Southwestern Industries ProtoTRAK Plus Programming, Operating & Service Manual

ProtoTRAK® Plus

Programming, Operating & Service Manual

Document: P/N 15692 Version: 070390

Southwestern Industries, Inc.

2615 Homestead Place Rancho Dominguez, CA 90220 USA T | 310.608.4422 | F | 310. 764.2668

Service Department: 800.367.3165

e-mail: sales@southwesternindustries.com | service@southwesternindustries.com | web: southwesternindustries.com

Copyright © 2008, Southwestern Industries, Inc. All rights are reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, mechanical, photocopying, recording or otherwise, without the prior written permission of Southwestern Industries, Inc.

While every effort has been made to include all the information required for the purposes of this guide, Southwestern Industries, Inc. assumes no responsibility for inaccuracies or omission and accepts no liability for damages resulting from the use of the information contained in this guide.

All brand names and products are trademarks or registered trademarks of their respective holders.

Southwestern Industries, Inc. 2615 Homestead Place Rancho Dominguez, CA 90220-5610 Phn 310/608-4422

 Fax 310/764-2668

Service Department Phn 800/367-3165

 Fax 310/886-8029

ProtoTRAK

Pl1r.s

Progrnmming.

Operaring & Cure Manual

Table

of

Contents

1

-0

Introduction

.............................................

1

2.0

Description

..............................................

2

Keyboard

............................................................

-2

..............................................................

Displays

3

Pendant Back Panel

................................................

-3

Power Control Cabinet

.............................................

-3

.............................................................

2.5

Encoders

-3

........................................................

2.6

Servo Motors

-4

...............................................

2.7

Ball

Screw Assembly

-4

................................................

2.8

Tape Cassette Deck -4

3.0

Definitions.

Terms.

and

Concepts

....................

5

.....................................

3.1 ProtoTRAK Axis Conventions

5

...............................

3.2

Absolute

&

Incremental Reference

-5

...........................

3.3

Referenced and Non-Referenced

Data

-6

.....................................

3.4

Tool

Diameter Compensation

-6

..................................................

3.5

Connective Events 10

..............................

...................

3.6

CONRAD

....

-10

4.0

DRO.

JOG.

POWER

FEED

Operation

..............

12

..........................................................

4.1

Clear

Entry

12

4.2

IN

to

MM

or

MM

to

IN

............................................

12

.....................................................

4.3 Reset One Axis

12

................................................................

4.4 Preset

12

4.5 Reset Absolute Reference

.........................................

12

.........................................

4.6 Preset Absolute Reference

12

............................

4.7 Recall Absolute Position of

All

Axes

12

4.8 Recall Absolute Position on One Axis

...........................

13

..................................................

4.9 Feedrate Ovemde 13 4-10

JOG

..................................................................

13

.........................................................

4.1

1

Power Feed 14

5.0

Programming & Program

Run

........................

15

.

...................................

.

5 ! Incremental

Reference

120sltion

15

...........................................................

5.2

CONRAD

15

..................

5.3 POSITION

or

DR[L,I..

(POSN/DRII,

L)

Events

16

...............................................

5.4

BOLT

HOLE

Events

17

........................................................

5.5

MILI, Events

18

........................................................

5.6

ARC Events

-20

.....................................................

5.7

CIRCLE

Events

22

ProloTR,.lK

Pll~s

Progratnrning. Oporurit1y & Care

Mnnuul

...................................................

5.8

POCKET Events -24

....................................................

5.9

REPEAT

Events

26

...........................

5.10

Start,

Stop

and Running Several Parts

28

5.11 Editing

..............................................................

29

..........................................

5.12 Tape Cassette Operation 34

...........................................

5.13 RS232 Communications 37

..................................................

5.14 Program Sample

-39

6.0

DO

ONE

Operation

.

Program

&

Run

..............

42

...................................

6.1 Incremental Reference Position

42

........................................

6.2

DO

ONE

Program

&

Run

-42

.....................................................

6.3 Cutting Comers

43

6.4

DO

ONE Editing

..................................................

-44

7.0

Math

Help

...............................................

45

...........................................................

7.1

Procedure -45

..................................................

7.2

Math

Help

Types

-46

8.0

Care & Service

.........................................

54

..............................................

8.1

General System Care -54

...............................................

8.2

Data Error Messages

54

....................................................

8.3 Fault Messages

-56

....................................

8.4 ProtoTRAK

Limited

Warranty

57

Section

1

Introduction

1

I

1.0

Introduction

Congratulations! Your ProtoTRAK is a unique, one-of-a-kind, control system which combines the simplicity of manual machining with the contouring capability of CNC controls.

The ProtoTRAK has been designed to maximize the interplay between manual and automatic machining.

o

It

acts like an advanced digital readout in manual machine

operation.

o It acts like

a

CNC when programmed to do complex contouring

jobs.

o And it acts with the best qualities of each when your job is best

done

by

transitioning back and forth between manual and contouring

CNC

operations with the powerful

DO

ONE

routines.

Section

2

provides a brief description of the ProtoTRAK.

Section

3

defines some terms and concepts useful in learning to program and operate

the ProtoTRAK. Section

4

describes the digital readout (DRO), jog, and power

feed

operation of the

ProtoTRAK. Section

5

describes general programming and program run.

Section

6

describes programming and running DO ONE routines.

Section

7

describes the Math Help features built into the ProtoTRAK.

Section 8 provides some suggestions for the proper care and maintenance as well as error messages.

Secrion 2 Descriprio~r

1

2

-0

Description

2.1

Keyboard

(Figure

1)

All of the data required to properly program and operate the ProtoTRAK is input through

the

keyboard. This sealed polycarbonate front panellkeyboard

will

beep when

proper contact has been made with

each

key.

X,

Y,

Z:

selects axis for subsequent commands.

DO

ONE:

calls up single cycle routines.

POSN

DRILL:

calls up the positionldrill routine.

BOLT

HOLE:

calls

up

bolt hole routine.

MILL:

calls up the straight line

mill

routine.

ARC:

calls up the arc mill routine.

CIRCLE:

calls

up

circular pocket or frame routines.

REPEAT: calls up programming of subroutines.

POCKET:

calls up rectangular pocket or frame routines.

START: initiates the start of a program or

DO

ONE.

PWR

FEED:

activates power feed routines.

FEED?:

feedrate override to increase feedrate.

FEED& : feedrate override to decrease feedrate.

INC

SET: loads incremental dimensions and general data.

ABS

SET:

loads absolute dimensions and general data.

INIMM: causes English to Metric or Metric to English conversion of displayed data.

TAPElRS232: calls

up

read or write cassette tape program storage and

CAD/CAM

interface routines.

INCIABS:

switches all or one axis from incremental readout to absolute or absolute

to

incremental

.

RESTORE:

clears an entry, aborts

a

keying

procedure, restores

;l

failure or warning

indication, and aborts Math

Help.

STOP:

halts motion during program or

DO

ONE

run.

GO:

continues rnotion after

STOP,

actuates

jog

routine.

MATH

HELP:

calls up Math Help routines. EDIT: calls up recall, add event, delete event, and special mode routines. RECALL DATA: cycles readout through programmed data.

*

:

not used.

0-9,

+I-,

.

:

inputs numeric data with floating point format. Data

is

automatically + unless

+I-

key is pressed. All input data

automatically rounded to the system's resolution.

2.2

Displays

(Figure

1)

X,

Y,

Z:

shows current position or data being entered during

program or

DO ONE

input. Non-dimensional program or DO

ONE

input will always be displayed in

2.

A red dot above the

+/-

display indicates absolute dimensions are being displayed.

EVENT:

shows event number and type being programmed or run.

D

indicates a posi tion/drill event; B for Bolt Hole; M for Mill;

A

for Arc; R for

Repeat,

C for Circle, and P for Pocket.

CONVERSATION: shows prompting messages for the operation during program and

Nn. SERVOS ON: indicates that the

DC

servo motors and amplifiers are turned on.

IN

POSITION: indicates that the tablelsaddle have stopped moving

and the

ProtoTRAK awaits further input.

2.3

Pendant

Back

Panel (Figure

2)

See Figure 2 for a description of the fuses, switches, and connectors

on

the pendant back panel.

2.4

Power

Control Cabinet

(Figure

3)

The power control cabinet contains the unique SWI digital servo amplifiers which drive the

DC

servo motors. See Figure 3 for a description of the

connectors located on the side.

2.5

Encoders

The encoders

used

to provide dircct table

and

quill position

feedback to

the

I'roto'I'RAK are sealed

against

typical shop environ-

men

ts and utilize the time proven gage-wheel principal. Model

M250C

is

used

all

axes.

Section 2 Description

1

4

2.6

Servo Motors

The servo motors are rated 280 in-oz maximum continuous torque which are sufficient

for

the heaviest cuts.

2.7

Ball Screw Assembly

The normal acme leadscrews are replaced with zero backlash ball bearing leadscrews to provide accurate positioning and precise contouring.

2.8

Tape

Cassette

Deck

(optional)

The cassette deck allows all programs to be saved on tape for future run. The deck is held in a separate enclosure which

can

be easily moved from one ProtoTRAK to another

or

used

with a

TRAK

CNC

or

TRAK CNC

2.

Additional tapes may be obtained by contacting:

Southwestern Industries,

Inc.

2605

Homestead Place

Rancho Dominguez,

CA

90220

2 131608-4422

FAX 2 131764-2668

L

0

+'

U

N

W

Ill

LOU

ms

cvr

w.rr

NC

nr

3mr

VJO

roo

000

rro

I-U

ado

POWER

CONTROL

CABINET

(Side

View)

X

Motor

Connector

.(im).

d

Pendant Logic

Connector

I

Switch

FIGURE

3

1

Section

3

Deiinjtions,

Terms.

and

Concepts

1

5

3.0

Definitions, Terms,

and

Concepts

3.1

ProtaTRAK

Axis

Conventions

X

Axis

-

Positive

X

axis

motion

is

defined

as

the

table

moving

to

the

left

when

facing

the

mill.

Consequently, measurement to

the

right

is

positive

on

the workpiece.

Y

Axis

-

Positive

Y

axis

motion

is

dehed

as

the

table

moving

toward the

operator. Measurement toward

the

machine

(away

from

operator)

is

positive

on the workpiece.

Z

Axis

-

Positive

Z

axis

motion is defined

as

moving

the

quill

up.

Measurement

up

is also

positive on the workpiece.

3.2

Absolute

&

Incremental

Reference

The

ProtoTRAK

may

be programmed

and

operated

in

either (or

in

a

combination)

of

absolute or incremental dimensions.

An

absolute reference

from

which all absolute dimensions

are

measured

(in

DRO,

DO

ONE

and

program operation) can be set

at

any point on or

even

off the workpiece.

To help understand the difference

between

absolute

and incremental

position

consider

the

example below:

1

Absol

ute

Dimensions

A.bsol ute

Reference

Iricremental Diinensi on5

3.3

Referenced

arid

Non-Referenced

Data

Data is always loaded into the ProtoTR4.K by using the

INC

SET

or

US

SET

key.

In

entering

any

X,

Y,

or

Z

position

data

the operator must note whether it is an incremental or absolute dimension and enter it accordingly.

All

other information,

such

as

tool diameter,

feedrate,

etc. is not a position

and

may,

therefore, be loaded

with

either

the

INC

SET

or

ABS

SET

key.

3.4

Tool

Diameter

Compensation

Tool

diameter compensation allows the machined edges

shown

direct-

ly on

the

print to be programmed instead

of

the center of the tool.

The

ProtoTRA.K

then

automatically compensates for the programmed

geometry so that the desired results are obtained.

If

the

cutter

in

the

sketch

above is moving

from

left

to

right

from

point

XI,

Y1

to

X2,

Y2

and on to

X3,

Y3

then

these

actual

points

can

be programmed instead

of

the

center of the

cutter.

Section

3

Definibbns,

Terms,

and

Concepts

1

7

Or

for

the

sketch

above

the

actual desired circle

with

radius

R

can

be

programmed instead

of

the

radius

of

the

center

at

the

cutter

Rc.

Tool

cutter

compensation

is

always

specsed

as

the

tool

either

right or

left

of

the

workpiece

while

looking

in

the

direction

of

the

tool

motion.

Below are

examples

of

tool

right:

Examples

of

tool

left

are:

Tool

center

means

no compensation

either

right

or left.

That

is,

the

centerline of the

tool

will

be

moved to the programmed

points.

3.4.1

Special Small Step

Milling

Situation

Ln

cases

where tool diameter compensation is to

be

used to

mill

a connective

step

whose length

is

less than

the

tool radius,

an

offset distance must

be

calculated

and

used to adjust the

beginning or ending point (depending on the direction of

the

milling

cut)

of the event.

-

7

'3

X4,

Y4

XI,

Y1

In

the

figure

above, to mill from

XI,

Y1

to X2,

Y2

to

X3,

Y3

to

X4, Y4

when the

length

of the step

from

X2,

Y2

to

X3,

Y3

is

less than

the

radius

(R)

of the tool, point

X2,

Y2

would have to

be

offket toward point

XI,

Y1

by

a distance equal to d.

d

can

be

calculated using the following formula:

where

R

=

tool radius

L

=

length of step

from

X2,

Y2

to

X3,

Y3

(2)

For rough machining d

may

be estimated quickly

by

multiplying the tool diameter

by

0.15.

CAUTION:

Using

this

method may result in larger than necessary

offsets

when

the step

is

very

small and the tool

diameter

is

very

large.

The

following examples show

how

d

map be calculated and

estimated. Example

2

iilustrates

how a larger than necessary

offset

results when a large tool is used

and

d is estimated.

Section

3

Definirions

Terms,.

and

Concepts

1

,9

EXAMPLE

1

Let

XI

=

0"

ABS

Using

Formula

1

to

calculate

d:

Y1

=

0"

AB

*

=

1,~

d

ABS

!.r,ri!z

d

=

(.125-.050)

(4~)

Y2

=

0"

ABS

2(.125)-.050

X3

=

1.500"

ABS

d

=

(.075)

Y3

=

0.050"

ABS

(m)

X4

=

3.000" ABS

d

=

(-075)

(G)

Y4

=

0.050"

ABS

Tool

Diameter

=

.250"

d

=

(.075)(.5)

Using

(2)

to

estimate

d:

By

using

d

calculated

X2

would

d

=

(.25)(.15)

be

adjusted

to

1.462"

ABS

for

d

=

.038

programming

EXAMPLE

2

Let

X1

=

0"

ABS

Using

Formula

1

to

calculate

d:

-

Y1

=

0"

ms

X2

=

1.500" ABS

d

=

(-375-.010)

(-)

Y2

=

0"

ABS

X3

=

1.500" ABS

d

=

(.365)

(m)

Y3

=

0.010"

ABS

X4

=

3.000"

ABS

d

=

(.365)

(F)

Y4

=

0.010"

ABS

\

/

Tool Diameter

=

,750"

d

=

(.365)(.116)

Using

(2)

to

estimate

d:

3.5

Connective

Events

Connective events occur between two milling events (either

MILL

or

ARC,

but not

CIRCLE)

when

the

X,

Y,

and

Z

ending points of

the

first

event are

in

the

same location

as

the

X,

Y,

and

Z

starting points of

the

In

addition,

the

tool ofFset-s and tool number of

both

events

must

be

the

same.

3.6

CONRAD

is

a

unique

feature of

the

ProtoTRAK in

that

it allows

the

operator to program

a

tangentially co~ecting radius

between

connec-

tive events

or

tangentially connecting

radii

for the corners of

pockets

and

kames

without

the

necessity of complex calculations.

A

few typical

examples

of

CONRAD

applications are described below.

For

the

figure below, the operator

simply

programs

a

MILL

event from

XI,

Y1

to

,W,

Y2

with

tool right offset

and

another

MILL

event from

X2,

Y2

to

X3,

Y3

also

with

tool right offset. During

the

programming

of

the first

MILL

event

the

system will

prompt

for

CONRAD

at which time

the

operator

inputs

the

numerical

value

of

the

tangentially

connecting

radius (r=k).

The

system will calculate the tangent

points

TI

and

TZ

and

direct

the

tool

cutter

to

move

continuously from

XI,

Y1

through

TI,

r=k,

T2

to

X3,

Y3.

kction

3

Def?njh'ons

Terms,

and

Concepts

I

11

For the

figure

below,

the

operator simply programs

an

ARC

MILL

event

from

XI,

Y1

to

X2,

Y2

with

tool

offset

left

and another

ARC

MILL

event

from

X2,

Y2

to

X3,

Y3

also

with

tool ofFset left. During

the

programming

of

the first

ARC

MILL

event the system will prompt for

CONRAD

at

which

time the operator

inputs

the

numerical value

of

the

tangentially

co~ecting radius r=K3.

The

system will calculate the tangent

points

TI

and

T2

and

direct

the tool cutter

to

move continuously from

XI,

Y1

through

TI,

r==,

T2

to

X3,

Y3.

NOTE:

CONRAD

must

always

be

the same or larger

than

the

tool radius

for inside corners.

Lf

CONRAD

is less

than

the tool radius

and

an

inside

corner

is

machined,

the

ProtoTRAK

will

ignore

the

CONRAD.

Secrion

4

DRO,

JOG,

POWER

FEED

Operation

1

12

4.0

DRO,

JOG,

POWER

FEED

Operation

The ProtoTRAK operates in manual operation as a sophisticated three-axis digital readout

(DRO)

with jog and power

feed

capability.

4.1

Clear

Entry

Press

RESTORE,

then re-enter

all

keys.

Press

WIMM

and observe position of decimal point

to

determine

measurement mode.

4.3

Reset

One

Axis

Press X or Y or

2,

INC

SET.

This zeros the incremental position in the

selected axis.

4.4

Preset

Press

X

or

Y

or

2,

numeric data,

INC

SET

to preset selected axis.

4.5

Reset

Absolute

Reference

Press

X

or Y or

2,

ABS

SET

to set selected axis absolute to zero at the

current position. See

4.7

and

4.8

to display this data.

NOTE:

This

will

also reset the incremental dimension

if

the

absolute

position is being displayed when it is reset.

4.6

Preset

Absolute

Reference

Press X or Y or

2,

numeric data,

ABS

SET

to set the selected axis

absolute to

a

preset location for the current machine position.

See

4.7

and

4.8

to display this data.

NOTE:

This will also reset the incremental dimension

if

the absolute

position

is

being displayed when it is preset.

4.7

Recall Absolute

Position

of

All

Axes

Press

TWC/ABS.

Note presence of red dot above each

+I-

to

determine

if

the axis is reading incremental (no red dot) or absolute data

(red

dot).

Press

INC/ABS

again to revert to the original reading.

4.8

Recall

Absolute

Position on

One

Axis

Press X or Y or

Z,

INCJABS.

Note presence of red dot above selected

axis

+I-

to determine if the axis is reading incremental data (no red dot) or absolute data (red dot). Repeat to get selected axis back to original reading.

4.9

Feedrate

Override

The feedrate may be modified during any program run (including while the table

is

moving), during Jog operation, and during Power

Feed

operation

(see

4.10 and 4-11 below).

Pressing and holding the

FEED&

key will slow the feed down. The

FEED

key increases the feed

in

the same

way.

The

limits are 10 percent to

150

percent of the programmed rate, but not faster than the

100

inches

per minute rapid speed. The

feedrate change will always stop as it passes

100%. Release the key and press again to continue the change.

While the

Feed?,

or

Feed\Lkey

is pressed, and for one second following

release, the percent

feedrate (or actual feedrate for power feed) will be

shown in the conversation display.

4.10

JOG

The servo motors can be used to jog the table. To jog at rapid

(100

ipm): a)

Press and hold for

3

seconds the

GO

key.

b)

The conversation display will flash

"JOG+"or "JOG-" and the Servo On

display will be lit.

c)

Press the X key to move at rapid speed in the X direction shown.

d)

Press the Y key to move at rapid speed in the Y direction shown.

e)

Press

+/-

key to switch between

"

+"

and

"-"

jog direction.

f)

Press

FEED?,

or FEEDbkey to change feedrate. The conversation

display will show the percentage

feedrate override.

g)

Press

RESTORE

to cancel jog operation.

For slower jog speeds:

Use

the same procedure as above except press a two-digit feedrate

(2

7

means to feed at

27

ipm) prior to pressing X or

Y.

The

new

feedrate

(27

in

the above example) can now be modified by the feedrate override.

The feedrate can be changed at any time by releasing X or Y, inputting a

new

two-digit rate, and re-pressing X or Y.

Section 4 DRO, JOG,

POWER

FEED

Operation

(

14

4.1

1

POWER

FEED

The servo motors can be used as a power feed for the table or saddle. a)

Press PWR FEED. The conversation display

will

read PWR FEED

100

(PWR FEED

2500

in metric), indicating the applicable feedrate.

b)

Press

FEED^,

or

FEED-~~O

adjust the feedrate between rapid and

0.2

inch per minute

(5mm

per minute).

c)

Press

X

or

Y,

the distance to move, and

MC

SET.

d)

Press

GO

to begin power feed.

e)

When complete, the

M

POSTTION

light will come on but the servos

will be

turned

off allowing manual X and Y movement.

f)

To power feed again, start at

@)

or (c) above.

g)

Press RESTORE to abort power

feed

operation.

Sectjoon

5

Programming

&

Program

Ron

1

15

Programming

Program

Run

5.1

Incremental Reference

Position

When

X

and

Y

data for the beginning position of any event are input

as

incremental data, this increment must

be

measured from some known point in the previous event. Following are the positions for each event type from which the incremental moves are

made

in

the

subsequent event:

POSITION/DlULL:

X

and

Y

programmed

BOLT

HOLE:

X

CENTER and

Y

CENTER

programmed

MILL:

X

END

and

Y

END

programmed

ARC:

X

END

and

Y

END

programmed

CIRCLE:

X

CENTER

and

Y

CENTER

programmed

POCKET:

X1

and Y1 corner programmed position

REPEAT:

The

appropriate reference position for

the

last event which

is

being repeated.

For example,

if

an

ARC

event followed a

MILL

event, a

2.0

inch

incremental

X

BEG

would mean that in the

X

direction the beginning

of

the ARC event is

2.0

inches from the end of the

MILL

event.

5.2

CONRAD

5.2.1

For

MILL & ARC

Events

During programming the ProtoTRAK will prompt for a CONRAD input for each

MILL

and

ARC

event. Section

3.6

describes

the

CONRAD routine and

specifies that to have a

CONRAD

between

two

events they must be

connective-that is the

X,

Y, and

Z

at the end of the first event must be

the same as the

X,

Y,

Z

of the beginning of the second, and the tool

compensation direction and number must be

the

same. When these

conditions are met the ProtoTRAK

will

machine (without stopping) through

the first event, through the connecting radius

(CONRAD)

and through the

second event. However, since no

Z

data is programmed into

the

ProtoTRAK it is impossible for the system to determine if all conditions for connective events have been met. Consider the figure below.

Lf

two milling events

are programmed from

XI,

Y1 to

X2,

Y2

and

X2,

Y2

to

X3,

Y3

should the

program immediately proceed in running the second

mill

event after the

first,

or

stop in between? How does the ProtoTRAK know

if

the second

cut

is

at

the

same or different depth?

The

following rules or procedures are used

to

make

the

determina-

tion:

1)

If

a non-zero

CONRAD

is programmed

by

pressing

NUMERIC

DATA,

INC

SET

or

ABS

SET

the

run will automatically

machine the connecting radius and proceed through

the

next event providing

all

other

(non-Z)

conditions for

a

connective event are met.

2)

If a zero

CONRAD

is

programed

by

pressing

0,

INC

SET,

or

ABS

SET

keys the

run

will

also automatically proceed through

the next event and generate

a

zero comer radius within the

lirnit of

the

tool.

3)

If

a

CONRAD

is

programmed without any numeric data (including

0)

bv

pressing just

INC

SET

or

ABS

SET

the run

will

stop at

the

end

of the first event and command

"SET

2".

Note that

if

the cutter is

not

raised before pushing

GO

to

mill

from

X2Y2

to

X3Y3,

the top of the corner

at

,XY2

will

be

milled

off

(see

Sec.

6.3.).

It is always good practice

to

raise

the

tool

between non-connective

events.

5.2.2

For

Pocket

Events

CONRAD

has

a

slightly different meaning

within

the

POCKET

event.

Here

the term means "comer radius"

which

is

the radius generated

at each

of

the four corners of

the

rectangular pocket or frame.

A

connective radius cannot connect

a

MILL

or

ARC

into a pocket or

frame,

or

used with the

CIRCLE

or

REPEAT

events.

5.3

POSI-[ION

or

DRILL

(POSN/DRILL)

Events

Th~s event tvpe positions the table at a speciiied position for subsequent operation

(like

drilling).

The

positioning

is

always at

rapid speed (modified

by

feedrate override) and

in

the most

direct

path

possible from the previous location.

Section

5

Programming

6

Program

Run

1

17

5.3.1

Position

or

Drill

Program

Displayed Prompt Definition of Prompt

Keyboard

Input

I

X

dimension

POSN/DRILL event

display

indexes

by

one

and

is

proceeded

by

D

NUMERIC

DATA,

INC

SET or

ABS

SET

dependmg on whether

X

dimension

is

incremental or absolute

Y

I

Y

dimension

NUMERIC

DATA,

INC

-

SET

or

ABS

SET

TOOL

#

input

Input

tool number--the same

as

last event

is

automatically

assumed

if

there

is

no numeric

5.3.2

Position

or

Drill

Run

NUMERIC

DATA,

SET

When

a

Position/Drill event is run the following sequences

take

place:

a) The table moves

at

rapid (or less

if

modified

by the feedrate

override) to the programmed

X

and

Y

along

the

most direct path.

b)

The actual feedrate is displayed in the conversation display.

c) When in position,

the

"IN

POSITION"

light

will

turn on.

d)

The

conversation display

will

command

"SET

Z"

e)

When

the event is complete and

the

tool is clear the operator

presses the

GO

key to proceed to the

5.4

BOLT

HOLE

EVENTS

5.4.1

BOLT

HOLE

Program

This

event

allows

a

bolt

hole pattern to

be

drilled without needing

to

compute and move to the positions of

each

hole.

Displayed

Prompt

Definition

of

Prompt

Keyboard

Input

I

#

HOLES

Number

of

eve*

spaced

holes

(up

to

99)

in

the

bolt

hole pattern

BOLT

HOLE,

the

event display

irldexes

by one and

is

proceeded

by

B

NUMERIC

DATA,

SET

number of

holes

in

the boll hole pattern

Displayed Prompt

X

CENTER

Y

CENTER

RADrLJS

ANGLE

Definition

of

Prompt

X

dimension to center of

hole pattern

Y

dimension to center of

hole pattern

Dimension from center of hole pattern to center of

any

hole

Angle from positive

X

axis

(that

is

3

o'clock) to

any

hole; positive angle

is

measured counterclockwise kom

000.000

to

359.999

degrees

Input

tool number;

the

same

as

last event

is

automati-

cally

assumed

if

there

is

no

numeric

input

Keyboard

Input

I

NUMERIC

DATA,

INC

SET

or

ABS

SET

KUMERlC

DATA,

INC

SET

or

ABS

SET

NWMERIC

DATA,

SET

NINERTC

DATA,

SET

NLJMERIC

DATA, SET

5.4.2

BOLT

HOLE

Run

When a Bolt Hole event is

run

the following sequences take place:

a)

The table moves at rapid (or less

if

modified

by

the

feedrate

override) to the first hole location along the most direct

path.

b)

The actual feedrate is displayed in the conversation display.

c) When in position, the

"IN

POSITION"

light will

turn

on.

d)

The conversation display will command

"SET

2"

e)

When the first hole is drilled the operator preses

GO

to move

to the next

hole.

f)

(a)

through

(e) are repeated for each hole.

g)

When the last hole is complete and the tool is clear, the

operator presses the

GO

key to proceed to the next event.

5.5

MILL

Events

This event allows

the

operator to mill in a straight line

from

any one

XY

point to another including at

a

diagonal.

It

may be

programmed with

a

CONRAD

if

it

is

connective

with

the next event.

Section

5

Programming

Si

Program Run

1

19

5.5.1

Mill

Program

Displayed Prompt

--

X

BEG

Y

BEG

X

END

Y

END

CONRAD

FEEDRATE

TOOL

#

Definition of Prompt

X

dimension to beginning of

mill

cut

Y

dimension to

begmnmg

of

mill

cut

X

dimension to end of

mill

cut; incremental

is X BEG

Y

dimension to end of

mill

cut; incremental is

Y

BEG

Dimension of tangential radius to next event (Note: must input

0

or a number

if

next event

is

connective,

otherwise no numeric input)

Select tool offset to right (I),

tool o&et to left

(2),

or tool center--no offset

(0),

relative to programmed edge and direction of

tool

cutter

movement

Keyboard Input

MILL,

event

display

indexes

by

one

and

is

proceeded

by

M

NUMERIC DATA,

INC

SET

or

ABS

SET

NUMERIC DATA,

INC

SET

or

ABS

SET

NUMERIC DATA,

INC

SET

or

ABS

SET

NlJhlERIC

DATA,

INC

SET

or

ABS

SET

NUMERIC DATA, SET

0

or 1 or

2,

SET

(press

only

SET

if

same

as

last event)

Milling

feedrate

in

in/min

from

.1

to

99.9

or

mrn/min

from 5 to

2500

TOOL

DU

*

I

Tool diameter

I

NUMERIC

DATA,

SET

NUMERIC DATA, SET

(press only

SET

if

same

as

last event)

Lnput tool number--the

same

as

last event

is

automatically

assumed if there

is

no

numeric input

*

No

prompt

if

the

tool

has

been programmed

in

a

previous event.

NUMEEUC

DATA,

SET

(press only

SET

if

same

as

last

event)

5.5.2

Mill

Run

When a Mill event is run the following sequences take place: a) The table moves at rapid (or less

if

modified

by

the

feedrate

override)

to the

X

BEG

and

Y

BEG

location along the most direct

path,

offset

to

the left or

right

by

the tool radius as

programmed.

b)

The actual feedrate is displayed during

all

movement

in

the

conversation display.

c)

When in position the

"IN

POSITION"

light will

turn

on.

d)

The conversation display comments "SET

Z".

e) When

Z

has been properly positioned the operator presses the

GO

key.

f)

The

table

moves in a straight line at the programmed feedrate

(or

as

modified by the percent feedrate override) to the

X

END

and

Y END

position again offset

by

the tool radius.

g)

The

"IN

POSITION"

light turns on.

h)

The conversation display comments

"SET

Z"

if

the next event

uses the same tool or "TOOL

N"

if the next event uses a different

tool, number

N.

i) The operator presses the

GO

key to proceed to the ne-xt event.

j)

Steps

(g),

(h),

and

(i)

are eliminated when there is a

CONRAD

(even

a

zero

radius

CONRAD) connecting to the next event.

5.6

ARC

Events

This

event allows

the

operator to mill

with

circular contouring

any

arc (fraction of a circle).

In

ARC

wents, when

X

CENTER

and

Y

CENTER are programmed

incrementally

they

are referenced from

X

END

and

Y

END

respectively.

Section

5

Programming

&

Program

Run

1

21

5.6.1

Arc

Program

Displayed Prompt Dewtion of Prompt

BEG

I

Y

dimension to

beginning

of

arc cut

--

X

BEG

-

X

dimension to beginning of

arc

cut

END

I

Y

dimension to end of arc cut;

incremental is from

Y

BEG

X

END

X

dimension to end of arc cut;

incremental is from

X

BEG

X

CENTER

Keyboard Input

-

ARC,

event display indexes

by

one

and

is

proceeded

by

A

X

dimension to center of arc;

incremental

is

from

X

END

Y

CENTER

NUMERIC

DATA,

INC

SET

or

ABS SET

Y.

dimension to center of arc;

incremental is from

Y

END

NUMERIC

DATA,

INC

SET

or

ABS SET

NUMERIC

DATA,

INC

SET

or

ABS SET

NUMERIC DATA,

INC

SET

or

ABS

SET

NUMERIC

DATA,

INC

SET

or

US SET

NUMERIC

DATA,

INC

SET

or

ABS SET

CONRAD

1

or 2,

SET

CW1

CCW2

Dimension of tangential radius to

next event (Note: Must input

a

number

or

0

if

next event is con-

nective, otherwise no numeric

input)

Select

if

arc is to be

milled

in clockwise

(I),

or counter-

clockwise

(2)

direction

NUMERIC

DATA, SET

CO

R1

LZ

FEEDRATE

Select tool offset to

right

(I),

tool offset to left (2), or tool center--no offset

(O),

relative

to programmed edge

and

direction

of tool cutter movement

TOOL

#

*

No prompt if

the

tool

has

been programmed

in

a

0

or 1 or

2,

SET

(press only

SET

if

same as

last

event)

Milling

feedrate

in

in/min

from

.1

to

99.9

or

rnm/min

from

5

to

2500

TOOL

DLA*

NUMERIC

DATA, SET

@ress only

SET

if

same as last event)

Input

tool number--the same

as

last event is automatically assumed

if

there

is

no numeric

input

NUMERIC

DATA, SET

(press only

SET

if

same

as

last event)

Tool diameter

NUMERIC

DATA,

SET

5.6.2

Arc

Run

When an Arc event is run the following sequences take place: a)

The

table moves at rapid (or less

if

modified

by

the

feedrate

override) to the

X

BEG

and

Y

BEG

location along the most direct

path, offset to the left or right

by

the tool radius as

programmed.

b)

The actual feedrate is displayed

during

all movement

in

the

conversation display.

c) When

in

position

the

"IN

POSITION"

light will

turn

on.

d)

The

conversation display comments

"SET

2".

e) When

Z

has been properly positioned the operator presses the

GO

key.

f)

The table moves along the arc at the programmed feedrate (or as

modified by the percent

feedrate override)

to

the

X

END

and

Y

END

position

a.gain

offset

by

the

tool radius.

g)

The

"IN

POSITION"

light turns on.

h)

The conversation display comments

"SET

Z"

if the next event uses

the same tool or

"TOOL

Nu

if

the next event uses a different tool,

number

N.

i)

The

operator presses the

GO

key to proceed to the next event.

j)

Steps

(g),

(h),

and (i) are eliminated when there

is

a

CONRAD

(even

a

zero radius

CONRAD)

connecting to

the

next event.

5.7

CIRCLE

Events

This event allows the operator

to

mill

a

circular frame or pocket.

A

circular frame

is

machining the circumference only. Frames may

be

inside (e.g., a circular cutout) or outside (e.g., cleaning up the circumference and

sizing

the diameter of

a

round piece).

A

circular

pocket is machining

the

circumference and all the material within

that

circumference.

The event also provides for an automatic finish

cut.

Section

5

Proprnmhg

&

Progran~

Run

1

23

5.7.1

CIRCLE

Event

Program

Displayed Prompt Definition of Prompt Keyboard Input

X CENTER

Y

CENTER

Select if event

is

a

pocket

(1)

or

be

(2)

X

dimension to center

of circle

Y

dimension to center

of circle

CIRCLE,

event

display

indexes

by

one

and

is

preceded

by

C

1

or

2,

SET

NUMERIC

DATA,

INC

SET

or

ABS SET

NUMERIC

DATA,

INC

SET

or

ABS

SET

RADIUS

FLnish

radius of circle

I

mE81C

DATA,

SET

FIN

CUT

FEEDRATE

TOOL

#

Select if circle

is

ta be

milled

clockwise

(I),

or

counterclockwise (2) direction

1

or

2, SET

Select tool o&et to right

(I),

tool o&et to left (2),

or too1 center--no o&et (O),

0 or

1

or

2,

SET

Width of

finish

cut;

if

0

is

entered no

finish

cut

will

be

made

relative to programmed edge and direction of

cutter

movement

NUMERIC

DATA,

SET

Milling

Feedrate

in

in/min

from

.1

to

99.9

or

mm/min

-

fiorr?

j

to

2500

TOOL

DIA

*

Tool dimetrr

I

SET

NIMERIC

DATA,

SET

Input

tool number; the same

as

last event

is

automati-

cally

assumed

if

there

is

no

numeric input

*

NO

prompt

if

the tool

has

been programmed

in

a previous event.

NUMERIC

DATA,

SET (press

only

SET

if

same

as

last event)

5.7.2

CIRCLE

Run

When

a

CIRCLE

event: is

run

the following sequences

take

place:

a)

The

table

moves

at

rapid (or

less

if

modified

by

the

feedrate override)

to

a

point on

the

circle

closest to

the

initial

position

of

the

tool,

and

offset

to the left

or

right

by

the tool radius

and

finish cut

as

programmed.

b)

The actual feedrate is displayed

in

the conversation display

during all movement.

c) When in position, the

"IN

POSITION" light will turn on.

d) The conversation display will command

"SET

2"

e) When

Z

has been properly positioned, the operator presses the

GO

key.

f)

For CIRCULAR

FRAMES

the table moves at the programmed feedrate

(or

as

modsed by override) to machine complete circle. At

completion, it moves to the final dimension and machines

the

finish cut.

g)

For CIRCULAR POCKETS the table moves at the programmed feedrate (or as modified by the override) to machine inside the circumference

leaving the

fkish cut. The feed continues until the interior of

the pocket is complete. Lastly, the finish cut

is

made to the final

programmed dimension.

h) The conversation display comments

"CHECK

Z"

if the

the

same tool or "TOOL

N"

if

the next event uses a different tool,

number

N.

i) The operator presses the

GO

key to proceed to the next event.

5.8

POCKET

Events

The POCXET event allows the operator to mill a rectangular frame or

pocket.

A

rectangular frame

is

machining the circumference only.

Frames may be inside

(e-g., a cutout) or outside (.e.g, cleaning up or

sizing the outside of

a

rectangular block).

A

rectangular pocket

is

machining the circumference and all the material

within

that

circumference.

The event also provides for an automatic finish cut and any legitimate corner radius providing it is greater than the tool radius on pockets and inside frames.

5.8.1

Pocket

Event

Program

Displayed Prompt Deanition

of

Prompt Keyboard Input

I

POCKET, went

display

indexes

by

one and

is

preceded

by

P

Select

if

event is a pocket

(1)

or

frame

(2)

1

or

2,

SET

X

1

X

dimension to

any

comer

NUMERIC

DATA,

INC

SET

or

ABS

SET

Section

5

Programming

&

Prugram

Run

1

25

Displayed Prompt Defhition of Prompt Keyboard

Input

I

CONRAD

FIN

CUT

FEEDRATE

TOOL

#

Y

dimension to

same

comer

as

X1

X

dimension to opposite

comer

as

XI.

Incremental

from

X1

Y

dimension to

same

corner

as

X3.

Incremental £rom

Y1

Value of tangential

radius

in

each comer

Select

if

rectangle

is

to be

milled

in

clockwise

(1)

or

counterclockwise

(2)

direction

Select

if

tool o&et

is

right

(I),

tool offset to left

(2),

or tool center--no o6et

(0),

relative to programmed edge and

direction of tool cutter

movemen

Width of

Wh

cut;

if

0

is

entered no finish cut

will

be

made

Milling

feedrate

in

in/min

kom

.1

to

99.9

or

mm/min

from 5 to

2500

Input

tool number; the same as

last event

is

automatically

assumed

if

there

is

no numeric

input

NlTMERIC DATA,

INC

SET

or ABS

SET

NUMERIC DATA,

INC

SET

or ABS SET

NUMERIC DATA,

INC

SET

or ABS SET

NUh4ERIC

DATA, SET

1

or

2,

SET

0

or 1 or

2,

SET

NUMERIC

DATA, SET

NUMERIC

DATA,

SET

NUMERIC

DATA,

SET

(press SET

if

same

as

last event)

NUhiERIC

DATA, SET

TOOL

DIA*

*

No prompt

if

the

tool

has

been programmed

in

a

previous event.

Tool diameter

5.8.2

POCKET

Run

When

a

POCKET

event is run the following sequences

take

piace:

a)

The

table moves at rapid

(or

less

if

modified

by

the

feedrate override)

to

the

XI,

Y1

corner offset

by

the

CONRAD,

finish

cut,

and tool radius.

b)

The actual feedrate is displayed

in

the

conversation display

during all movement.

c)

When

in

position, the

"IN

POSITION"

light is turned on.

d)

The conversation display

will

command

"SET

2".

e)

When

Z

has been properly set, press

GO.

f)

For the

FRAME

option, the table moves

at

the

programmed feedrate

(or a modified

by

the override)

to

machine the rectangle

with

proper corners

and

finish

cut offset.

At

completion

it

moves

to

the

final dimension and machines

the

finish

cut.

g)

For the

POCKXT

option, the table moves at

the

programmed feedrate

(or

as

modifled by the

override)

to

machine inside

the

circumference

with

proper corners

and

offset

by

the finish cut.

The

feed

continues

until

the

interior

of

the

pocket is complete.

Lasdy,

the

hish cut is made to

the final

programmed dimension.

h)

The conversation display comments

"CHECK

2"

if

the

same

tool,

or

"TOOL

N"

if

the next event uses

a

different

tool, number

N.

i) The operator presses

GO

to proceed to the next event.

5.9

Repeat

Events

This

event is

very

useful

when

a

series

of

identical machining

operations

are

required.

This

may include

a

series

of

evenly

spaced

holes,

a

duplication of

a

set of holes--once for centerdrilling, the

second time for

drilling,

or even entire programs for multiple

fixture operation. Single events or

a

continuous group of

prior

events

may

be

repeated

up to

99

times.

The

only

restriction

is

the

level

of

allowable

nesting. Specifically,

a

REPEAT

event

may

contain

events

which

are

themselves

REPEAT

events,

but

this

event

may

not then

be

included

as

an event

to

be repeated subsequently.

For

example,

if

event

3

was

a

repeat

of

events

1

and

2,

then

event

4

could

be

a

repeat of

3

or

1

through

3,

but event

9

could

not

be a repeat including event

4.

In

programming

language

this

means

one

level of nesting.

5.9.1

Repeat

Prograni

Displayed

Prompt Dehtion

of

Prompt

Keyboard

Input

ZI'

FROM

REiPEAT,

event

display

Fndexes

by

one and

is

preceded

by

R

The

event

#

of

the

first

event

to

be

repeated

NUMERIC

DATA,

SET

Section

5

Programming

&

Program

Ron

1

27

Displayed Prompt Definition of Prompt Keyboard Input

I

TO

X

OFFSET

Y

OFFSET

#

REPEATS

TOOL

#

TOOL

DIA*

The

event

#

of the

last

event

'

to be repeated;

if

only one

event is to be repeated,

FROM

'

Event

#

same as

TO

Event

#

Incremental

X

offset from event

to be repeated

Incremental

Y

offset from event

to be repeated

Number

of times

events

are to

be repeated--up to

99

hput tool number of tool to be

used

in

first repeated event

Diameter of

kt tool

of

events

to be repeated

NUMERIC DATA,

SET

NUMERIC

DATA,

INC

SET

NUMERIC DATA,

INC

SET

NUMERIC DATA, SET

*No prompt

if

the tool has been programmed

in

a

previous event.

5.9.2

Repeat

Run

When a Repeat event is run the following sequences take place:

a)

The

table moves at rapid (or less

if

modified by the feedrate override)

to the initial beginning location of the first repeated event offset

by

the

programmed offsets and tool compensation.

b)

The ProtoTRAK

will

complete

all

repeated events,

with

their normal

commands and instructions, offset

by

the programmed offsets.

c)

The operator presses the GO key to proceed to the next event.

5.9.3

Finish

Cuts

Automatic finish cuts are not a built-in automatic feature of the ProtoW

except for the

CIRCLE

and POCKET events. However, it can be "tricked"

into

maktng a finish cut using

the

following procedure:

a)

Program

the

event(s) to make the required cuts with some

TOO1

#.

b)

For

the

above event(s), "lie" and input

a

TOOL

DM

that is larger than

the actual tool used (make the false diameter equal to

the

true diameter

plus

2

times the desired finish cut).

c)

Do a Repeat of the above event(s) calling out a new TOOL

#

(even

if

you

use the same tool)

and

the

actual true TOOL

DM.

5.10

Start,

Stop

and

Running

Several

Parts

5.10.1

START

Once a program has been written, loaded into the ProtoTRAK

and

checked (see Section

5.11

for Editing) it

may

be run

with

the

following procedure:

a)

Locate the centerline of a tool or the spindle over

the

programmed absolute zero location on

the

part.

b) Press and hold the START key for

3

seconds. This always sets

a new absolute zero at this (that is,

[a]

above) location.

If

you do not

wish

to set a new absolute zero, refer to the

RESTART

Section below.

c)

The conversation display will prompt to load the first tool

"TOOL

1".

d)

Press

the

GO

key to initiate the actual

run.

e)

The conversation display will comment

"RUN

OVER" at the

completion of the last event.

5.1

0.2

RESTART

If the operator wishes to start

in

the

middle of a program, say at

event

13

then:

a)

Press (but

do

not hold)

START,

the display will read

AT

EVNT

#,

then press

13.

b)

Then press and hold for

3

seconds START.

NOTE:

This will not reset

a

new absolute zero.

The

program will

use

the

last absolute zero which

was

set (either by a 3 second

START

push as in 5.10.1

(b)

above or

by

a subsequent

ABS

SET)

as

reference for continuing the program run.

c)

The

conversation

will

prompt to load

the

tool associated

with

event 13.

d)

Press

the

GO

key to initiate run in event

13.

This restart feature allows the operator to do some manual machining (for example, to clean out the inside of a pocket)

in

the

middle

of a program and

then

restart without any

initial

positioning.

To

start

at

the beginning of

a

program without resetting a new

absolute zero,

use

this

Restart procedure

and

input

1

when prompted

AT

EVNT

#.

Section

5

Programming

&

Program

Run

1

29

5.10.3 STOP

At

.any time the program may be halted by pressing the STOP

key.

This

freezes the program at that point. To continue, press the

GO

key.

5.10.4

Exiting Program or Program Run Operation

To

revert the ProtoTRAK to normal

DRO

operation press the

RESTORE

key.

Warning: Do not press

RESTORE

in

the

middle

of a run unless you wish

to completely abort the, run.

5.1

0.5

Running

Several

Parts

The procedure

for

starting

in

Section

5.10.1

above requires the operator to

position the spindle over the program absolute position.

This

is always necessary on the first part, but can be avoided on subsequent parts providing they are positioned when held the same as the

fist (for example,

in

a fixture or against a stop).

When the first part is complete the conversation display comments

"RUN

OVER".

The appropriate procedure

is:

a)

Change parts-being sure the next

is

held in the same position

as

the

first.

b)

Press the

GO

key instead of

START

c) The conversation display will prompt to load the first tool

"TOOL

1".

d)

Press

the

GO

key again.

e) The table

will

move from

its

current position (probably not the

programmed absolute zero) to the beginning location of the first event.

5.1

1

Editing

The

Proto73A.K allows for complete editing of programs including the recall

(and

correction) of data, adding events

in

the

middle of a program, and

deleting events within

the

program.

5.1

1.1

Recall

and

Data

Correction

To

recall and correct data press the

EDIT

key.

The co~iversation display

will respond

RECALL.

Press INC SET or

ABS

SET and the display

will

ask

"EVNT

#".

Enter the event number to be recalled and press

INC

SET

or

ABS

SET. The first piece

of

data in

that

event

will

be displayed

in

the

conversation and

X,

Y,

Z

displays. Press the

RECAL

DATA

key to sequence

to the next data. Continuing

to

press

RECAL

DATA

will cycle through all

the data and automatically proceed on to the next event.

If

any

data is incorrect it may be

reinput while it is displayed. Press

RESTORE

to abort edit. The following rules apply to editing data: a) Editing

any

data except Tool Diameter and Feedrate

in

any

event

will

not edit the data

in

any other event.

b)

If

the Tool Diameter value is edited in

any

event it will

automatically be edited

in

every event

with

that same tool

,

number.

c)

If

the Feedrate is edited in any event it will automatically

be edited in every subsequent and contiguous event

with

the

same Tool number and feedrate. For example, let's say events

5

through 10, and

13

through

16

were all programmed with tool

number

2

and

5

inches per minute feedrate.

If

you edit the

feedrate in event

7

to

3

inches per minute, it will automa-

tically change event

8,

9,

and

10

also. Events

5,

6,

13,

14,

15, and 16 will not be affected.

Data may also be corrected during programming

by

re-pressing the

event type

key (or a different one) and re-inputting all the data

for that event.

5.11.2

Adding

an

Event

Events may be added at the beginning, middle or end of any program one at a time. To do so press the EDIT key twice so the display reads

"ADD

EVENT". Press INC SET or

ABS

SET and the

display

will

ask

"AFR

EVNT"

(After Event). Then input the event

number which the added event will follow and press

INC

SET or

ABS

SET. The new event

may

now be programmed in the normal way. For

example, to add

a

Mill event between events

13

and

14

the following

input is required: Keyboard Input

EDIT

INC SET

13

INC

SET

MILL

data as prompted

NOTE:

This new event will

be

number

14

and the old event

number

14

will

be

automatically shifted to

15

and so

on. Data

in

repeats

will

also automatically be shifted.

To add an event

in

front of event 01,

input

and SET

0

when the

display prompts

"APR

EVNT".

Press RESTORE to abort the Add Event

routine.

Section

5

Programming

&

Program

Run

1

31

5.1

1.3

Deleting Events

Events may be deleted one at a time or in continuous groups. To delete, press the EDIT

key

three times so the display reads

"DLT

EVNT'.

Press

INC

SET or ABS SET and the display will

ask

"DLT

FROM".

Then input the first event number of the group to be deleted and press

INC

SET or ABS SET (the display will change to read "DLT

TO")

input the

last event number of the group to be deleted and press

INC

SET

or

ABS

SET. If only one event is to be deleted, input it for both

FROM

and

TO.

For example, to delete events

7

through

15

the following input is required:

Keyboard Input

EDIT EDIT EDIT

INC

SET

7

INC

SET

15

ABS

SET

NOTE:

The old event number

16

is now switched to event

7

and so on.

Data

in

repeats

will

also automatically be shifted.

5.1 1 -4

Special

Modes

Lf

the EDIT key is pressed a fourth time the display

will

read "SPEC

MOD".

Press set to enter into the special mode options. These are

special modes of operation which are used

in

sales demonstrations, installation, service and for special applications. Please press EDIT again to return to

RECALL.

To enter

"SPEC

MOD," press

INC

SET

or

ABS

SET and the display will prompt "CODE."

5.1

1.4.1

Hysteresis Test

When

the

ProtoTRAK prompts "CODE", input

1 1

and press SET.

The

X

and

Y

readout will display the free plus elastic hysteresis in

the ballscrew, table, and drive hardware for each axis.

Ln

general,

this value should be less than

0.0050

inches.

5.1

1.4.2

Simulation

When the ProtoTRAK prompts "CODE", input

2

and press

SET.

This allows programs (including

DO

ONE'S) to be run without table

motion. All prompts, messages, and counting occur normally.

NOTE:

The

simulation feature

will

work

even

if

the pendant display is disconnected from the motors, sensors, and power control cabinet.

If

the

ProtoTRAK

is

turned

off

the

simulation

mode

will be aborted

5.1

1.4.3

Abort

Simulation

When the ProtoTRAX prompts

"CODE",

input

8

9

and press

SET. This aborts the simulation mode (see

5.8.4.2)

without

the

loss

of position data (which would occur

if

the system

were turned off).

5.1

1.4.4

Software

I.

D.

When the ProtoTRAK prompts "CODE", input

3

and press

SET. The display

will

read

A=VER

.

which shows

the software version or rev.

in

the

A-KernTry

device.

Press

RECALL

DATA

to read

B

and

C

and

D.

Press

RESTORE

to abort the software

I.D.

mode and revert back to

DRO

operation.

5.1

1.4.5

Continuous

Test

Run

When the ProtoTRAK prompts "CODE", input

5

and press

SET. The tape cassette

(with

a program) must be properly

connected

or

this mode aborts.

The

ProtoTRAK reads the tape program displaying

all

tape messages and then automatically and continuously runs it without interruptions or stops for operator input (like SET

2).

This

mode

is

primarily used for long-term testing and to

set up cycles for troubleshooting.

5.1

1.4.6

Extended

Display

When

the

ProtoTRAK prompts

"CODE",

input

4

and press

SET. This mode extends the readouts from

+/-99.9995

to

+/-999.999

inches. This mode

is

aborted

if

the display

is turned off.

5.11.4.7

Trial

Run

When the ProtoTRAK prompts

"CODE",

input

3

5

and press

SET.

The display will prompt

"CHECK

2".

Make sure

the

tool is clear and press

GO

to run the entire program at

rapid speed and

with

no pauses for tool change, set

Z,

or check

2.

Rapid

may

be reduced

with

the feedrate

override.

Section 5

Programming

B

Program

Ron

1

33

5.1

1.4.8

Abort

Extended

Display

When the ProtoTRAK prompt. "CODE", input

8

and press

SET

to

abort the Extended Display mode,

5.8.4.6.

5.1

1

-4.9

Streamline

Programming

When the ProtoTRAK prompts

"CODE",

input

7

and press

SET.

When this mode is active the input required for programming connective events is significantly reduced. Whenever a

CONRAD

is

input as

0

or a number

X

BEG

and

Y

BEG

are not prompted and

set to

0

INC in the next event; and

CO

R1

L2,

TOOL

DIA

and

TOOL

#

are not prompted and automatically set

with

the same

value as

the

current event.

Consider the following example: Event

8

is a

MILL

event

with

CONRAD

=

.25, tool offset right

el),

TOOL

DIA

=

.5

and

TOOL

#

=

3.

Because event

8

has a numeric

CONRAD

(or it could

have been

0),

then

event

9

must be connective

with

8

and must

be

a

MILL

or

ARC

event.

In

either case,

X

BEG

and

Y

BEG

for event

9

will

not

be prompted

and

will be loaded as

0

INC;

and

R1

L2

CO,

TOOL

DW,

and TOOL

#

will not be prompted and

will

be

loaded

with

the same value as in event

8.

All data not prompted and automatically loaded

may

be recalled and

edited.

Once activated, the Streamline Programming Mode will be continuously activated

until

aborted as described in 5.11.4.10 below.

Even turning the

ProtoTRAX off for an extended time will not

deactivate Streamline Programming.

5.1

1.4.1

0

Abort Streamline

Programming

When the ProtoTRAK prompts

"CODE",

input

7

8

and press

SET

to

abort Streamline Programming

as described in 5.11.4.9 above.

5.1

1.4.1 1 System Initialization

When the ProtoTRAK prompts

"CODE",

input

9

and press SET.

This mode completely initializes the

ProtoTK4K

by

erasing all system memory. It also automatically aborts Simulation and Streamline Programming.

5.1

1.4.12

Sensor

Calibration

When

the

ProtoTRAX

prompts

"CODE",

input

1

2

3

and press SET

to calibrate

a

TRAK

Sensor. The procedure

is

as

follows:

Displayed Prompt Definition of Prompt

SELECT AXIS

Select

the

axis

to

be

cali-

brated

MOVE

BEG

STD/

THEN INC

SET

(flashing

back

&

forth)

Move table and touch dial indicator off

on

one side

of the standard

MOVE

END STD/

THEN INC SET

(flashing

back

&

forth)

Keyboard Input

X

or Y or

Z

Move table to other end of the standard.

NOTE:

The

display

must

read the same

or more

than

the standard

length

INPUT

STD/THEN

INC

SET

(flash-

ing

back

&

forth)

INC SET

or

ABS SET

Input

the

length of the

standard

in

inches or

mm

INC SET

or

ABS

SET

NUMERIC DATA, INC SET

or

ABS

SET

If a legitimate calibration is computed (actual divided

by

standard length)

the

system will automatically abort to the DRO mode of operation. Repeat the entire procedure for each axis to be calibrated.

If

the calibration is not

legitimate the display will read

"CAL

ERROR.

This occurs

if the displayed readout in the calibration procedure

was

less than the standard length or too much (the maximum allowable is

1%

more than the standard). If less, increase the sensor tilt and repeat the calibration procedure. If too much, verify

the

standard and request

SWI

or distributor

service.

5.1

2

Tape

Cassette Operation

The Cassette Recorder is attached to

the

ProtoTRAK

PLUS

through

a

special 15-pin connector on the back panel of the display.

A

spare

connector

is

inserted in the display connector and should remain there for protection unless the cassette recorder is plugged in. To do so remove the spare connector and insert the cassette recorder connector.

Keep your Cassette Recorder out of the

shop

environment when it

is not

in

use. Keep the top to

the

Cassette Recorder case closed

except when loading or unloading a tape.

NOTE:

Tapes programmed on the older ProtoTRAX

may

be

run

on the

ProtoTRAK PLUS, but not vice-versa.

5.1

2.1

Loading

Tapes

To load (or unload) a cassette tape, open the top of the cassette carrying case

and

open

the tape chamber

by

pressing the release key.

Section

5

Programming

&

Program Run

1

35

Slide the tape cassette into

the

side grooves on the underside of the

lid of the tape chamber, being careful to place

the

desired read/write side

of

the

tape face downward

with

the exposed tape section of the

cassette

towards the back of the tape chamber. Store the tapes

in

their plastic carriers

in

a

clean

and safe place.

5.1

2.2

Write

Tape

ProtoTRAI( programs are stored

on

the tape

two

times and

then

verified

against the program data stored

in

the display. This allows the program to

be reinspected when read back into the display at a later time.

The

procedure to store

a

program is:

a) Press the

TAPE/RSZ~Z key and

the

display will alternately

flash

"TAPE

=

I",

"COMM

=

2".

b) Press

1

and the conversation will flash

back

and forth

"RECEIVE=l"

and

"SEND

=

2".

c) Press

2.

d)

A

small red light on the Tape Cassette Recorder will turn on for one to

two

minutes and the display will say

"SENDING",

then

e)

The display will read

"GOOD"

f)

Press

RESTORE

to return to normal non-cassette operations.

NOTE:

When a program

is

written on to a tape it is not lost

from

the

ProtoTRAK memory.

5.12.3

Read

Tape

When a program

is

read from tape into the ProtoTRAK memory it

is

checked to be sure no reading or storage error has occured. The procedure to read a tape is: a) Press the

TAPE/RSZ32

key and the display

will

alternately flash

"TAPE

=

I",

"COMM

=

2".

b)

Press

1,

and

the

conversation

will

flash back and

forth

"RECELVE=l"

or

"SEND

=

2".

C) Press

1.

d)

A

small

red light

on

the tape cassette recorder

will

turn

on

for one to

two minutes and the display

will

say

"RECEIVING",

then

e)

The display will read

"IEADY'

f)

Press

RESTORE

to return

to

normal non-cassette operations.

NOTE:

When a program is read from a

ape

it

still

remains recorded on

the tape. However, all previous data

in

the ProtoTRAX memory

will

be

erased and replaced

with

that

on

the

tape.

5.1

2.4

Tape

Cassette

Error

Messages

The

following

messages are displayed

if

there is a problem associated

with

reading or

writing

a tape. Also listed is the recommended corrective

action.

Cassette

Recorder

Diagnostic

Messages

I

CASSETTE FUNCTION

1

MESSAGE

I

NEANING

I

ACTION

I

(

Read or Write

I

PLUG

(

Cassette Deck harness not plugged into

I

1)

Check.

I

(

Operation

I

(flashing)

I

display; no tape cassette: lid to

I

cassette transoort chamber aiar.

I

1

FAIL

1

Broken tape or bad tape deck.

1

1) Examine cassette for broken tape.

1

I

(flashing)

I

1

2) Try another cassette.

I

Read Operation

I

ready

I

Proper transfer of first pass data from

I

1)

RSTR for rerurn to normal non-cassette

I

deck to display memorv

1

operation.

I

ready

1

Proper transfer of second pass data

frml

1)

RSTR for return to normal non-cassette

I

pass 2

I

recorder to display mmry, but first

I

operation.

1

I

1

pass had errors.

(

2) Re-record progrpm at most

convenient

time.

(

I

Possibly use new cassette

if

tape is

I

1

deterioratino.

1

I

ready

I

Proper transfer of third data from re-

I

1)

RSTR for return to normal non-cassette

I

pass

3

I

corder to display memory. but first and

I

operation.

1

/

second pass had errors.

1

2)

Re-record program at most convenient time.

1

I

Possibly use new cassette

if

tape is

I

1-

I

deterioratino.

I

1

read

I

All three passes on tape had errors.

I

1)

Master Clear to clear

mry.

1

error

I

Display memory also has errors.

1

2) Clezn cassette tape head.

I

1

(flashing)

I

1

3)

Try another cassette.

I

1

I

41

Call for servlce if not reccifid.

I

1

read

I

Hajor difficulty in reading cassette.

I

I)

Try again.

I

fail

I

1

2)

Try another cassette.

I

(flashing)

I

1

3)

Clean cassette tape head.

I

1

I

1

4)

Call for service

if

not rztified.

1

read

1

System cannot read anything on cassette.

1

I)

See

~f

tape is present in casser:e.

1

I

bad

I

(

2) 8e sure cassette is not blank.

1

I

(flashlnol

1

31

Use cassette tape head.

1

'ir i te Operat ion

I

read

I

Write protect tab on cassette has been

/

I)

Use another cassette or ocher side.

I

removed.

I

1

I

god

(

Program transferred to cassette and

I

I)

RSTR

to return to normal non-cassette

1

verified correctlv.

I

operation.

1

I

record

I

An error was found in one of the record I 1) Re-record.

,

1

I

error

(

passes during verification.

I

2) Try another cassette.

I

(flash~n~)

1

~1

1

record

I

Hajor difficulty recording on cassette.

I

1)

Re-record.

I

1

fail

I

1

2)

Try another iassecte.

I

1

(flashinoj

1

31

Clean cassette tape head.

i

I

record

I

System cannot ver~fy that anyth~ng was

I

I)

Re-record.

I

bad

I

recorded.

/

2) Try another cassette.

1

/(flashlnq)

me head.

1

Section

5

Programming

iC-

Program Run

1

37

5.1

3

ProtoTRAK Plus

RS232

Communications

The ProtoTRAK Plus has an

RS232

communication port which allows you

to

interface to

CAD/CAM

offline programming systems.

For those of you not

familiar

with

CAD/CAM

systems, the following is

a

very

brief and basic explanation.

CAD

or Computer Aided Design is computer software which helps

the

user define the geometry of a

part.

Essentially, it

"draws

and

dimensions" a part in the computer.

AUTOCAD

is a well-known

CAD

software system.

CAM

or Computer Aided Manufacturing

is

computer software which, for

machining, takes the part defined

by

CAD

and

with

the assistance of

the

user decides how to machine the part. In general, it is not common to hd

CAM

only software--usually it is combined

with

CAD

as a complete

CAD/CAM package.

A

Post-Processor is additional software which customizes the general

output of

CAM

to

the particulars of a specific

CNC

control brand and

model. Some

CAD/CAM

packages allow the operator to write his own

post-processor for each of his CNC models. For other packages

the

post-processors must be or can be provided by the

CAD/CAM

distributor

or manufacturer.

5.1

3.1

Downloading From CAD/CAM or Retrieving

A

Program From

Your Computer's Floppy

Disk

Before attempting to download a program from your

CAD/CAM

system, be certain you have properly conducted the installation

and

testing procedures

in

the ProtoTRAK

Plus

CAD/CAM

Interface

manual.

The

procedure

for

downloading a program from

the

https://manualmachine.com/~

is

as

follows:

a)

Delete any program which map already be

in

the ProtoTRAK.

b)

Press TAPE/RS232 key

and

the display

will

alternately

flash

TAPE

=

1,

COMM = 2.

c) Press

2,

and the display

will

alternatelv flash

"RECEIVE=

I",

"SEND

=

2".

d)

Press

1,

+

/-

keys

and

the

display

will

read

"OK

TO

RW'.

e)

Be certain the communication port is properly codgured. For

IBM

PC compatible computers type

MODE

COM1:4800,e,7,ll

f)

At the computer,

type

COPY,

the

name

or

number

of

he

part

program,

COMl

and

the

ENTER

key.

For

example, if your program

was

labeled "1234PLUS", then you would type COPY 1234PLUS COMl

then

press

ENTER

for an

LBM

PC compatible computer.

Lf

you

have a different computer, use the standard send message.

g)

When

the program

has

been completelv sent, the ProtoTRAK Plus

will

read

RECEIVE

OK

h)

Press

RESTORE

and

go into

EDIT

if

you wish to review or

modify

the

data.

5.13.2

Saving

A

Program

On

Your

Computer's

Floppy

Disk

The

procedure for saving a ProtoTl3A-K

Plus

program on your computer's

floppy disk

is

as

follows:

a)

Press

"TAPE/RS232"

key

and

the display will alternately flash

"TAPE

=

I",

"COMM

=

2".

b) Press

2,

and the display will alternately flash "RECEIVE=lM,

"SEND

=

2".

c) Press

2,

+/-

keys and the display

will

read

"OK

TO

SEND?".

d)

Be certain the communication port is properly configured. For

IBM

PC compatible computers

type

MODE

COM1:4800,e,7,1

e)

At

the computer, type

COPY

COMl and the program name and the

"ENTER key. For example,

if

your program

was

labeled "1234PLUSN,

then

you would type COPY COMl 1234PLUS then press

ENTER

for an

IBM

PC

compatible computer.

If

you

have

a

different computer,

use the standard send message.

f)

At

the

ProtoTRAK,

press the

"NC

SET" or

"M3S

SET' key. The

program

will

be

sent, and

the

display

will

read

"SENDING".

When complete,

the

display

will

read

"SEND

OK1.

g)

Press

"RESTORE"

to

exit

this operation.

Section

5

Progranming

B

Progrim

Run

1

39

5.14

Program

Sample

This

part

will

be programmed using point

A

(the

center

of

the

-750

radius

circular pocket)

as

the absolute zero reference. Streamline Programming

(see Section

5.11.4.9)

will

be activated.

The

machining

sequences

will

be: center drill the 1.125 radius bolt hole

pattern;

finish drill

the

bolt hole

pattern.

Using

a

.500

end

mrll

machine

the

.750 radius circular pocket, including a .010 finish cut.

Using

the same end

mill,

machine

the

perimeter

of

the

part

from

point

B

to

point

C

toward

point

D

through

the

.841

radius and

back

to

point

B.

Prompt

Input

Explanation

-

Bolt

Hole To

center

ddl

5

hole bolt hole

pattern

#

HOLES

5,

INC

SET

X

CENTER

ABS SET

Zero

is

assumed when

no

numeric

data

is

entered

Y

CENTER

ABS SET

RADIUS

1.125,

INC

SET

ANGLE

45.,

INC

SET

First

hole

to

be

drilled

is

+45

degrees

from

the

3

o'clock position

Prompt

TOOL

#

PROM

TO

X

OFFSET

Y

OFFSET

#

REPEATS

TOOL

#

TOOL

DLA

--

PKl

FR2

X

CENTER

Y

CENTER

RADIUS

CWI

cm2

FIN CUT

FEEDRATE

TOOL

#

TOOL

DLA

-

X

BEG

Y

BEG

X

END

Y

END

Input

1,

INC SET

REPEAT

1,

INC SET

1,

INC SET

INC

SET

INC SET

1,

INC SET

2,

INC SET

.25,

INC SET

CIRCLE

1,

INC SET

ABS SET

ABS

SET

.75,

INC SET

2

.01,

INC SET

8.,

INC SET

3,

INC SET

.5

INC

SET

ARC

ABS SET

-2

45

ABS SET

US

SET

2.45

AES

SET

ExDlanation

Tool

#1

is center

drill

To

finish

drill the five holes center drilled

in

Event

#1

The first event to be repeated

is

Event

#1

The

last

event to

be

repeated is

also

Event

#1

There

is

.no o&et since

the

holes

are

to

be

drilled

in

the same location

as

the

center

drilled

holes

To

machine

the

,750

radius

circular pocket

To

select

pocket

(not

kame)

Finish

radius

of

circle

To

select counterclockwise

tool

path

To

machine

,010

finish

cut

To

speclfy 8 ipm feedrate

To

speclfy

.500

end

mill

To

mill

from

R

to C

Prompt

X

CENTER

Y

CENTER

CONRAD

FEEDRATE

TOOL

#

--

X

END

Y

END

CONRAD

FEEDRATE

--

X

END

Y

END

CONRAD

FEEDRATE

Input

ABS

SET

ABS

SET

0,

INC

SET

2,

INC

SET

1,

INC SET

8.,

INC

SET

3,

INC

SET

MILL

-3.064,

ABS

SET

.5045,

ABS

SET

.841,

INC

SET

INC

SET

MILL

ARS

SET

-2.45,

ABS

SET

INC

SET

INC

SET

Section

5

Programming

&

Program

Run

1

41

Explanation

-

To

command system to

machine

a

zero radius

at

point

C

and continue towards

point

D

To

command system to

machine

to

the

right

of

the

programmed

arc

To

mill

from

C

toward

D

through

the

.841

radius

To

connect

CD

to

DB

No

need

to

reinput data

if

feedrate remzins

same

as

previous event

To

mill

back

to

point

B

Section

6

DO

ONE

Operation

-

Prob~arn & Run

1

42

ONE

Operation

Program

Run

The major portion of

many

jobs can best be done manually

with

DRO.

However, there are often just a few

cuts

that require excessive time

and

set-up, for example, long position moves, arcs, or diagonals.

DO

ONE

programming assists the operator

in

performing these more

time-

consuming operations without the necessity of detailed programs, etc.

NOTE:

DO

ONE

events may only be programmed and

run

one at

a

time.

When a

DO

ONE

event

has

been run it is erased

&om

the ProtoTRAK's memory.

6.1

Incremental Reference

Position

The

incremental reference position for any

DO

ONE

event is the current position of the tool (or actually the table and saddle). That is, the position at the time the event is run. So

an

incremental input will move

the table

by

that amount from where it currently

is.

The

absolute

reference is unchanged from where it already is.

6.2

DO

ONE

Program

&

Run

DO

ONE programming and run is nearly identical to

the

complete part

programming described

in

Section

5.

There are, however, a few

differences. They are: a) Press the DO

ONE

key before pressing

the

event key; for

example,

DO

ONE,

MILL

or DO

ONE,

PCKT.

b)

The conversation display never prompts for

TOOL

#.

Since it

is

a

program of one event it could only use one

tool.

c)

DO

ONE

Mill and

Arc

Events will not prompt for

CONBAD.

There is

no second event to connect to. However,

the Pocket Event will

prompt for

CONRAD

to define the corner radius.

d) There cannot be a DO ONE Repeat Event. There are no other events

in the program to repeat.

DO

ONE

program run is identical

to

complete

part

program runs (Section

5)

with

the exeption listed below:

a) When all of the data are programmed, the conversation display

will

prompt

START?

It

is

asking

if

you

want to run

the

DO

ONE

program.

If

you do, press

START

for

three

seconds.

b)

After you

start,

the display

will

prompt

CHECK

Z

to remind you

to

raise

the

quill.

c)

Press

GO

to begin the

event

run.

d)

The

DO

ONE

program is

run

identically

to

any complete

part

program

except

that at

its

completion, the semos

are

turned

off

and

the

ProtoTRAK reverts to normal

DRO

operation.

6.3

Cutting

Corners

Care

must

at

corners.

be

taken

when programming successive

DO

ONE

events

In the figure above

if

a

DO

ONE

mill event

was

programmed

from

XI,

Y1

to

X2,

Y2

with

tool right offset the cutter would

move

from

a

to

b.

Lf

another

DO

ONE

mill

event

was

programmed horn

X2,

Y2

to

X3,

Y3

with

tool right offset the

cutter would first move

from

b.

to

c

(the

end

of the &st

to

the

beginning of the second

with

their offsets) then on

command from c to

d.

Kore that

if

the cutter is not raised

in

moving from

b

to c

the

tip of the corner at

X2,

Y2

will

be machined off. It is good practice to

always

raise

the

tool between successive

DO

ONE

mill

or arc routines.

NOTE:

In

regular programming (see Section

6)

this

is

not a

problem

as

long

as

the

two

mill

events are connective.

The

ProtoTRAK automatically compensates

and

''walks

around

the

comer."

Section

h

DO

ONE

Operation

-

Program

k

Run

1

44

6.4

DO

ONE

Editing

Because

DO

ONE

events are singular (that is only one can be

programmed and

run

at a time) and brief, there is no procedure for their

recall and edit. If

the operator wishes to edit a

DO

ONE

event he

must

press the event

type (like

MILL)

and reinput

the

entire event.

If

the operator does

not

wish to

run

a

DO

ONE

event after it

is

partially

or

wholly programmed he must press

DO

ONE

and

RESTORE.

Section

7

Math

Help

1

45

Help

Prints are, unfortunately, not always drawn and labeled in such

a

way

as to provide all of the points necessary for programming. To minimize this problem the

ProtoTRAK provides a math help function which can be

used to automatically calculate points of intersection, centers of arcs,

trig

functions, square roots, etc.

7.1

Procedure

The

procedure for each calculation is

as

follows:

a)

At

any time during Program or in

DRO

operation (except during run,

jog, or when non-dimensional data is being prompted), press

MATH

HELP.

b)

The display

will

read TYPE--locate in Section 7.2 the type of problem

to be solved or data to be acquired

and input the number and SET.

c)

The conversation display will prompt for the necessary data specified in Section 7.2--input the numeric information and press

ABS SET (all

dimensions must be absolute).

d)

For many problems there are two or even more correct solutions (for

example, the intersection of a line and a circle). In these cases the

display will indicate the number of possible solutions and name

them

A,

B,

etc. Press

RECALL

DATA.

e) The conversation display

will

read out which solution is being

presented.

X

and

Y

positions for the indicated solution will be shown

in

the

X

and

Y

readout.

All

other data will be shown in

the

Z

readout. Press

RECALL

DATA to

view

additional data for the same

solution or

the

data for other possible solutions. Record the data

for

each solution.

f)

If

two or. more solutions are given, the operator must decide which is correct or appropriate for his particular problem. In general, the appropriate solution is obvious, but occasionally careful plotting on

the

print will be necessary to choose.

g) Press

RESTORE

if

data is incorrectly input and

start

the

MATH

HELP

routine over. Press

KESTORE

to abort

the

MATH

HELP

subroutine and

return to the

DRO

or

Program Mode. After abort the ProtoTRAK

will

return to the same status as before the

MATH

HELP

key

was first

pressed.

7.2

Math

Help

Types

7.2.1

Type

10:

Find

the intersection

of

two

lines

when

any

two

points are known on

each

line.

Find

XY

Display prompts:

XI,

Y1,

Y2,

X3,

Y3,

X4,

Y4

Number

of possible solutions:

1

7.2.2

Type

11:

Find

the

intersection of two lines

when

two

points

are

known

on

one

line, one point is known on the other line and the angle

between

the

lines

is

known.

Find

XY

Angle

X2,

Y2

Display prompts:

XI, Y1,

X2,

Y2,

X3,

Y3,

ANGLE

Number of possible solutions:

2,

A

and

B

7.2.3

Type

12:

Find the intersection

of

two lines when

two

points

are

known

on

one,

one point is

known

on

the

other,

a

radius

tangent

to

both

lines

is

known,

and

when

one

of

the

points

on the

two

known point

lines

is also on

the

radius.

Find

XY

NOTE:

Point

X2,Z

is

on

line

X1,

Yl--X2,

YZ

and

on

the

arc

with

radius

R

between

the

lines

Display Prompts:

XI,

Y1,

X2,

Y2,

X3,

Y3,

RADIUS

Number

of possible solutions:

2,

A

and

B

7.2.4

Type

13:

Find

the

intersection

of

a line

and

an

arc

when

2

points

are known

on

the

line and the arc's center

and

radius

are known.

Find

32'

/

X

Center

Y

Center

Display

PrompB:

XI,

Y1,

X2,

Y2,

XCENTR,

YCENTR,

RADIUS

Number

of possible solutions: 2,

A

and

B

7.2.5

Type

14:

Find

the

intersection

of

a

line

and

an

arc

when

two

points

are

known

on

the

line,

two

points

are

known

on

the

arc,

and

the

arc

radius

is

known.

Find

XY

Display

Prompts:

XI,

Y1,

X2,

Y2,

X3,

Y3,

X4,

Y4,

RADIUS

Number

of

possible

solutions:

4;

A,

B,

C,

D

7.2.6

Type

15:

Find

the

intersection of two

arcs

when

the

center

and

radius

of

each

are

known.

Find

XY

Display

Prompts:

XI,

Y1,

Rl,

X2,

Y2,

R2

Number

of

possible solutions:

2;

A

and

B

If

anly

one

solution

is

given

the

circles

are

tangent.

section

7

~ath

~eip

1

49

7.2.7

Type

16:

Find

the two intersections

of

a

line

tangent to

two

arcs

when

the

centers

and radii

of

each are

known.

Find

XlYl

and

X2Y2

NOTE:

Tangent

Line

does

not

cross

line

between

centers

XI

Center

YI

Center

~2

Genie:?

Y2

Center

Display

Prompts:

XlCNTR,

YlCNTR, R1,

X2CNTR,

YZCNTR,

R2

Number

of

possible

solutions:

2;

A

and

B

for each

point

7.2.8

Type

17:

Find

the intersection

of

a

line

tangent

to

an

arc

when

one

point

is

known

o.n

the

line

and

the

arc's center

and radius

are known.

Find

X

Y

Display

Prompts:

XI,

Y1,

XCNTR,

YCNTR,

RADIUS

Number

of

Possible

Solutions,

2;

A

and

B

7.2.9

Type

20:

Calculate

the

center

of

an

arc

when two

points

on

the

arc

and

its

radius

are

known.

Find

X

CENTR

Y

CENT'R

/

j

X

Center

-

.

dnti:

Y

Center

,

2

Display

Prompts:

XI,

Y1,

32,

Y2,

RADrCTS

Number

of

possible solutions:

2;

A

and

B

7.2.10

Type

21:

Calculate a point on

an

arc

when

the

center, another point

on

the

arc,

and

the

angle between

the

arc

points

are known.

Find

,XY

VX

Center

Y

Center

Display

Prompts:

XI,

Y1,

XCENTR,

YCENTR,

ANGLE

Number of possible solutions:

2; A and

B

7.2.11

Type

22:

Calculate

the

radius

of

an

arc

or

circle

when

one

point

on

the

arc

and

the

center

are

known.

Find

R

::

Center

Y

Center

Display

Prompts:

XI,

Y1,

XCENTR,

YCENTR

Number

of possible

solutions:

1

7-2-72

Type

23:

Calculate

the

center

of an

arc or circle

when two

points

on

the

arc

and

the

angle

between

them

are

known.

Find

X

CENTR

Y

CENTR

X

Center

Y

Center

Display

Prompts:

XI,

Y1,

X2,

Y2,

ANGLE

Number

of

possible solutions:

2;

A

and

B

7.2.13

Type

24:

Calculate

the

center

and

radius of

an

arc

or

circle

when

three

different

points

on

the arc

or

circle

are

known.

Find

R

and

X

CENTR

Y

CENTR

X

Center

Display Prompts:

XI,

Y1,

X2,

Y2,

X3,

Y3

Number of possible solutions:

1

7.2.14

Type

25:

Calculate

the

cartesian

(X

and

Y)

location

when

polar

(R

and angle)

coordinates are

known.

Find

XY

Angle

-;2----

Display

Prompts:

MIUS,

AYGLE

(NOTE:

The

angle

is

always measured

from positive

X

axis

or

3

o'clock.)

Number

of

possible

solutions:

1

section

7

hi at^^

~eip

1

53

7.2.1 5 Common

Mathematical

Numbers

Type

Data

Required Prompt

3

0

31

3

2

3

34

35 36

37

(to find

sine cosine

tan

arc sine arc cosine arc

tan

square root

decimal value) degrees,

minutes,

ANGLE ANGLE ANGLE NUMBER NUMBER

NUMBER

seconds

DEGREES

...

MINUTES..

.

SECONDS

...

Swbm

8

Care

&

Serl.ic-e 1 54

Care

Service

8.1

General

System

Care

The ProtoTJ3A.K is very rugged

and

durable

but

requires some special care

in

the

machine shop environment. The system should not be exposed to

excessive vibration or

contaminents.

Care

should be taken that

the

mylar face of the control pendant is

kept

out

of

the

way of excessive

chips

(especially

if

hot). The mylar face

is

resistant to minor abrasion

and

most

common solvents. Heavy abrasive

rubbing

and

a few chemicals

may

ruin the surface.

A

tppical window

cleaner

like

Windex is recommended. Make sure that the cleaning cloth

does not contain metal chips. The encoder

(TRAK

Sensor) has been designed and

built

to withstand

the

typical machine shop environment. Under normal circumstances, the

onIy

maintenance required is

a

periodic change of the wiper pad (approximate-

ly

every

6

months) and an occasional recalibration (approximately every

6

months) to minimize machine tool inaccuracies. These typical

time

periods

are greatly dependent upon the actual environment in the encoder area.

8.2

Data

Error

Messages

Sections

5

and

6

specify

several programming rules (listed below) that

must be followed. For

many

of these, the ProtoTRAK

has

the ability

to

self check to ensure

they

have not been violated.

When

they

have, the

conversation display will say

"DATA

ERR

"

specifying

which rule

has

been broken. These error messages will3eaisplayed during program run (where their consequences can

be

measured by the Protom and

NOT

during the actual programming. In every case the corrective action

is

to press the

RESTORE

key.

Run

will

abort and

the

conversation display will read

"

-

AT

EVNT

#"

to

show

which event has been programmed incorrectly. Press the

RESTORE

key

a second time and edit the improper data in the program.

Some errors can

be

detected by the ProtoTRAK immediately upon input.

In

these cases the conversation display

will

read

"INPUT

ERR.

This

incorrect data will not be loaded into the

Protom Press

RESTORE,

check the data, and re-input

it

into the system.

Listed below are the data errors,

"DATA

ERR

-

",

which may

be

displayed along with an explanation of the error.

01

-

Drill event cannot

be

connective. That

is,

the event preceding the

drill event

calIed for a

CONRAD

which

is

not allowed.

02

-

Repeat event cannot

be

connective. That

is,

the event preceding

the

repeat event called for

a

CONRAD

which

is

not allowed.

03

-

The

starting

event

cannot be

a

repeat event.

04

-

No double repeat nesting. That is, none of the events to be

repeated can be a repeat event of a repeat event.

05

-

Repeat events can only repeat previous events.

06

-

In a repeat went, all of the events to

be

repeated have

been deleted and none have been substituted.

07

-

A

CONRAD

is programmed but the

end

point of the first event

does not equal the beginning point of the second.

NOTE:

This problem

may

also occur when

CAD/CAM

generated

programs are edited at the

ProtoTRAK. When

this

happens,

alw-ays be certain that

X

BEG

and

Y

BEG

in

the second

event

are

programmed

as

0

INC

SET at the ProtoTRAK.

08

-

A

CONRAD

is programmed but the tool offset

(CO

R1

L2)

of

the

first event does not equal the tool offset of the second.

09

-

A.

CONW is programmed but the tool diameter of the first

event does not equal

the

tool diameter of the second.

10

-

A

CONRAD

is programmed but the tool number

of

the first

event does not equal the tool number of the second.

11

-

It is mathematically impossible to define a circle

with

the

XY

beginning, end, and center points given. Check accuracy

of data including tolerances.

12

-

Circle event must not be connective.

13

-

The circle or arc is a point. That is,

,XY

beginning, end,

and center are all

the

same.

14

-

The mill

or

pocket event is a point. That is,

XY

beginning is

the

same as

XY

end.

15

-

The

tool diameter

is

too big. See Section

3.4.1.

16

-

CONRAD

too big. Mathematically impossible to calculate a tangent

point on at least one

of

the mill segments adjacent to

the

connective segments.

17

-

Pocket event must not be connective.

18

-

Finish cut too big. Must

be

less than or equal to tool radius.

19

-

Tool

diameter

is

0

20

-

Pocket too

small.

Short side

is

less than tool diameter plus

2

times

finish cut.

21

-

CONRAD

too

big

in Pocket Event.

22

-

Tool

too

big

in

Arc

or

Circle Event

Section

8

Care

&

Sen.,ice

1

56

8.3

Fault

Messages

The ProtoTRAK performs a number of automatic checks on its ability to perform properly (especially when it Is first turned on). When problems are

idenmed they are shown on

the

conversa-

tion display as

"FAULT

II

-

Listed below are

the

fault indicators that may be displayed and

the

recommended action to be taken.

01

-

The sensor calibration factor of one or more

of

the sensors has

been lost. Recalibrate all sensors.

If

fault reoccurs call for service.

02A

Part of

the

ProtoTRAK's master internal memory has been lost or

02B electronically altered. The system will probably not operate

02C

properly. Call for senice. 02D 02E

03

-

Part of the ProtoTRAK's servo drive internal memory has been lost or

electronically altered. Call for service.

04

-

The master microprocessor fails to communicate with

the

servo drive

microprocessor. Press

RESTORE,

turn

the ProtoTRAK off for a

minute and

try

again.

If

fault persists call for service.

05

-

The servo drive microprocessor fails to communicate

with

the master

microprocessor. Press RESTORE,

turn

the ProtoTRAK off for a

minute and

try

again. If fault persists call for service.

32

-

Total memory clear.

This

may occur normally when the ProtoTRAK

is first powered-up during installation. Press RESTORE.

33

-

Bad memory integrated circuit.

X

-

X

axis

mill

not move properly. Press

RESTORE.

Check to

be

certain the table is not jammed; check

the

cables and connections

from the motor to

the

Power Control Cabinet and from

the

Sensor to the Display Pendant. Be sure they are plugged into their current socket.

Try

again;

if

fault persists call for service.

Y

-

See

X

above, but check

Y

axis.

XY

-

Both axis fail. See

X

above and check both axes. Be sure

X

and

Y

cables are not switched when plugged into Power Control Cabinet

and/or Pendant.

CALIBRATE

X,Y,Z

-

The ProtoTRAK sensor encoders have not been

calibrated or the calibration correction factor

has

been lost. Recali-

brate the sensor encoder for the axis shown.

MEM ERR

(flashrng)

-

Some or all of the program data

has

been lost or

altered. Press RESTORE. Check and re-input where applicable the

entire

program.

EEM

ERR

(flashing)

-

Press

RESTORE.

Recalibrate all sensors.

8.4

ProtoTRAK

Limited Warranty

TRAK

products are warranted to the original purchaser to be £ree from

defects of

workmanship and

materials

for one year.

The

warranty period starts on the date

of

the

invoice

to

the

original purchaser

from

Southwestern Industries,

Inc.

(SWI)

or

their authorized distributor.

If

a unit under warranty fails it

will

be

repaired

or

exchanged at

our option

for

a properly functioning

unit

in similar or better

condition. Such repairs or exchanges

will

be made

FOB

Factory/Los

Angeles or the location of our nearest factory representative or

authorized distributor.

8.4.1

Disclaimers

of

Warranties

1.

SWI

is not responsible for consequential damages from use or

misuse of

any

of its products.

2.

TRAK

products are precision electronic-mechanical measurement

systems and must be given

the

reasonable care that these

types of instruments require:

o Replacement of wipers is the responsibility of the customer. o Accidental damage, beyond the control of

SWI,

is not covered

by

the warranty. Thus,

the

warranty does not apply

if

an

instrument has been abused, dropped,

hit,

disassembled or

opened.

3.

Improper installation by or at

the

direction of

the

customer

ir,

stlch

a

w2y

that

the

product consequently fails, is considered to be beyond the control of the manufacturer and outside the scope of the warranty.

4.

Warranty repairs/exchanges do not cover incidental costs such

as installation, labor, etc.

5.

This warranty is expressly

in

lieu of

any

other warranties, express or implied, including any implied warranty of merchantability or

fitness for a particular purpose,

and

of any other

obligation or liability on the part of

SWI

(or

any

producing

entity,

if

different).

Specifications subject to change

without

prior notice.)

This

product

is covered by one or more

of

the foIlo\v~ng U.S. Patents:

0194,853;3,30:,265; 3,311,985; 3,373,929;

3,561,120;

3,561,121;

3,i24,0[12; 3,740,856;3.1176,164; 3,1177,273: 3,771,230; 3,844,044.

Other

patents issued and pending in

the

U.S.

and

other countries.

PROTOTRAK PROCRAMMING

FOP&

DATE

PART

#

DESCRIPTION

PROMPTS

:

Southwestern Industries ProtoTRAK Plus Programming, Operating & Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual