optionally in the main viewport. The default viewing position may be adjusted under the Configuration menu as described elsewhere. The FastFRAME default viewing position before any user reconfiguration is in the upper south-east octant from which position a strictly isometric view is obtained. (A wire-frame cube would be seen as 6 equilateral triangles whose outer boundary is seen as a regular hexagon.). Plan (onto global XY plane from above), South Elevation and East Elevation views may also be set by command button, and one of these is often sufficient for many simple frameworks. For more complex frameworks, it is often required to obtain a view straight up or down the axis of a nominated member, or perpendicularly onto a plane containing two member longitudinal axes. Such views are available from a Custom View command button, and facilitate the gauging of the degree of overlap of any two members at a node. A „Title Bar‟ can optionally be added to the view, containing a user-defined line, its length, and


optionally the name of the node. (Use the mouse right button to drag the line.) Global axes, and named member axes, may also be optionally added to the view. The title bar length shows true length only for members whose axes lie in the viewing plane. Hence, while the view is drawn to no particular scale, it can be seen and printed with all structurally relevant information attached. To assist with visualization, cut-away views and / or perspective views may also be generated, and finally, the view may be shaded. Some cautions concerning shading are necessary. This matter should NOT be considered in the normal way that CAD program shading is considered. In the latter case, shading is normally the result of removing (under direct user control0 the unwanted portions of intersecting surfaces, leaving behind sets of facets which nominally are free from intersection bit will meet along common curves. As explained earlier, FastFRAME templates (each comprising 100 or so facets) will frequently intersect as a matter of absolute necessity – eliminating the „unwanted‟ portions in this case is totally out-of-court, nothing is unwanted. In this scenario, a shading request may not in all cases be successful or even timely. For all practical purposes, the open „wireframe‟ view is normally quite adequate. Note that members in view have been arbitrarily truncated at a constant multiple of their diameters from their IP‟s. In the case of very acute intersections, the curve of intersection may lie beyond the plane of truncation, thereby giving that member a partly „inside-out‟ appearance. This is not a „bug‟ – it simply indicates that the particular member was truncated too close to its IP. Truncation distance (the default is 2.5 diameters), may be adjusted in the Configuration forms – see elsewhere.

Parametric Information

Scope : all feasible members (including chord segments when optionally defined.) Method : simple solid geometry. „Nuff said? No …….. Parametric information is summarized on the Cutting Parameters Help form.


Note that member axes previously defined for members in situ in the framework (and directly applicable to templates) are modified for the purposes of presenting parametric information. Axes at the Near node are identical with the previous definition, but at the Far node are inverted so that the local „z‟ axis along the member centerline is always directed outwards away from the node. The template seam location remains in physical context, at TDC (or east face) for straight members, and at inside of bend for cranked or curved members. Parametric information satisfies two purposes. First, when templates are output in either CAM or DXF format, they can be edited to include additional information such as slotting for inserted connection plates. Parametric data includes (amongst other things) angles of generators in the template which define the location of planes parallel to the common plane of two members. Otherwise, parametric information adds little to the data already available directly from the template itself. Second, various pipe profiling machines employ „canned‟ solutions for pipe to other pipe or plane intersections which require input of parametric data, either manually (MDI) or automatically via data files containing parametric information relevant to the particular machine. FastFRAME does not, in v2.0, attempt to address the vagaries of any particular machine, but attempts, in lieu, to advise „obvious‟ parameter values which may with reasonable effort be converted to the required form. Information is listed in the format … KEYWORD, Data [,Data, Data ….] … and more specifically as … REMARK, AnyRemarkOptional JOB, JobNumber, JobDescription NAME, MemberName DIAM, D


WALL, t GEOM, EffectiveGeom SEGMENTS,NumberOfSegments

SEGMENT, SegmentNumber, SegmentName, NettLength PATHS,NumberOfCuttingPaths

PATH,PathNumber ERR,ErrorCode END,EndCode TO_DIA, d , Name CROTCH_ANGLE, a ECCENTRICITY, e OFFSET,Offset, ORef ROTATION, r EFF_WALL, f BEVEL, b

Indentation of KEYWORD is irrelevant, and included only to promote readability of the list as presented in FastFRAME. Leading spaces are stripped from the line when output to file. Each member (or chord) starts at NAME, and information is fairly self evident down to PATHS. Certain parameters require comment which is offered below in the context of the information being read by other software (and possibly being recast by that software) for onforwarding to an NC profiling machine having „canned‟ cycles for various cutting paths. EffectiveGeom As noted earlier, FastFRAME handles members specified as cranked or curved which are actually straight (3 nodes are collinear). EffectiveGeom = 0 in such a case, otherwise EffectiveGeom = Geom. When EffectiveGeom = 2 (curved member) it is likely that the machine will be unable to cut the member, so we would skip to the next NAME keyword. When EffectiveGeom = 1 (cranked), information for a MemberList feasible member is presented as 2 separate segments, and for a Chord in 2 or more separate segments. An EffectiveGeom = 0 member is presented in a single segment. Naming and numbering of segments has been discussed earlier. NettLength This is the overall length of the segment after cutting, and is taken from template data which assumes all radial cuts – see the Template Help form. Note that cranked member or chord segments are not assumed to be prenested in this case. If the NC machine has bevel cutting capabilities, the NettLength will still be correct after all bevel cutting is complete, however, some parts of cut paths will be made in what will later become scrap. Hence the user may care to add a margin (say about one wall thickness or more) to the length at each end of the segment.


EndCode Because the axes have been inverted at the Far node end as explained earlier, and all offsets are now local to the relevant node, EndCode is used to identify which end of the member the parameters are applicable to. 0 = Near end, and 1 = Far End for a straight single segment member, (or Near / Further and Nearer / Far in the case of a 2-segment cranked member cut at the crank / midnode) This information may be required by the machine for purposes of effecting its own axis transformations, sign conventions, and setting kerf compensation direction, etc. Paths Beauty here is in the eye of the beholder, and will be judged by capabilities of a particular machine that the beholder has in mind. Each intersection between the member and a previously assembled branch or main acquires 1 or 2 paths, as follows, with reference to the Weld Preps Help form ... A weld type –1 has 2 paths, one for the inside of the pipe and one for the outside, both assumed cut radially. (It would be illogical to specify this weld detail when the machine had bevel cutting capabilities) A weld type –2, if requested and for reasons associated with „phantom‟ solutions discussed elsewhere, is automatically converted here to a „w=0‟ type, where „w‟ is the component of weld root face measured in the radial direction. A weld type „w=0‟ has no weld root face and hence only a single path which is for the groove face. A weld type „0 < w <= t‟ has a weld root face (component „w „ measured radially) , and, provided w < t ( where t = wall thickness), a weld groove face. Hence it has 1 or 2 paths. How the root face and groove face will actually be cut depends on the machine, its beveling capabilities, and its „canned‟ cycles. Parameters affecting these details are EFF_WALL (effective wall thickness) and BEVEL (angle) The effective wall thickness is the depth measured radially from the outer surface of the pipe to a reference point through with an oblique cut must pass. (More accurately, there is a series of points defining a reference curve through which the entire (obliquely cut) path must pass. „The‟ Reference point as shown on the Help form is one very specifically defined point which lies on this curve.) For the root face cut, the reference point lies at the bottom of the cut, i.e. on the inner surface of the pipe, so effective wall thickness is actual wall thickness. For the bevel face, the reference point lies at the bottom of the groove (top of root face), so effective wall thickness is


(t-w). Assuming the canned cycle permits, the root face cut would be made to correspond with the dihedral angle in the intersection of the two pipes, so that the root face would nominally lie flat around the previously assembled member. This angle can change considerably around he circumference of the pipe but at one extreme is represented approximately by Crotch Angle. The groove face cut would then be cut at the (dihedral +/- bevel) angle. In this scenario, if bevel angle specified exceed crotch angle, the torch would try to cut outwards from the inside of the point over some portion of the path. (In practice, the torch is unable to cut anywhere near this extreme, and the CNC needs to provide its own protection. FastFRAME provides a warning, but does not omit the path.) If cuts were made radially through the reference point, fitup at either top or bottom of the weld face would be achieved (varying around the circumference) instead of at both top and bottom, and the groove angle may be naturally larger than required in some places, while being too small in others and in need of secondary processing. The Reference Point, Rotation and Offset This was defined above and is shown on the Help form – it is a specific point on a reference curve which locates the reference curve physically on the pipe. Two parameters are used to locate the Reference Point. These are Rotation and Offset. A third parameter (ORef) has been added for cross-reference with other data in the Cutting List, and to allow for possible variations between machines, so that it may be necessary for the user to add Offset + ORef. Rotation is always measured in a counter-clockwise sense when looking into the node, starting from the template seam position which is constant for all cutting paths. Note that the Reference point is always located on the obtuse side of the intersection, opposite from the CrotchAngle which always defines the more acute angle within the intersection. At 90 degrees, either side of the member is as good as the other for both Reference Point location and CrotchAngle definition, although the user may NOT interchange them if any eccentricity exists. Eccentricity Eccentricity is the perpendicular separation between two parallel planes, one containing the member axis and the other the previously assembled member axis. The direction in which eccentricity is measured is critical, from the member plane to the other plane, positive or negative according to a vector at Rotation+90 degrees, as shown in the Help form Note that the Reference point is always located in the member plane. TO_DIA - The previously assembled (supporting) member This is the OD of the previously assembled member, assumed to be a pipe unless it‟s OD is


listed as zero. The previously assembled member name is indicated for reference as appropriate. A zero diameter means that the cut path lies in a plane, hence we have either a miter cut in a chord or cranked member, or a simple square cut free end, or (in principle at least) we have an intersection with a physically planar element. For reasons associated with phantom solutions, FastFRAME v2.0 does not in practice on all instances define parameters for intersection of pipe branches with RHS mains. The phantoms however, can disappear when either of D or B is set at 0. The „RHS‟ then becomes a flat plane which can be considered to extend beyond its limits as defined by the non-zero cross-sectional size. If the „RHS‟ is a cranked main and now comprises two planes, there may remain some phantoms hiding on the outside of the bend. In these cases of a plane cut, eccentricity becomes irrelevant and is reported as 0. It should be clear that the Reference point will now be located on the extreme end of the template or cut member, so Offset = 0, and it is common that ORef becomes negative, indicating that the IP lies within the overall cut length. All other parameters remain relevant „Phantoms‟ Phantoms were discussed earlier in relation to solving templates. To recap, common situations where phantoms occur are pipes framing into RHS mains or the outside areas of cranked mains, and the type –2 weld prep detail. The same exist here, only with a vengeance that may not be resolvable. The types of machine most likely to make use of parametric information are those which simply cut all paths fed to the machine, which is identical with cutting all paths created on the template. This is also identical in effect, although less efficient, than selecting a single cut path from among all candidates which removed most scrap from the ends. As previously noted, this stratagem fails in many cases because it follows „phantom‟ solutions. For a pipe profiling machine of the type considered here to be able to eliminate phantom situations, it (a) must have access to all parameters for all cut paths at a member end before commencing any cutting, (b) must be capable of then analyzing the entire set of information as distinct from simply using it sequentially as it arrives, and (c) must be able to stop cutting on one path and start cutting on another when those paths intersect in an appropriate manner. The first, (a), is simply a matter of having sufficient storage capacity within the CNC, and today cannot be a problem. The second, (b) is also a question of memory, plus how smart the CNC software and its programmer may be. The third, (c), raises a number of questions … In order to eliminate phantoms, the path intersection must become in effect a re-entrant corner. Whereas in the „maximum scrap off‟ situation, corners formed by path intersections are external – we can always cut beyond the corner, loop back while changing torch angle, and re-pierce at the corner – we are no longer able to do this. The reentrant corner must be


navigated somehow, after the manner of cutting a rectangular beveled hole in the wall of the pipe, and most such machines contain other canned cycles do exactly that. The most probable reason for the need to remain wary of phantoms is (b) – the CNC simply having no way of sorting out the mess. The user will need to do so, and some assistance is provided by FastFRAME in ErrorCode warnings – see below. Other likely machine-oriented problems arise from partial intersections or complete misses, that is, canned cycles assuming that there is always a complete intersection between a member and its prior mate, with a system crash or refusal otherwise. FastFRAME provides for the insertion a cutoff square to the axis through the IP ( a „free end‟) whenever there is a likelihood of such being needed, on the assumption that machine‟s canned cycles can detect and handle partial intersections. To summarize the issue of avoiding phantom parametric solutions …

Do NOT use cranked members UNLESS it can be guaranteed that all branches will fully intersect the inside of the bend (inside face in the case of RHS)

Do NOT use RHS having both D>0 and B>0

DO acknowledge warnings issued in the ErrorCode for each path ErrorCode For all the above and other reasons, FastFRAME also provides an ErrorCode parameter for each cutting path. In the event that a cutting path has been omitted, the reason can only be reported in the last path at an end, usually a „free end‟ path, or simply a „free end‟. In other cases, the ErrorCode may appear as a warning with the cut path, and again with the free end which was judged necessary to eliminate possible problems. The ErrorCode is a binary „bitwise‟ number with component values and significance as follows 0 No error, normal situation 1 This free end was added, there being no other cutting paths detected. 2 Weld prep for this path was modified from Type –2 to Type w=0 4 This path is for member intersecting segment of cranked main. Free end added. 8 A member intersected an RHS main, path was omitted. This free end substituted. 16 CrotchAngle < 5 degrees. Path was omitted. This free end substituted. 32 Eccentricity and/or Offset not found for a path. Path omitted. This free end substituted 64 Warning : this path a partial intersection only. Free end added 128 A complete miss, path was omitted. This free end substituted 256 Warning : Bevel exceeds Crotch Angle on this path 512 Warning : This path probably for a phantom branch intersection This list may be expanded and or modified in future releases. Clearly, not all parameters in the list can be used by a given machine without consideration of the ErrorCode and several other parameters.


As stated at the outset, FastFRAME does not attempt to address the vagaries of a host of different pipe profiling machines, but aims to provide a generally useful set of parameters applicable to many, either directly or after minor modification or reinterpretation.

User Verification and Checking

It has already been mentioned that, owing to FastFRAME attempting to permit the user maximum latitude in matters of setting out and member connectivity, it then behooves the user to ascertain that the solutions provided by FastFRAME are indeed as intended. We cannot overemphasize this point. Ample means are available for the user to verify, final check and document all data and results. Any failure to do so is entirely at the responsibility of the user. As a minimum, the following is recommended Especially if the global axes have been reassigned, but generally otherwise, use the Verify Frame menu to confirm handing of the overall framework, and any bulk errors in node coordinate or axis transformation data. The aim here is to get the structure in the right paddock, facing the right way, and so on. Printout the basic data in Node, Member and Chords tables. Formally check by marking off against source data drawings or equivalent every data cell entry for at least the node coordinates (Nodes list) and IP (Members list) moves. The aim here is to ensure that finer detail requirements are complied with, (like doors fit in doorframes type of stuff, and purlins run in straight lines, and so on). FastFRAME will never be able to detect when a node or IP was +100mm instead of –100mm from its planned position. (When minimum or maximum overlap, or particular weld details, are specified it might also ensure that doorframes etc. remain in their designated positions for some reasonable time) Use Verify Member views for every member required to ascertain that all required previously assembled members are indeed present. Sign-off on the member list? Use the Node 3D views to confirm the completeness of the solution at each end of every member. Either sign off on the Node list, and / or print as many 3D views as are required to demonstrate specification compliance.

Output

All output is produced with a common filename basis which may be configured to default to the JobNumber. Output files directly related to individual members have _MemberName appended to the base name while CuttingList and CuttingParameter file have _CL and _CP appended.


Standard filename extensions are .CAM FastCAM template file ready for editing, plotting or pathing to NC code .DXF Standard Drawing Xfer Format file, for member templates editing / plotting .FFD FastFRAME Data file, (independent of File Save (As) menu function) .CSV Standard Comma Separated Variable file, CuttingList, and CuttingParameters FastCAM supports NC code for numerous profiling machines, including some pipe profilers. The .CAM file output from FastFRAME can be later read and processed by FastCAM, or, a batch stream can be setup at time of output which automatically outputs further files of NC code for the machine. (The .CAM files continue to exist, and can be reprocessed later if desired.) FastFRAME v2.0 does not include dihedral and bevel data in the .CAM file (or in the .DXF file), hence only radial cutting from templates is supported at this stage.

The FFD file It was mentioned earlier that some FastFRAME users had developed their own procedures for automatically and semi automatically creating either complete or partial FFD (FastFRAME Data) files. The file format is defined below. Note that much quantitative data is enclosed in “” marks, and that records appear in CSV standard format. The purpose of the “” is to maintain international capability. The CSV standard specifies use of commas as variable separators regardless of any Windows configuration setting for use of national standard list separators, decimal separators, and so on. The classic instance is the European use of the comma as the decimal separator. Presenting data such as a European “27,3” (which would be shown below as “27.3”), ensures that the decimal comma is not mistaken for the CSV separators. Use of “” is optional when data contains no characters that may be mistaken for separators (e.g. integer numbers) In the case only of the Chord table, the NodeList column is shown below as “a,b,c …” and in


this case only, the commas within that character string would be replaced with the national list separator character as defined in the Windows configuration. The actual records are shown in bold print, explanation in normal print below.

Output

When output .NCP files will pop up:

In the output form, choose the path you want to output, type the bevel angle you want

to add(default is 0). If tick positive bevel mode, the output bevel angle will always >0

There are some options you can choose:

Cut from Path start: no rapid move for the first path

All paths are same: when there are many pipes need to output, as in FastFRAME, this

option is useful.

Save to Database: is an option that used for pipe nesting program that under

development.

Save Combine File: is used for PipeSplice that can combine many picese cut.

Configuration


Most of the configuration form is self explanatory. A few extra remarks will assist

General / Dimensions

Units may be defined as 0=metric (mm), 1=Imperial (inch), 2=Imperial (ft.inch). FastFRAME does not effect any unit conversions. A file saved in one unit set may only be opened in the same unit set. In this sense, both the Imperial sets are deemed to be identical in terms of input which may be ft. and inches with only fractional inches, or inches only, using either decimal or fractional presentation. For example, 3‟4 1/8 , 40 1/8 and 40.125 are all valid representations of the same distance when Units = 1 or 2, but 3‟4.125 and 2‟16 1/8 etc. will raise errors. Use an apostrophe between ft and inch, and a space between whole and fractional inches. The finest resolution recognized for fractional inches, either input or output, is 1/64. For the most part, lengths are output as they are input by the user, errors and all !. Output in terms of calculated lengths appears only in the CuttingList, CuttingParameters, and Graphic display title bars, cursor positions etc. Only decimal representation appears in CuttingList and CuttingParameters, since it is likely to be read by other software. Output representation and precision may be defined by the user, and is confined to the Graphic displays and printouts. Minimum Significant Dimension is an effective zero, and should be set at around the level of the expected CNC resolution. Default value is 0.1 mm (0.004”) General Dimensional Tolerance is that which applies generally to boilermaking in the workshop. Default is 1 mm (0.04”). FastFRAME makes many decisions on the basis of both these numbers which should be maintained at practical levels. The Materials and Pipes files should be maintained using a text editor (WordPad, NotePad) or a spread sheet using CSV file „open‟ and „save as‟ procedures. These files may need to be updated or reselected when Units are reselected. It is necessary to Save the configuration, quit the program and restart whenever these files are reselected or changed – they are read only on FastFRAME startup.

Template Display

Colors used to display templates may be changed here, and default responses to the template length data defined.


3D Display

Various 3D display setting may be changed here, including the truncation length of members in the 3D Node view.

Output Defaults

This tab, as its title suggests, simply defines the defaults offered when the Output form is opened, plus an option to check the JobNumber for Windows filename compatibility.

List of program files

The following files are installed with FastFRAME into the directory-of-user-choice,

default being C:\ProgramFiles\FastFRAME …

FastFRAME.exe Application executable

FastFRAME.bmp Replaceable application banner bitmap picture

FastFRAME.doc This documentation in MS Word 6 format

**********.FFD A selection of FastFrameData files, to get you started

PipeMaterial.txt A user-editable (NotePad) text file

InchPipelist.txt A user-editable (NotePad) textfile of pipes in Inch

sizes

MetricPipeList.txt A user-editable (NotePad) textfile of pipes in Metric sizes

…plus, optionally …

FaSTframe.cfg FastFRAME configuration file, if requested.

A variety of .DLL and .OCX files may also be added to your \Windows\System

directory according to standard Windows installation standards.

FastFRAME Sample

Simple Truss

FastFRAME will create wraparound templates or machine cut connections for tubular structures.

(Where suitable equipment is available) The first task is to define the frame as Nodes, Members and

Struts.

A clear sketch of the frame should be used and marked to identify each node, member and strut. The

frame must be fully defined within FastFRAME before you can proceed to verification and output.


All nodes are at the intersections of connecting elements in the frame. They are used as the reference

points for Members or Struts. These intersections are called Interpoints, they are located at the

intersection of axes between the elements of the frame.

A member is the main supporting section of a frame. A frame must have at least one Member.

Secondary members are referred to as struts. They are the connecting elements between Members or

other struts. Multiple struts and members can join at a single node, up to a maximum of 12.

Figure 1 shows a simple truss. Typically all frames will have free ends at the terminations of the main

members, in this example the ends have been extended 150mm from the endmost nodes. You will need

to define free ends in any FastFRAME description, if not your data should be changed to incorporate

them.

Figure 2 shows the drawing with nodes referenced. This particular drawing has 10 nodes from N1 to

N10. The nodes can be drawn in any sequence, but for ease of data input a linear sequence should be

used.


The main members can now be specified. In this example there are only 2 main members. They have

been named MTop and MBottom. This can be seen in Figure 3.

The struts, or connecting elements can now be labelled. Again, choosing a logical or linear naming

sequence will ensure ease of data input. Figure 4 shows the struts with labels.

FastFRAME can now be started and the data entered.

The first piece of data to be entered should be the Job number and description. These fields are in the

top left corner of the screen.

For this example a Job Number of 1 and a description of "Sample Truss" can be used.

Data can be verified either automatically or manually. Automatic verification of data can be activated

by selecting the automatic option in the top right corner of the screen. Usually manual verification is

fine. This allows the user to enter most of the data and then check the data, only when required.

The node names (n1 - n10) and their relative positions can be entered into the top grid.


The origin (0,0,0) of this example is at the bottom left hand corner. The X(+ve) axis runs towards the

right, the Y(+ve) axis is into the page and the Z(+ve) axis is up.

节点 X Y Z

N1 0 0 1750

N2 150 0 1750

N3 2650 0 1750

N4 5150 0 1750

N5 5300 0 1750

N6 5300 0 0

N7 5150 0 0

N8 2650 0 0

N9 150 0 0

N10 0 0 0

Once the nodes positions have been entered, the main members can be added to the bottom table.

The easiest way to accomplish this is to use the "Chords" function. The Chords function will split the

Main members into sections. FastFRAME uses these split members for calculations in FastFRAME

There are two chords in this example: the top and bottom members

Chord 1 has been named MTop and Chord 2 named MBottom. Enter the Names and select the top

chord by clicking in the data box and then press the pipe list button.

The Pipe list button allows the simple selection of standard pipe types. For this example the pipe used

will be:

Class Seamless

Specification AS 1835

NPS (Nominal Pipe Size) 50

Schedule 60.3 x 3.9 (Sch40;STD)

Select this pipe size and press OK.

The outside diameter and the thickness is then automatically entered into the grid. Now the geometry

needs to be set, to do this enter a geometry of 1 for bothe MTop and MBottom. There is no need to

specify a mid-node as the mid-node is automatically set after completion of the Chord information.


The node-list should now be set. This is a list of nodes through which the member traverses. MTop

intersects n1,n2,n3,n4,n5 and MBottom intersects n6,n7,n8,n9,n10. The nodes are entered into a list

(from the upper grid) with each item separated by a comma. Once this window is filled in, the settings

are accepted. Accepting the chords dialog will automatically fill in the lower grid with correct member

details.

The struts can now be detailed in the lower grid, below the members.

Strut s1-s5 have the same description, type, D, and "t or B", as the other members above. The geometry

for all struts is "0" because the member is straight.

All struts in this example only need a near and far node. The midnode is not required as the struts are

straight and not cranked. The strut layout is:

Near Node Far Node

S1 n2 n9

S2 n8 n3

S3 n7 n4

S4 n8 n2

S5 n8 n4

The frame connection information can now be entered. This is done on the upper grid. As Node n1 is

a free end it has no secondary (or strut) intersections. There is no need to specify any connection

information for free nodes. With the exception that of 揷 ranked?members FastFRAME does not

develop any main members, only the intersecting elements between them.

Node n2, has a main member and two intersecting members. These members are specified in the lower

grid. The main member is MTOP_N2 and the branch members are s1 and s4. Following this rule Node

n3 has one main, MTOP_N3 and one branch s2.

The complete node table is shown below: (This is an except from the upper grid)

Node Name Main Br.1 (Branch 1) Br.2 (Branch 2) Br.3 (Branch 3)

n1

n2 MTOP_N2 s1 s4

n3 MTOP_N3 s2

n4 MTOP_N4 s3 s5

n5

n6

n7 MBOTTOM_N7 s3

n8 MBOTTOM_N8 s2 s4 s5

n9 MBOTTOM_N9 s1


n10

The cutting patterns can now be displayed and output. From the main menu select Display then Nodes.

This will show a list of nodes and a 3 Dimensional view of each node intersection.

The output is generated by selecting the output menu item. The output dialog will be shown. The

selected templates will be saved to disk depending on the output type selected.

The output options are:

CAM File

A CAM file can be saved in a format for generating NC pipe profile from FastCAM. It

can also generate cam files so they can be printed as a Wraparound template for exisitng

pipes.

DXF File

A DXF file can be saved for opening saved templates in other cad packages.

FFD

A FastFRAME Data File can be automatically saved if requested. This backs up the

current FastFRAME data so it can be modifeid or output again in the future.

Cutlist

This is a CSV (Comma separated variable) file containing the cutting list details.

Cut Parameters

This is a CSV file containing the list of cutting parameters for the selected templates.

Usually all that is required is a wraparound template CAM file. The templates can then be printed and

the pipe intersections cut.

More Complex Truss


Figure 1 shows a typical Bridge truss. In this example the free ends have been extended 500mm from

the endmost nodes. You will need to define free ends in any FastFRAME description, if your

development does not incorporate them. The free ends are required to aid in the development of end

vectors.

Figure 2 shows the drawing with nodes referenced. This particular drawing has 10 nodes from N1 to

N10. The nodes can be drawn in any sequence, but for ease of data input a linear sequence should be

used.

The main members can now be specified. In this example there are only 2 main members. They have

been named MTop and MBottom. This can be seen in Figure 3.


The struts, or connecting elements can now be labelled. Again, choosing a logical or linear naming

sequence will ensure ease of data input. Figure 4 shows the struts with labels.

FastFRAME can now be started and the data entered.

The first piece of data to be entered should be the Job number and description. These fields are in the

top left corner of the screen.

For this example a Job Number of 2 and a description of "Bridge Truss" can be used.

Data can be verified either automatically or manually. Automatic verification of data can be activated

by selecting the automatic option in the top right corner of the screen. Usually manual verification is

fine. This allows the user to enter most of the data and then check the data, only when required.

The node names (n1 - n16) and their relative positions can be entered into the top grid.

The origin (0,0,0) of this example is at the bottom left hand corner. The X(+ve) axis runs towards the

right, the Y(+ve) axis is into the page and the Z(+ve) axis is up.

Node X Y Z

1 1000 0 1200

2 1500 0 1200

3 2500 0 1200

4 3500 0 1200

5 4500 0 1200

6 5500 0 1200

7 6000 0 1200

8 7000 0 0

9 6500 0 0


10 5500 0 0

11 4500 0 0

12 3500 0 0

13 2500 0 0

14 1500 0 0

15 500 0 0

16 0 0 0

Once the nodes positions have been entered, the main members can be added to the bottom table.

The easiest way to accomplish this is to use the "Chords" function. The Chords function will split the

Main members into sections. FastFRAME uses these split members for calculations in FastFRAME

There are two chords in this example: the top and bottom members

Chord 1 has been named MTop and Chord 2 named MBottom. Enter the Names and select the top

chord by clicking in the data box and then press the pipe list button.

The Pipe list button allows the simple selection of standard pipe types. For this example the pipe used

will be:

Class Welded

Specification AS 1836

NPS (Nominal Pipe Size) 250

Schedule 273.1 x 25.4 (Sch140)

Select this pipe size and press OK.

The outside diameter and the thickness is then automatically entered into the grid. Now the geometry

needs to be set, to do this enter a geometry of 1 for both MTop and MBottom. There is no need to

specify a mid-node as the mid-node is automatically set after completion of the Chord information.

The node-list should now be set. This is a list of nodes through which the member traverses. MTop

intersects n1,n2,n3,n4,n5,n6,n7 and MBottom intersects n8,n9,n10,n11,n12,n13,n14,n15,n16. The

nodes are entered into a list (from the upper grid) with each item separated by a comma. Once this

window is filled in, the settings are accepted. Accepting the chords dialog will automatically fill in the

lower grid with correct member details.

The struts can now be detailed in the lower grid, below the members.


Strut s1-s11 have the same description, type, D, and "t or B", as the other members above. The

geometry for all struts is "0" because the member is straight.

All struts in this example only need a near and far node. The midnode is not required as the struts are

straight and not cranked. The strut layout is:

结构近节点远节点

s1 15 2

s2 14 2

s3 14 3

s4 13 3

s5 13 4

s6 12 4

s7 12 5

s8 11 5

s9 11 6

s10 10 6

s11 9 6

The frame connection information can now be entered. This is done on the upper grid. As Node n1 is

a free end it has no secondary (or strut) intersections. There is no need to specify any connection

information for free nodes. With the exception that of 揷 ranked?members FastFRAME does not

develop any main members, only the intersecting elements between them.

Node n2, has a main member and two intersecting members. These members are specified in the lower

grid. The main member is MTOP_N2 and the branch members are s1 and s4. Following this rule Node

n3 has one main, MTOP_N3 and one branch s2.

The complete node table is shown below: (This is an except from the upper grid)

Node Name Main Br.1 (Branch1) Br.2 (Branch2) Br.3 (Branch3)

n1

n2 Mtop_2 s1 s2

n3 Mtop_3 s3 s4

n4 Mtop_4 s5 s6

n5 Mtop_5 s7 s8

n6 Mtop_6 s9 s10 s11

n7


n8

n9 Mbottom_9 s11

n10 Mbottom_10 s10

n11 Mbottom_11 s8 s9




n15 Mbottom_15 s1

n16

The cutting patterns can now be displayed and output. From the main menu select Display then Nodes.

This will show a list of nodes and a 3 Dimensional view of each node intersection.

The output is generated by selecting the output menu item. The output dialog will be shown. The

selected templates will be saved to disk depending on the output type selected.

The output options are:

CAM File

A CAM file can be saved in a format for generating NC pipe profile from FastCAM. It

can also generate cam files so they can be printed as a Wraparound template for exisitng

pipes.

DXF File

A DXF file can be saved for opening saved templates in other cad packages.

FFD

A FastFRAME Data File can be automatically saved if requested. This backs up the

current FastFRAME data so it can be modifeid or output again in the future.

Cutlist

This is a CSV (Comma separated variable) file containing the cutting list details.

Cut Parameters

This is a CSV file containing the list of cutting parameters for the selected templates.


Usually all that is required is a wraparound template CAM file. The templates can then be printed and

the pipe intersections cut.

Automatic Data Entry AutoCAD is one of the software used to design Pipe(Network) frame structure, FastFRAME 3X

supports operation under AutoCAD’s design interface and allows direct structure and node conversion

to a FFD file. Also, during the conversion the engine determines 2 modes of assembly, the customised

assembly sequence and preset assembly method (automatic), providing flexibility and convenience.

Main Material Form Arrangement

In FastFRAME we provided many form of material carriers, this is not limited to pipe material,

but also plate, RHS, Channels, etc. To allow automatic recognition of plate and pipes, in defining layers

the following is used: R for Plate, RHS and Channel, C for Round Pipe, ZC for Bend Pipe to mark these

differences.

Pipe Diameter and Wall Thickness Arrangement

se different settings for main pipes and branch pipe’s diameter and wall thickness. In CAD

layers, assign main pipes and branch pies of the same size to the same layer. e.g.: main pipe diameter of

300mm, wall thickness of 10mm, 3 main pipes are equivalent. Branch pipe diameter of 100mm, wall

thickness 10mm, all branch pipes are equivalent. Then in CAD layers, build the layers 300x10,

100x10,and assign the Main Pipes and Branch Pipes into the corresponding layer

.

Assembly Sequence Arrangement

As NC cutting code is generate in the 1 pass for the many main and branch pipes within the entire

structure, and taking into account the scenarios where multiple pipe penetrations, each branch pipe’s

assembly order will be different. Because the cutting path will have lots of differences, and there is

consideration for the assembly processes and methods preferences on site, we provide a setting in the

layers to directly label the assembly priority of each pipe. This provides a huge convenience for

assembly later on, the priority levels are in integers, and with 1 being highest priority.

Layer Example

e.g. we are cutting a pipe of diameter 300mm, thickness 12mm, and to be assembled second, in

the CAD layer it is labelled as : Cx300x12x2. The ‘x’ is the letter ‘x’

AutoCAD command application

FastFRAME is highly compatible with AutoCAD, Whether in AutoCAD it is flat pattern center

line structure or single pipe penetration structure, through FastFRAME NC code can be directly

generated according to weld bevel type.

命令说明


FRAME Used in generating output for center line structure (during code generate every node

and pipe name is automatically labelled

CLEARTEXT clear center line structure node labels and pipe names.

C Directly output for Single pipe with penetration (both ends are penetrating sections)

C11 Directly output for Single pipe with penetration(both ends are grooved)

Example1:

Xuzhou, Beijing-Shanghai Railway Station Platform Structure. 3D structural drawing created

using AutoCAD

Project Description:

A Canopy stretches between a Platform beam to a off platform beam, the length is 437m. It

has a terminology required structure. The Canopy’s steel frame structure covers an area of 74705m2.

This project is designed to operate for 50 years maximum, has a structural construction safety rating

level 2, quake resistance level/class/degree 7.

Process and Explanations:

1. In AutoCAD open the Pipe frame design Model, Analyse the entire structure formation,

large complicate model should considered in stages.


2. New Construction Layer is use to preserve each specification and priority pipe centre lines,

The Layer name format is such as : Cx300x10x3 ( Circular Pipe x Diameter x thickness, x assembly

priority). C for Circular Pipe, R for Rectangular Pipe/Channel surface contact material. ZC for main

pipe being a Bend.

3. Select a predefined section of structure to being, put the pipe center lines that share the

same priority into the same layer

4. Hide the other extra phsycial layers, only display all of the specifications for pipe

center lines


5. Confirm and verify the pipe’s assembly priority at every node, in the same not there

should not be 2 branch pipes with the same priority (should not be the same colour), where as

a branch pipe that connect to different nodes can be within the same layer.

i. 6. Select the part of the frame structure you need. (In the structure each pipe

cannot be referenced as main pipe and branch pipe at the same time to other

pipes, otherwise it indicates an error).

7. In Command console enter ‘frame’, In the Pop-up Window enter working mark (for each

paragraph) and the best view angle , select enter. Also select to save path and file name.

(during operation, if the desire is to remove the labels created by the Frame software, use the

‘cleartext’ command)


8. Now the software will automatically generate the 3 dimensional nodes and pipe names for

the users’ convenience to further create diagrams or other outputs for verification.

9. Star the ‘Frame’ software, enter cutting and related settings.

10. After saving the generated FFD file, all of the nodes and pipe names will be sorted.


11. In the display of the nodes, show flat pattern short cut key check areas for details.

12. Finally click output NC Now will generate each pipe’s NC code for cutting.


Example 2 : 2010 Chang Zhou Logisitics ( the 16th

) Chang Zhou Sporting Complex Project

(Convert from Tekla to ACAD 3D structural drawing) Project Background: Chang Zhou Sporting Complex situated in Chang Zhou New Chang Zhou Road

originated from bai yun miao po area, this covers an

area of 240,000 square meters, of which 80,000

square meters is for the Sporting Complex’s

Facilities, 60,000 for the Sports Park, 80,000 for

Athletes’ Village, 20,000 square meters for

city-planned road. Total area covered by

construction is 170,000 square meters.

Chang Zhou Sporting Complex facilitie

s consists of: Main Stadium, Training Stadiu

m, Common Podium, Administration Tower,

Food Court, Central Power Center, Parking


Block, Athlete Village and Village Parking, Commercial Block, etc. The Complex’s main focus is spo

rting competitions, but as facilitates arts performance and exhibitions, it is a multi-purpose sports buil

ding.

The Main Stadium entrance consist of around 1500 square meters of round plaza, wide spac

es, and is ideal for large gatherings. The main stadium construction area is 39,635 square meters, It sp

ans a maximum length of 160 meters and 110 meters in width. Inside the stadium there are placed larg

e and small (24-16 square meters) seat boxes. Standard seats 10018, VIP seats 654, fixed seats 5044 a

nd rotary seats 4320.

The Training Stadium has a construction area of 19412 square meters, spans a maximum len

gth of 151.5 meters, width 70 meters. Inside the stadium there are training area for different sporting e

vents, swimming pool, basketball court, warming up room, sports news room and school social halls

and supporting technical facilities.

Project Production Process: This project uses space model designed with Tekla Structures (XSteel). It can be output to

DXF structure diagram, as such, after completing the design, DXF 3D Structure diagrams were created

(center line base).


Following Manufacturing and Processing specifications split the whole structure in to 12

sub-groups.

Different Types of Pipe are classed by their name, such as ‘Cx200x10x1’ (type x diameter x

thickness x priority) Different layers are given different colours, the system can automatically sort

branch pipe by their priority in the same node.


Select every and in the AutoCAD command console enter ‘FRAME’, In the pop-up window

enter job number (separate paragraph) and ideal axis for view angle. Also select to save path and file

name, the software will automatically name each node and output FFD file

Verify every node to check for duplicate name and correct line type and

structure.


Again output via CAD (LI), TAKLA (right click check), FRAME will also check if branch pipe

numbers, type and dimension are correct on important nodes. The system will follow the label and

structure for nodes to class the node’s diameter, thickness and wedling preparation data, and then

automatically calculate the pipe length, flat patter and cutting assembly for this space frame structure.


Generate cutting list (left), NC cutting code (right), lining them up with the names in the assembly

diagram. In the NC code it includes bevel angle (AWS standard), remnant, compensation (both

automatically calculated). With high speed in one step complete all of the complex calculations for

nodes with multiple pipes and pipe to pipe penetrations for the entire pipe frame.


Example 3: Directly output NC codes to cut Solid pipe

In some structure, because of multiple related factors, it is not possible to use the centre line

approach to generate an output. At the same time the pipe structure has solids shapes with intersecting

tracks, as per diagram

Take the solid pipe and copy it to a new AutoCAD model to run the explode command, and then in the

command console enter ‘C’and material. A save file dialog will appear, enter the file name and path to

obtain the NC cutting code for the solid pipe.



Example 4 : bevel type and form

FastFRAME provides a rich set of Bevel form and type, 7 of which are mainly used. 1. G/F Mode

The distinct feature of this is the heel meets with pipe external surface, and the toe meets with the

interior surface of the pipe


2. a standard mode

The distinct feature of this is the heel meets with the interior of the pipe, whilst the toe meets

with the exterior of the pipe, the rectangular area needs to be grinded or a full melting weld

needs to performed


Both the 2 above type is for 2 axes cutting or 2 axes cutting is used for pipe thickness less than

5mm, during welding It is possible to do a full melting weld or a ¾ melting weld.

1、 Fully closed ( matching) mode

This is a common type of G/F mode addition, normal G/F mode uses 2 axes cutting, this makes it

impossible to achieve the cutting for the leftover areas (instead having to rely on the heat generated

during the welding process to melt through) and grinding is required. When cutting with 3 axes or

above, the leftover area can be cut away as well during the cutting process, to achieve a matching

surface between branch and main pipe.

2、 Variable bevel angle mode. This is a common bevel used in china, the distinct features the heel of the branch pipe matches the

surface of exterior and the interior surface. The toe section naturally is ready for bevel (cutting machine

deviation at 0 degrees).


This bevel is commonly used for pipes with wall thickness between 6mm – 12mm, the heel of the

branch and the main pipe meet at the dihedral angle a natural bevel angle

For the implicit choice of ‘choose positive bevel mode”, it is possible to set the pipe thickness

range of this implicit behaviour in the Fastframe.xml file, with the tag

<postsettingthickness>10</postsettingthickness>. The 10 specified in this case indicates all thickness

below 10, then the choice of positive bevel angle is automatic. If the pipe thickness is specified above

this range, then manually setting positive bevel is

required.


3、 Fixed angle bevel mode.

Fixed bevel, the dihedral between the main pipe and the branch pipe penetration allows the

formation of fixed bevel angle. e.g. 30 degree in FRAME data near/far enter @30, after the pipe has

been cut, branch pipe and main pipe can have a fixed 30 degree bevel.


4、 AWS 1.1 CJP


5、 AWS 1.1 PJP



In AWS1.1 CJP and PJP’s biggest difference is when CJP cannot cut the largest SOMETHING

position, the lift (cut short) method is used. The small angle between branch and main pipe intersection

can be fully melted into the weld, where PJP cannot use the lift methos (use instead half melt or another

method of welding).

5 Several common practical cutting problem

1. Measurement length

⑴ If the cutting length is longer (less then 3mm difference), you can use FastFRAME.XML and set

the <kerf></kerf> value to 0. ⑵ Bevel mode has an effect, e.g 2 axes standard mode and G/F mode has significant differences in

dimensions.

2、Practical assembly has to follow the priority in AutoCAD, especially when there are multi-pipe

penetrations, otherwise it may lead to the situation where assembly becomes impossible to complete.

3、The axes in the cutting machine has motion issues ( e.g. if the cutting machine

require many height adjustments, the axes’s accuracy.

4、During cutting be aware of inaccuracies introduced during the breaking of question。

5、When Assembling the whole structure, take care of the tolerance of the assembly structure (if

the assembly structure has a problem, it is possible to result with some pipes being too long and some

being too short, as well as the gap between connecting items being too large

6、The 2 ends of the pipe being assembled should not be left behind carelessly, NOTE: label each

pipe carefully (of course in some cases both ends are the same), this can lead to other penetrations

having problems.


Addenda

Any changes to this Manual, or future revisions to the FP software, will be

published (in MS Word format) in a separate file ReleaseNotes.pdf

This file can be accessed at any time via The FastCAM web site or email support

service (see Help) to enable users to keep up to date an latest developments.

Appendix A – The FastFRAME.xml Data File

Note, this sample may changed without notice.

<?xml version="1.0" encoding="UTF-8"?>

<pipe>

<version>0.5</version>

<post>

<machine id="1">

<m3machine id="1">

<machine>

<machinetype>1</machinetype> //机器类型 1 输出X、Y(A) 2 输出X、Y(A)、B 34 输出X、Y(A)、B、C

<ncrefnumber>1</ncrefnumber>

<description>2-Axis</description> //本设置支持的轴数

<machineaxes>3</machineaxes> //设置为4轴的数学模型下3轴输出

<postsettingthickness>5</postsettingthickness> //正坡口模式的自动选择(数字值以上

为自动选中状态，以下为不选择状态)

<style>eia</style> //代码类型目前支持EIA和ESSI

</machine>

<chuck>

<side>right</side> //固定盘所处位置,参数有(left/right)

</chuck>

<diameter>

<min.diameter>100</min.diameter> //管的最小直径

<max.diameter>610</max.diameter> //管的最大直径

</diameter>

<length>

<max.loadable.length>12000</max.loadable.length> //管的最大距离

<length.at.drive.na.for.work>400</length.at.drive.na.for.work> //管的最小距离

</length>

<thickness>

<min.thickness>3</min.thickness> //最小管壁的切割厚度

<max.thickness>30</max.thickness> //最大管壁的切割厚度


</thickness>

<coat>

<allowed>no</allowed> //允许管材壁厚

</coat>

<kerf> //割封补偿

<side>right</side> <crossing>yes</crossing> </kerf>

<bevel> //坡口角度设置(最大弧度)

<limit.b>45</limit.b> <limit.c>45</limit.c> </bevel>

<axes> //轴设置(机器类型可参考上文机器结构)

<sign.name.x>+x</sign.name.x> <sign.name.y>+y</sign.name.y> <sign.name.z>+z</sign.name.z> <sign.name.a>+a</sign.name.a> <sign.name.b>+b</sign.name.b> <sign.name.c>+c</sign.name.c> </axes>

<orgs>

<origin.x>0</origin.x>

<origin.y>0</origin.y>

<origin.z>0</origin.z>

<origin.a>0</origin.a>

<origin.b>0</origin.b>

<origin.c>0</origin.c>

</orgs>

<cut.parameters>

<cutting> //切割信息(需要更改或添加)

<thickness>3</thickness> //管的厚度

<feedrate>1400</feedrate> //切割标准速度

<kerf>2.0</kerf> //割缝补偿值

<edgepierce>-1</edgepierce> //边缘穿孔类型

<internalpierce>-2</internalpierce> //内部穿孔类型

<entrylength>10</entrylength> //引入线长度值

<edgedistance>10</edgedistance> //引出线长度值

</cutting>

<cutting> //切割信息(需要更改或添加)

<thickness>4</thickness> //管的厚度

<feedrate>1350</feedrate> //切割标准速度


<kerf>2.0</kerf> //割缝补偿值

<edgepierce>-1</edgepierce>

<internalpierce>-2</internalpierce>

<entrylength>10</entrylength> //引入线长度值

<edgedistance>10</edgedistance> //引出线长度值

</cutting>

..................

<cutting>

<thickness>60</thickness>

<feedrate>180</feedrate>

<kerf>4.2</kerf>

<edgepierce>-1</edgepierce>

<internalpierce>-2</internalpierce>

<entrylength>10</entrylength>

<edgedistance>10</edgedistance>

</cutting>

</cut.parameters>

<rapid>

<max.feedrate>6000</max.feedrate> //空移最大速度

</rapid>

<crank>

<single>1</single>

</crank>

</m3machine>

<controller id="1"> //输出切割代码类型 (1)

<brand>EDGE</brand> //代码类型 EDGE

<model>11m</model> //X轴向最大长度

<nccode style="eia">

<tool number="1"> //序列为1

<name/>

<type>

</type>

<on>M07</on> //切割代码(开)

<off>M08</off> //切割代码(关)

<begin/>

<end/>

<feed type="auto"/>

</tool>

<tool number="2">

<name/>

<type>


</type>

<on/>

<off/>

<begin/>

<end/>

<feed type="auto"/>

</tool>

<program.units> //设置单位及代码

<inch>G70</inch> //英制

<metric>G71</metric> //代码使用公制单位

<incremental>G91</incremental> //代码使用相对坐标

<absolute>G90</absolute> //代码使用绝对坐标

</program.units>

<movement>

<rapid>G00</rapid> //空行程代码

<linear>G01</linear> //直线切割代码

<circle.clockwise>G02</circle.clockwise> //圆弧切割代码(顺时针方向)

<circle.anticlockwise>G03</circle.anticlockwise> //圆弧切割代码(逆时针方向)

<dwell>G04</dwell> //延迟代码

<axis> //输出实际轴显示设置

<x>X</x> //实际输出的为X

<y>Y</y> //实际输出的为Y

<z>Z</z> //实际输出的为Z

<a>A</a> //实际输出的为A

<b>B</b> //实际输出的为B

<c>C</c> //实际输出的为C

</axis>

<feed>F</feed> //速度标识代码

<pause></pause>

</movement>

<block.numbers on="True"> //是否启用行号(True/False)

<start>10</start> //行号起始号

<increment>1</increment> //行号增长率

<maximum>30000</maximum> //最大行数

<letter>N</letter> //行号标识代码

<digits></digits>

<headerline>3</headerline> //开始增加行数

</block.numbers>

<pierce/>

<arc.type/>

<arc.centre/>


<file.extension></file.extension>

<decimal.places>2</decimal.places> //小数位

<program.id/>

<parameters>

<kerf.on side="left"/>

<kerf.on side="right"/>

<kerf.off/>

<rapid.on/>

<rapid.off/>

<program.end>M02</program.end> //切割结束代

<header position="upper" enabled="true" style="absolute">

<line>%</line> //文件头代码设定

<line>G92X0.A0.</line> //文件头代码设定

</header>

<header position="upper" enabled="true" style="incremental">

<line>%</line>

<line>G92X0.A0.</line>

</header>

<footer enabled="false" style="incremental"> //文件尾代码设定

<line>EIAFooter1</line>

<line>EIAFooter2</line>

</footer>

<program.start/>

<leadout enabled="false">

<length>10</length>

</leadout>

<program.rewind></program.rewind>

<comments enabled="false"> //代码输出中是否含有板材等信息 True

<comment.on>(</comment.on>

<comment.off>)</comment.off>

<part.comment code=""/>

<header.comment code=""/>

<job.number code=""/>

<drawing.number code=""/>

<assembly.number code=""/>

<revision code=""/>

<remarks code=""/>

<prepared.by code=""/>

<checked.by code=""/>

<material.class code=""/>

<material.spec code=""/>


<material.default.feedrate code="F"/>

<material.thickness code="T"/>

<outside.diameter code="R" />

<outside.diameter code="D"/>

<kerf.amount code="K"/>

<tool.comment code=""/>

<job.comment code=""/>

<special.header>ON</special.header>

</comments>

<comment.on enabled="false">(</comment.on>

<comment.off>)</comment.off>

<header position="lower" enabled="false">

<line>Lower1</line>

<line>Lower2</line>

</header>

<a.translate.y>False // 输出的是角度(A)或周长(Y)【TRUE 表示Y FALSE 表示A】

</a.translate.y>

<feedrateA.adjust>True</feedrateA.adjust> //速度合成

</parameters>

</nccode>

<units>

<in>metric</in> //输入为公制(metric)单位或英制(inch)单位

<out>metric</out> //输出为公制单位

<cordinate.positioning>absolute //相对坐标(incremental)或绝对坐标

</cordinate.positioning>

</units>

<nccode style="essi"> //使用ESSI代码格式

。。。。。。。。。。。。。

<data>

<pipelist>

<metric>

<pipe> //板材信息(可以更改或添加)

<nps datatype="real">25</nps>

<outside.dia datatype="real">33.4</outside.dia> //管径(外直径)

<thickness datatype="real">3.4</thickness> //管壁厚

<schedule datatype="text">Sch40;STD</schedule> //显示目录

</pipe>

<pipe>


<outside.dia datatype="real">33.4</outside.dia>


<thickness datatype="real">4.5</thickness>

<schedule datatype="text">Sch80;XS</schedule>

</pipe>

。。。。。。。。。。

<pipe>


<outside.dia datatype="real">914.0</outside.dia>

<thickness datatype="real">19.1</thickness>

<schedule datatype="text">Sch40</schedule>

</pipe>

</metric>

</pipelist>

<pipe.material>

<mpipe> //材质信息(可以更改或添加)

<class>Welded</class> //材质

<specification>AS 1836</specification> //等级

<density>7850</density> //密度

</mpipe>

<mpipe>

<class>Seamless</class>

<specification>AS 1835</specification>

<density>7850</density>

</mpipe>

。。。。。。。。

<mpipe>

<class>Seamless</class>

<specification>API 5LB</specification>

<density>7850</density>

</mpipe>

</pipe.material>

</data>

</pipe>


Contact Information

World Wide Offices

FastCAM Inc PO Box 56074 Chicago IL 60656-0074 USA Telephone: (312) 715 1535 Facsimile: (312) 715 1536 Email: [email protected] Website: www.fastcamusa.com

FastCAM Pty Ltd Australia Telephone: (03) 9699 9899 Facsimile: (03) 9699 7501 Email: [email protected] Website: www.fastcamusa.com

FastCAM （China）

A-318, 563 Songtao Road, Pudong,

Shanghai China 201203

地址：上海浦东张江松涛路563号A座318室

(张江海外科技创新园)

Tel: (021) 5080 3069

Fax: (021) 5080 3071

Email: [email protected]

Website: www.fastcam.cn

Software Support

For any support issues, please contact your local representative. Alternatively you

may contact FastCAM directly.

http://www.fastcam.cn/

Documents

FastPIPE/FRAMEFRAME) Manual english V1... · 2018. 7. 22. · FASTCAM.EXE or SETUP.EXE and run it to start the installation process manually. Select Simplifed Chinese or English based