User Manual - KPNhome.planet.nl/~folke195/postprocessor/CHMEDM.pdf · Page: 3 of 23 Version: 1.1 User Manual Postprocessor CHMEDM Charmilles - Robofil 6000 Date: 30 may 1995 Date

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User Manual

Postprocessor CHMEDM Charmilles Robofil 6000

version 1.1 date: 30 may 1995

Copyright © 2005 by CAM-postwriter. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher.

Page: 2 of 23 Version: 1.1 User

Manual Postprocessor CHMEDM Charmilles - Robofil 6000 Date: 30 may 1995

Date printed: 16 November 2005 Page 2

Contents 1. INTRODUCTION.......................................................................................................................................3

2. NC WORDS.................................................................................................................................................4

3. G AND M CODES. ...................................................................................................................................5

4. DIAGNOSTICS...........................................................................................................................................6

4.1. GENERAL. ........................................................................................................................................ 6 4.2. CAM-POSTWRITER ERROR MESSAGES. ............................................................................................ 6 4.3. POSTPROCESSOR ERROR MESSAGES. ................................................................................................ 7 4.4. POSTPROCESSOR WARNINGS. ........................................................................................................... 8

5. POSTPROCESSOR STATEMENTS........................................................................................................9

5.1. AUXFUN........................................................................................................................................ 9 5.2. CLRSRF.......................................................................................................................................... 9 5.3. COOLNT ........................................................................................................................................ 9 5.4. CUTCOM...................................................................................................................................... 10 5.5. DELAY ......................................................................................................................................... 11 5.6. FEDRAT ....................................................................................................................................... 11 5.7. HEAD ........................................................................................................................................... 11 5.8. INSERT......................................................................................................................................... 12 5.9. MACHIN ...................................................................................................................................... 12 5.10. OPSKIP..................................................................................................................................... 13 5.11. PARTNO................................................................................................................................... 13 5.12. PPRINT..................................................................................................................................... 13 5.13. PREFUN ................................................................................................................................... 14 5.14. RAPID....................................................................................................................................... 14 5.15. SEQNO ..................................................................................................................................... 15 5.16. STOP......................................................................................................................................... 15 5.17. THREAD .................................................................................................................................. 15 5.18. TRANS...................................................................................................................................... 16 5.19. UNLOAD.................................................................................................................................. 17 5.20. FINI........................................................................................................................................... 17

6. MISCELLANEOUS..................................................................................................................................19

6.1. WORK PIECE COORDINATE SYSTEM................................................................................................ 19 6.2. LIMIT SWITCHES............................................................................................................................. 19 6.3. MOTIONS. ...................................................................................................................................... 19

7. POSTPROCESSOR OUTPUT. ...............................................................................................................21

7.1. TIME CALCULATION....................................................................................................................... 21 7.2. NCLIST......................................................................................................................................... 22 7.3. NCDATA...................................................................................................................................... 23




1. Introduction.

The purpose of this manual is to provide the NC part programmer all relevant information to obtain a correct NC data file from the NC programming system and the postprocessor. The reader of this manual is assumed to have good knowledge and expertise of the NC programming system and experience in NC part programming. This manual contains chapters that are less relevant for the part programmer but are added to give a complete overview. The programming manual of the machine tool and the machine control are considered as appendices of this manual. Information listed in these manuals will not be repeated here. A part program contains a sequence of statements. The first statement has to be a PARTNO statement and the last statement has to be a FINI statement. The postprocessor statement MACHIN has to proceed the first motion. The next postprocessor statements generate an immediate output to the NC data: AUXFUN, CLRSRF, COOLNT, CUTCOM, DELAY, FEDRAT, HEAD, INSERT, PARTNO, PPRINT, PREFUN and STOP. The postprocessor statements MACHIN, FEDRAT, RAPID, THREAD, TRANS and UNLOAD are of influence on the following motions that will be output to the NC data.




2. NC words.

NC word

sign code

Number of digits

zero code

min. value

max. value

units

N 1 8 3 0 99999999 1 G 1 2 3 0 99 1 H 1 7 2 0 9999999 0.001 mm D 1 3 3 0 999 1 X 2 8 2 -99999999 99999999 0.001 mm Y 2 8 2 -99999999 99999999 0.001 mm Z 2 7 2 0 99999999 0.001 mm U 2 8 2 -99999999 99999999 0.001 mm V 2 8 2 -99999999 99999999 0.001 mm W 2 8 2 -99999999 99999999 0.001 mm I 2 8 2 -99999999 99999999 0.001 mm J 2 8 2 -99999999 99999999 0.001 mm R 2 8 2 -99999999 99999999 0.001 mm E 1 3 3 1 999 1 F 1 8 2 1 99999999 0.001 sec. M 1 3 3 0 150 1

Explanation of sign code and zero code.

sign code

value output value output Remarks

1 +123 123 -123 123 no sign 2 +123 123 -123 -123 no + sign, - sign in front 3 +123 +123 -123 -123 + and – sign in front 4 +123 123 -123 123- no + sign, - sign at rear 5 +123 123+ -123 123- + and – sign at rear

zero code

value output value output Remarks

1 00100 00100 00000 00000 no sign 2 00100 ^^100 00000 remove leading zeros 3 00100 ^^100 00000 ^^^^0 remove leading zeros,

except the last one 4 00100 001^^ 00000 remove trailing zeroes 5 00100 001^^ 00000 0^^^^ remove trailing zeroes,

except the first one 6 12.30 12.3^ 02.34

00.00 ^2.34 ^0.^^

decimal point programming. remove leading and trailing zeroes except last one before decimal sign "."

( ^ represents a space. )




3. G and M codes.

G-codes G 0 Rapid motion G 1 Feed motion G 2 Circular motion CLW G 3 Circular motion CCLW G 4 Dwell time (Time in NC word F) G27 Normal machining mode G38 Change cutter radius compensation before motion G39 Change cutter radius compensation after motion G40 Deactivate cutter radius compensation G41 Cutter compensation left G42 Cutter compensation right G92 Define work piece coordinate system M-codes M0 Program stop M1 Optional program stop M2 Program end M7 Upper flushing on M8 Lower flushing on M9 Upper and lower flushing off M13 Hammering mode




4. Diagnostics

4.1. General. There are 3 types of diagnostics: • CAM-postwriter error messages. • Postprocessor error messages. • Postprocessor warnings

4.2. CAM-postwriter error messages. CAM-postwriter signals unknown input and input which contains illegal values. The output of the postprocessor is invalid. It is the responsibility of the part programmer to check for, and to correct errors. The total number of CAM-postwriter error messages is printed at the end of the NCLIST file. See example below.

.... Input error(s) in input file.

The CAM-postwriter error messages are printed in the file NCLIST at the location they are met in the part program. See example below for an overview of CAM-postwriter error messages. The error messages 1, 2, 3 and 4 indicate that a parameter in a postprocessor statement or a CL record has a value that lies beyond its specified range. The line number of the statement in the part program that caused the error and the name of the parameter are printed as part of the message. Note: The INTERGRAPH system Cutter Location File doesn’t support statement line numbers. Instead of the statement line number the CL file record number is printed! The error messages 5 and 6 indicate that an unknown postprocessor statement or CL record is met in the CL file.

1. *** INPUT ERROR *** Overflow of operand in postprocessor statement. On line : .... of part program. Item : ....




2. *** INPUT ERROR *** Underflow of operand in postprocessor statement. On line : .... of part program. Item : ....

3.

*** INPUT ERROR *** Overflow of operand in cl_record. On line : .... of part program. Item : ....

4.

*** INPUT ERROR *** Underflow of operand in cl_record. On line : .... of part program. Item : ....

5.

*** INPUT ERROR *** Unknown postprocessor statement format. On line : .... of part program.

6.

*** INPUT ERROR *** Unknown cl_record in input. On line : .... of part program.

4.3. Postprocessor error messages. An error is detected during postprocessing and the postprocessor generates an error message. Postprocessing continues to search for possible other diagnostics. The output of the postprocessor is invalid! It is the responsibility of the part programmer to check for, and to correct errors. The total number of postprocessor error messages is printed at the end of the NCLIST file. See example below.

.... Error message(s).

Every postprocessor error message is proceeded by the text:

Error in record: ....




Overview of postprocessor error messages:

More than 1 MACHIN statement. No MACHIN statement before first motion. Upper and lower wire support not vertical alligned.

4.4. Postprocessor warnings. A possible problem is detected during postprocessing and the postprocessor chooses a possible solution. It is the responsibility of the part programmer to decide whether the chosen solution is correct or not. The total number of postprocessor warnings is printed at the end of the NCLIST file. See example below.

.... Warning(s).

Every postprocessor warning is proceeded by the text:

Warning in record: ....

Overview of postprocessor warnings:

Illegal character in program number. Axis travel override. U-machine = .... V-machine = ....




5. Postprocessor statements.

5.1. AUXFUN Specification AUXFUN/ mcode mcode = number of the auxiliary function M.

0 <= mcode <= 150 Description AUXFUN/ mcode generates a NC block with the specified auxiliary function: N.... M(mcode)

5.2. CLRSRF Specification CLRSRF/ rplane rplane = Distance from reference plane to secondary plane with sign.

-999.999 <= rplane <= 999.999 Description The CLRSRF statement is used to define the distance from the reference plane to the secondary plane. The distance is measured in Z direction, including a minus “-“ sign when measured in negative direction. CLRSRF/ rplane generates a NC block with: N.... G27 R(rplane*1000)

5.3. COOLNT Specification COOLNT/ HIGH




COOLNT/ LOW COOLNT/ OFF

Description COOLNT / HIGH generates upper flushing on: N.... M 7 COOLNT / LOW generates lower flushing on: N.... M 8 COOLNT / OFF generates flushing off: N.... M 9

5.4. CUTCOM Specification CUTCOM / LEFT, offset_register CUTCOM / RIGHT, offset_register CUTCOM / OFF 1 <= offset_register <= 999

Description The CUTCOM statement is used to define the direction of the tool diameter compensation. CUTCOM / LEFT, offset_register Offset left of the programmed tool path. CUTCOM / RIGHT, offset_register Offset right of the programmed tool path. CUTCOM / OFF Deactivates tool diameter compensation. CUTCOM / LEFT, offset_register generates before the next first motion: N.... G38 G41 D(offset_register)

CUTCOM / RIGHT, offset_register generates before the next first motion: N.... G38 G42 D(offset_register)

CUTCOM / OFF generates: N.... G39 G40




5.5. DELAY

Specification DELAY / delay_time delay_time = delay time in sec. 0.001 <= delay_time <= 99999.999 sec.

Description DELAY / delay_time Generates: N.... G 4 F(delay_time*1000)

5.6. FEDRAT Specification FEDRAT/ techn_register 1 <= techn_register <= 999 techn_register = register number that holds the technology to be used. Description After a FEDRAT statement the next motions will be in feed mode. A RAPID statement switches to rapid mode. This rapid mode is only active for the next motion. After this motion the feed mode will be active again. FEDRAT/ techn_register Generates: N.... E(techn_register)

5.7. HEAD Specification HEAD/ z_head 0.001 <= z_head <= 162. Description




The HEAD/ z_head statement positions the lower and upper wire support at a distance z_head. This positioning is only possible when the lower and upper wire supports are perpendicular to the XY plane. If this restriction is not met, a error message will be generated. HEAD/ z_head Generates: N.... G0 Z(z_head*1000)

5.8. INSERT Specification INSERT insert_string text Description Generates a NC block containing the insert_string. The insert_string contains max. 66 characters. INSERT G10 L2 P3 X12 Generates: N.... G10 L2 P3 X12

5.9. MACHIN Specification MACHIN/ CHMEDM, zid, wpl

zid = distance from lower wire support to lower surface of the work piece. (Without a sign.)

wpl = distance from lower surface of the work piece to reference plane. (With a sign.)

Description The MACHIN statement calls the postprocessor. The MACHIN statement and the next FROM statement establish the work piece coordinate system. MACHIN / CHMEDM, zid, wpl FROM/ xa, ya generate the next NC block: N.... G92 X(xa) Y(ya) W(wpl*1000)




5.10. OPSKIP Specification OPSKIP / ON OPSKIP / OFF

Description After an OPSKIP / ON statement the character slash ("/") will be placed before each generated NC block. The OPSKIP / OFF statement stops this mechanism.

5.11. PARTNO Specification PARTNO partno_string

Description The partno_string is printed in the header of each page of the NC listing. The partno_string contains max. 66 characters. The first PARTNO statement generates the first NC block with the program number. The second through ninth characters of the first PARTNO statement contain the program number. The program number may contain the characters "0" through "9". Example: PARTNO.12345678 partnr: 894563/34 Wheel bearing. generates a NC block with: %12345678

5.12. PPRINT Specification PPRINT pprint_string




Description The pprint_string is printed in the NC listing and can be used to give instructions to the machine operator. The pprint_string contains max. 66 characters. If the first character in pprint_string is a asterisk “*” then the pprint_string after is placed between brackets, "(" and ")", and output as a NC block. In this way instructions also can be given on the display of the machine control. The pprint_string is checked for occurrences of "(" and ")". If these characters are part of the pprint_string they are replaced by spaces. Example: PPRINT* Remove fixture at side (A) of work piece. Generates a NC block with: (* Remove fixture at side A of work piece.)

5.13. PREFUN Specification PREFUN/ gcode 0 <= gcode <= 99

Description Gcode is the number of the preparatory G function. PREFUN/ gcode generates the output of the NC block: N.... G( gcode )

5.14. RAPID Specification RAPID

Description Generates rapid positioning in the next motion. (Rapid speed is 900 mm/min.)




RAPID

GOTO/ xa, ya generates:

N.... G 0 X(xa) Y(ya) RAPID is NOT modal. The second motion after a RAPID statement will be in feed mode. Time calculation: Rapid mode motions are not added to the calculated processing time of the part.

5.15. SEQNO Specification SEQNO/ block_incr 1 <= block_incr <= 25

Description From this statement on a NC block number increment is used equal to block_incr. The default value of block_incr is 5.

5.16. STOP Specification STOP

Description The STOP statement halts the processing of the NC program. STOP generates: N.... M0

5.17. THREAD




Specification THREAD/ h THREAD/ ATANGL THREAD/ OUT

h = height of work piece in mm. 0.001 <= h <= 999.999

Description The THREAD/ h statement is used to define the height of the work piece at the location of the wire eroding. THREAD/ h GOTO/ xa, ya Generates the next motion block: N.... X(xa) Y(ya) H(h) The THREAD/ ATANGL statement inserts the wire at the current position. The THREAD/ OUT statement interrupts the wire. The wire will be broken, possibly to be inserted again at another position. A tool path with the same start and end point results in a piece of loose material. When this tool path is programmed between the THREAD/ ATANGL and THREAD/ OUT statement the remaining material stays fixed by a triangular shaped form. The first motion after THREAD/ ATANGL will be output with G48 in the NC block. The endpoint of this motion will be “remembered” by the postprocessor being the "GLUE_POINT". The contour of the tool path will return to the "GLUE_POINT". This motion will not be output but will be replaced by a NC block with: N.... G49 All motions from this “GLUE_POINT” until the next THREAD/ OUT statement will be ignored.

5.18. TRANS Specification TRANS / xtr, ytr xtr = X coordinate translation. ytr = Y coordinate translation.




Description This translation is subject to all coordinates. One can choose a better coordinate system in the workpiece model or drawing.

5.19. UNLOAD Specification UNLOAD / ON UNLOAD / OFF

Description After UNLOAD/ ON at each programmed point a “hammer blow” will be given to remove remaining material. UNLOAD/ OFF will stop this mechanism. Example: UNLOAD/ ON

GOTO/ x1, y1 GOTO/ x2, y2 GOTO/ x3, y3 UNLOAD/ OFF

Will generate: N.... X(x1) Y(y1) N.... M13 N.... X(x2) Y(y2) N.... M13 N.... X(x3) Y(y3) N.... M13

5.20. FINI Specification FINI

Description FINI completes the postprocessor run and finishes the part program. FINI




Generates: N.... M 2




6. Miscellaneous.

6.1. Work piece coordinate system. The workpiece coordinate system is established by the first FROM statement in the part program. The FROM position becomes the current position in the work piece coordinate system. MACHIN / CHMEDM, zid, wpl FROM/ xa, ya generates a NC block with: N.... G92 X(xa) Y(ya) W(wpl*1000) This NC block defines the work piece coordinate system.

6.2. Limit switches. Axis travel is monitored at the next axis positions: U-minimum = -50 U-maximum = 50 V-minimum = -50 V-maximum = 50 When one or more axis's travels beyond these limits, a warning is given.

6.3. Motions. Explanation of used parameters: xa = X coordinate in workpiece coordinate system. ya = Y coordinate in workpiece coordinate system. ua = U coordinate in workpiece coordinate system. va = V coordinate in workpiece coordinate system. i = Component of tool vector in x direction. j = Component of tool vector in y direction. k = Component of tool vector in z direction. xc = X coordinate of center of circle in workpiece coordinate system. yc = Y coordinate of center of circle in workpiece coordinate system. um = U coordinate in machine coordinate system. vm = V coordinate in machine coordinate system. xtr = Translation of X coordinate. (TRANS statement)




ytr = Translation of Y coordinate. (TRANS statement) rplane = Distance from reference plane to secondary plane. (In Z direction, with sign.) wpl = Distance from lower surface of the work piece to reference plane. (In Z direction, with

sign.) z_head = Distance between lower and upper wire support. (Without sign.) zid = Distance from lower wire support to lower surface of the work piece. (In Z direction,

without sign.) Motion commands in NC programming system: GO.... xa ya GO.... xa ya xc yc New workpiece coordinates are calculated by adding translation from TRANS statement: xa := xa + xtr xc := xc + xtr ya := ya + ytr yc := yc + ytr ua := i / k * rplane va := j / k * rplane um := i / k * ( z_head - zid - wpl ) vm := j / k * ( z_head - zid - wpl ) Output of motions in NC data file: G 0 Z(za) G 0 X(xa) Y(ya) G 1 X(xa) Y(ya) G 1 X(xa) Y(ya) U(ua) V(va) G 2 X(xa) Y(ya) I(xc) J(yc) G 3 X(xa) Y(ya) I(xc) J(yc) Calculation of machine coordinates: um := i / k * ( z_head - zid - wpl ) vm := j / k * ( z_head - zid - wpl )




7. Postprocessor output.

7.1. Time calculation As an indication for the production time the length of each contour is calculated. This length is, for each used technology register “E”, printed at the end of the NC listing in a table. This table also contains the used offset register for each technology register in the last column. Example:

E Length D

123 12345 123

123 12345 123

123 12345 123 123 123

123 12345 123 123

123 12345 123 123 123




7.2. NCLIST The output of the postprocessor is written to the file “NCLIST”. This file is written in the local directory. Next the layout of this file:

In this layout one can find the position of all NC words. The file NCLIST contains the same information as the file NCDATA except for the information that is printed in the columns after the double asterisks (**). However, the information is written in a more readable format. The column after the double asterisks gives information about the geometry used in the CAM system.

N * G * G * X * Y * U/I * V/J * Z/W * H *D/E * F/R * M ** Drive surf. ----------*---*---*----------*----------*----------*----------*----------*--------*----*----------*----**------------- /N12345678*G12*G12*Xt12345678*Yt12345678*Ut12345678*Vt12345678*Zt12345678*H1234567*D123*F123455678*M123** ABCDEF 123 It12345678 Jt12345678 Wt12345678 E123 R+12345678




7.3. NCDATA The NCDATA consists of:

%(program number) (LF) NC-blocks (LF) %

Documents

User Manual - KPNhome.planet.nl/~folke195/postprocessor/CHMEDM.pdf · Page: 3 of 23 Version: 1.1 User Manual Postprocessor CHMEDM Charmilles - Robofil 6000 Date: 30 may 1995 Date