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ACIES2515T. system overview. 18 th -Sept.- 2013 Amada America Inc. R&D Dept. Turret innovation + Laser process brings you High Speed, No Scratches and process integration!. “ACIES” is Latin for keeness, edge, sharpness. (Cutting Edge) . The main benefits of this new machine are:.

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slide1

ACIES2515T

system overview

18th-Sept.- 2013

Amada America Inc.

R&D Dept.

slide2

Turret innovation + Laser process brings you High Speed, No Scratches and

process integration!

“ACIES” is Latin for keeness, edge, sharpness.

(Cutting Edge)

The main benefits of this new machine are:

  • Scratch-free processing (die lowers for all tools)
  • Intelligent Auto Tool Changer and Buffer Turret, eliminates need for dedicated Turret Station numbers in NC (reassigned dynamically by ACIES controller based on machine’s tooling status)
  • Slug suction for all stations
  • Energy-Save mode
  • Last Cut for Part TakeOut can be either Punch or Laser (for systems with Multi-TK part remover unit)
  • Digital Tool and Die system (by QR code and scanner) with web-based Tool Server
slide3

ACI300DE Rack tool storage, stores 300 punches with 2 dies for each punch

Tool/Die sensors

Pendant control

Tool/Die loading shelf

(in slid-out position)

Inside view of Rack storage,

with view of Buffer Turret

(in center)

Tool Loader arm

slide4

ACIES New Innovation

New MP-T tap unit

Full-flat table

New slug suction

high quality slug suctionavailable for all stations!

Tap auto change for 7 kinds

for M2.5~M8!!

Scratch free on back side!!

Intelligent ATC&Buffer turret

Tooling ID

Non die assignment job

Die change Buffer turret station,Available to set up during processing (※)

Digital management of die information

Track without T number

No dead zone at Track!!

(※) Under development

slide5

ACIES New Innovation

Multi TK unit

Cut by punching

Cut by laser

Possible final-cutting by punching or laser process

Multi stocker

Saving energy mode(Ecology)

Saving energy mode

Electricity control during laser machine stand-by

Drastically reduction of electricity consumption!!

Scratch free & Reusable material stockingStack parts without scratch!! Saving material!!!(ECO)

slide6

New Innovation Detail

Tooling ID

1.Auto check of tooling installation

3.Prevent scratch on back

When clamp axis moves, die moves down depends on die height automatically, informed die height with tooling ID

Read the ID tooling carved seal automatically and check the punch & die installation status. Less tooling mis-installation and defectiveness by tooling shape or key angle mistake

*Teach the die height for down forming

Tooling info

ID data

ID carved seal

IDcarved seal

When clamp axis move, die move down depends on die height

Tooling ID server

ACIES

Tooling ID server

Die height (open height)

Auto read

2.Tooling grinding amount display and die height adjustment

4.Tooling condition management

Tooling grinding amount is shown on tooling ID server so that anyone can grind proper quantity. Grinded tooling adjusts automatically height with ACIES referring to the ID tooling information.

Estimate the edge abrasion by tooling use result and ID tooling information. After processing, auto update and mage. Understand the tooling status always and it is useful to keep tooling longer.

Grinding

:Maintenance time

Condition

Processing redult

:Change(No grind quantity)

Grinding quantity shown

Finish grinding

Tooling ID server

Edge status and grind result

ダイ

ACIES

Tooling ID server

*No die shim adjustment

Tooling management by tooling ID system supports high speed stable processing.

slide7

New Innovation Detail

Multi TK unit

Final laser cutting

Long length

small

Large

Multi-TK

Ability of joint-less operation for small parts and long length parts with punching or laser cutting (8 shelves)

Final punching cutting

Long length

small

Large

Punch

Laser

Punching is for vinyl-covered material. Laser cutting is for thick material. It is possible to operate joint less from small to large size parts, helping to reduce secondary processing.

slide8

New Innovation Detail

Intelligent ATC & Buffer turret

Before

After

・36ST(2AI)-(Max E range)

・32ST(4AI)-( MaxE range)

・32ST(4AI)-( MaxD range)

・69 tooling・・

・65 tooling ・・

・75 tooling ・・

33

Max E range

43

Max D range

・A spec・・300 tooling

・B spec・・179 tooling

Standard turret:58ST(2AI)

slide9

New Innovation Detail

Slug Suction

Before

After

Slug suction for each tooling size

                 =Improved suction

*Conventional: Only E range size

Power vacuum

1/2 inch

Vacuum 1-1/4 inch size tooling

Slug suction

Slug suction for each tooling size

The suction power is adjusted in three level by thickness and tooling size with inverter control.

E range size slug suction

slide10

New Innovation Detail

No dead zone at Track

Before

After

Punch center

Punch center

Upper turret

Upper turret

Clamp

Clamp

130mm

170mm

Limited tool layout around forming tool

Unlimited tool layout

Clamp

Longer clamp, Full flat table, no dead zone at track

slide12

上段

上段

中段

中段

Eレンジ無

Eレンジ有

下段

下段

HA236ZR

HA432ZR-D

HA432ZR-DE

バッファモデル用ストレージ

ACI65

ACI69

ACI75

ACI300xx

ACI179xx

slide13

43 station

33 station

ACIES Buffer Turret Layout

Free location for tooling set up and operation

*( ) is number of machine turret

*( ) is number of machine turret

slide14

MJC Unit

Multi-TK detail

5x10

0

320

370

475

2700

R

Base point

C20

0

17.5

75

130

0

320

370

475

2700

L

Base Point

C20

0

17.5

75

130

190

0

145

565

slide15

0

105

216

316

395

550

775

1150

1375

1675

1975

2225

2575

P50x2

P50x2

P50x2

P50x2

P50x2

P50x2

P50x2

P50x2

Base point

0

25

R

105

130

Multi-TK detail (cont’d)

5x10 - RIGHT ARM

2700

Rアーム

0

15

50

85

150

200

250

300

430

Diameter

Qty

P8x3

P8x3

P8x4

P8x4

Ø10

20

P8x3

P8x4

P8x4

0

0

Ø15

41

14.5

25

Ø20

2

37.5

40

Ø40

52

93

95

106.5

115

118.5

Power of vacuum

P8x3

Ø10

0.15kg

P8x3

P8x4

P8x4

16

Ø15

0.3 kg

Ø20

0.6 kg

0

15

50

150

250

422

Ø40

2.5 kg

Sensor(Ø8)

slide16

Lアーム

Diameter

Qty

Ø10

20

0

105

216

316

395

Ø15

41

Base point

Ø20

8

0

Ø40

46

25

L

105

130

MJC Unit

Power of vacuum

Ø10

0.15kg

MJC Unit

Ø15

0.3 kg

Ø20

0.6 kg

Ø40

2.5 kg

550

775

1150

1375

1675

1975

2225

2575

P50x2

P50x2

P50x2

P50x2

P50x2

P50x2

P50x2

P50x2

Multi-TK detail (cont’d)

5x10 – LEFT ARM

2700

0

15

50

85

150

200

250

300

430

P8x3

P8x3

P8x4

P8x4

P8x3

P8x4

P8x4

0

0

14.5

25

37.5

40

93

95

106.5

115

118.5

P8x3

P8x3

P8x4

P8x4

16

0

15

50

150

250

422

Sensor(Ø8)

slide17

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

R

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

L

MJC Unit

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

Multi-TK detail (cont’d)

5x10Cup Groups

slide18

Programming for the ACIES2515T

There really isn’t anything unique about programming for the ACIES2515T machine when compared to any other EML+PDC system.

For Dr.ABE Blank, just specify the Turret Name and Storage Name in Machine Information. You’ll need to have at least v2.12.07 to have the new Turret Types and PDC Storage types show up.

Note: At this time (June 2013), the Multi-TK support is not ready for Dr.ABE Blank…so only standalone ACIES+ACI300DE is supported.

slide20

Programming for the ACIES2515T

1. Place your Inventory tools into the correct Storage stations.

(Note: The Storage Numbers start at 101 and go to 400…just keep in mind that at the machine the H# numbers go from 1 to 300. The NC Code needs to be output with the Storage numbers being “100” higher, that is why it is this way.)

2. Then right-click and select Set Up if you want to assign this Storage tool to a particular Turret Station.

"Ordinary"- Define the ordinary tools are defined as resident tools, which will remain in the turret after punching

"Non-resident"- Define the tool as a non-resident tool, which will return to the PDC when punching process is done.

If several non-resident tools (with the same range) are used to process one sheet, all these non-resident tools will have the same station number.

slide27

ACIES AMNC-F settings and NC Converter setup

There are a few initial things that need to be setup out at the ACIES controller (AMNC-F).

First, is the Maintenance section to perform the H# conversion.

Go to Application Settings, from the MAINT section…and set up the dialog as below, leaving the Air Blower and NEX Tool items unchecked. Also do not setup the Management Name DETAIL button section, it is not necessary.

(The Die Clearance values can be adjusted to the customer’s preferred values.)

slide28

ACIES AMNC-F settings and NC Converter setup

The next thing that needs to be set up is the NC Code Converter, which takes the 7-digit Tool Code and converts it to an H number.

Browse the AMNC-F control to the C:\asis1v11\Bin folder, and launch the “Ni_NTRConv_InputParameter.exe” executable.

If prompted for password:

slide29

ACIES AMNC-F settings and NC Converter setup

Setup the H-Number Convert Settings exactly as specified in the screenshots here.

Make sure that your Machine (workcenter) name is checked if it appears in the list

slide32

ACIES AMNC-F screenshots: H# screen

The following slides will show the new AMNC-F setup screens for the ACIES.

slide33

ACIES AMNC-F screenshots: TURRET screen

Selecting a Tool Station will show its detailed content info on the right-side.

In all of the Tool Setup sections, Operator can also scroll the Station detail section to the right to see additional data.

slide35

ACIES AMNC-F screenshots: RACK screen

Note: RACK numbers are not sequential.

See the Rack Station and H# chart for detail.

slide36

ACIES AMNC-F screenshots: Tool Exchange/Install screen

Check the Punch and Die(s) for the area you want to Install/Exchange and press the Tool Exchange button.

Then verify the info and press Agree.

Note: if you are adding non-QR-coded tooling (old-style), make sure to turn OFF the Match property.

slide37

ACIES AMNC-F : Loading a PROGRAM

Choose the program loading location from the Media/Folder tree on the left.

Choices are SDD, local drive, and external drive (usb stick).

Click on MEDIA SETTING to configure the file-loading locations.

NC file

LZH file

slide38

ACIES AMNC-F : Returning Tools to the RACK

1. Make sure Arrangement Mode is set to ON.

2.

  • Go to SETUP page
  • Select TURRET or BUFFER
  • Highlight/Select the TOOL to return
  • Press TOOL RETURN button

Use Tool Size and Type filters if necessary

slide39

ACIES AMNC-F : Returning Tools to the RACK (cont’d)

3. Return to Rack dialog will show on controller.

4.

Go to ACI pendant and press F4 button

5. Repeat as necessary for any other tools needed to be returned to the Rack.

slide40

H# Conversion process and logic

  • It is important to get a clear understanding of how the H# conversion process works.
  • I’ll summarize it briefly here, and there are additional following slides from Amada Japan on the H# conversion detail.
  • First off, as a programmer or operator, once the system (software and control) are setup properly…you don’t really need to worry about the details of the H# conversion, since it occurs automatically.
  • If you are loading a program from the PRE-EDIT screen, an initial H# conversion will occur. Do not be alarmed if these H#’s look incorrect. They are temporary. The conversion module simply assigned the first available H# for that range to that tool and rewrote the NC code line. If you remain in PRE-EDIT and press the SIM button, the conversion process will occur again and this time the result H#’s will be correct. However, to end up with the correct H numbers it is not necessary to press the SIM button, because when the program is transferred to the PROGRAM section the H# conversion will be run again.
  • If you are loading the program from the PROGRAM area of the controller, then the double-conversion occurs instantaneously and the H#’s will immediately be correct.
a h number conversion flow overview
A. H-number Conversion Flow (Overview)

1.Make G-code for ACIES

2. Calling the Program

4. Running the SIM..

 (from SDDJ --- AMNC-F/AMNC-IT)

 (AMNC-F/AMNC-IT)

(AP100/Dr.ABE)

>Seven-digit T-code

>Convert to the temporary H-number.

>Convert to the correct H-number

M33

(X10.149Y46.874T3101011)

X10.149Y46.874H22 (211)

X1.392Y46.952

Change the seven-digit T-number to the temporary H-number, when calling the program data from SDD-J. (Using the Converter definition file)

In addition, T-number of UTL / UTLX file is also changed to the temporary H number as well.

Using the setup simulation(SIM.), compare the temporary H-number and the H-number of loaded tools in the tool rack and will be converted to the correct H-number.

Setup SIM. Is required.

slide42

A.Definition part of the temporary H-number.

Reference example of the rack model

Converter definition file

%ASISSystemRoot%ASIS1V11\Ni_NTRConv\MachineInfo\Ni_NTRConv-Eng.xxx

Get the rack information that is managed by the machine when setup a Converter, The Converter definition file is manage the number of each Tool-range of the rack.

[RackData]A-Range No. AA , to No. BBA-Range No. EE , to No. GG It is multiline if No. is not sequential.B-Range No. CC , to No. DD::

The contents of the definition file is different depending on the rack configuration (layout) of the Machine.

a additional info example of the temporary h number assignment
A.Additional info. : Example of the Temporary H-number assignment.

Example: 300 rack layout

Count the number of each range of rack form file (FLX_RackForm.XML), assign a serial number of 300 tools.

This number is just a sequential number and has nothing to do with the actual H-number of the rack. An assigned number is different by the rack form and is not serially in the same range.

Upper

(252

tools)

B 20本

A 24本

B 20本

A 64本

B 25本

B 35本

A 64本

A-Range03

=215-278

B-Range05

=180-214

A-Range02

=143-166

B-Range03

=118-142

B-Range01

=1-20

A-Range01

=21-84

Middle

(25

tools)

B 3本

B 8本

B 14本

B-Range02

=85~107

B-Range06

=279-292

B-Range04

=167-174

Lower

(23

tools)

C 6本

D or E 4本

C 4本

C 5本

D or E 3本

D or E

1本

C-Range01

=108-113

D-Range01

=114-117

C-Range02

=175-178

C-Range03

=293-297

D-Range03

=298-300

D-Range02

=179-179

slide44

A.Temporary H-number conversion by the Converter

Change the seven-digit T-number to H-number, when calling to the program data from SDD-J.

Note: The Converter does not communicate with the ID-Tool Server

- Flow of changing the seven-digit T-code to H-number

1. Reading the T-number from the beginning of the G-code.2. Checking the range of tools in use.3. Changing to the temporary H-number of the range to be converted.

If using multiple tools of the same tool-range, the H-number is assigned in order from the first number of each tool-range in the Converter definition file.

For example. if a A-Range01 is set the 21 to 84 and using two A-range, the temporary H-number are assigned the H21 and H22.

If the A-range is using 85 tools or more, to be assigned the number of Range02.

Befor Conversion

T3101011 ---- Range - A T3032531 ---- Range - A

Checking the rack information to convert.

Original G-code

Converter definition file

Converted data

After Conversion

H211 ← T3101011 H221 ← T3032531

同レンジの先頭の番号へ   順番に振りなおしします。

slide45

A.H-number matching by the setup simulation

Convert to the correct H-number in the setup simulation (Running the SIM.).

Previous SIM.

After SIM.

Changing to the correct H-number

Compare to loaded tools in rack by setup simulation (Run SIM.), convert to the correct H-number to use.

slide46

A.Location of configuration files, conversion module files.

The standard setting is the following.

Location :

%ASISBinaryRoot%ASIS1V11\BIN\Ni_NTRConv_Eng_amnc.exeNi_NTRConv_InputParameter.exe Ni_NTRConv_InputParameter_rc.dllNi_NTRConv_TurretRackConv.exe Sddmdh.dll Sddmdh_rc.dll

%ASISSystemRoot%ASIS1V11\Ni_NTRConv\*.*

ACIES Converter Module files

ACIES Converter Configuration file

Definition file for converting are saved here.

Converter definition file : Ni_NTRConv-Eng.xxx

%ASISSystemRoot%ASIS1V11\Ni_NTRConv\MachineInfo\Ni_NTRConv-Eng.xxx

slide47

A.Location of Tools Form files.

[AMNC-F,FMS Controller]

File location of the machine side information.

There are 3 files, Rack Form / Buffer Form / Turret Form.

\ASISSystemRoot\Master\FS30i\TBRS\FLX_RackForm.XML\ASISSystemRoot\Master\FS30i\TBRS\FLX_BufferForm.XML\ASISSystemRoot\Master\FS30i\TBRS\FLX_TurretForm.XML

slide48

Location of ACIES master system Tool Load file

This is for reference only, you shouldn’t ever need to mess with this file…but whenever a tool is added to the ACIES system, the master Tool Data file is located here:

slide49
The purpose of this document is to provide some detail for programming for the ACIES + PRIII L 300 (LKI) system. It will also illustrate some SY2 detail and troubleshooting methods.

It assumes user has some general knowledge in using Dr.ABE Blank and also assigning Arm Locations and the DoStack module.

NOTE: Some of the information contained may be subject to change.

slide50

PRIII (L) Specification

    • Minimum Part Pickup for M384: 3.937” x 3.937” (100 x 100 mm)
    • Minimum Part Pickup for M383: 6” x 6” (150 x 150 mm)
    • Maximum Part Pickup: 98.425” x 39.370” (2500 x 1000 mm)
    • Material Thickness Min: 22 Gauge (0.5 mm)
    • Material Thickness Max: 0.236” (6.0 mm)
    • Maximum Weight (Pickup): 110 lbs. (50 kg)
    • Stacking Area: 134” x 55” (3400 x 1400 mm)
    • Maximum Stack Height: 17.7” (450 mm)
    • Max. Sheet size: 120” x 60” (3000x1500 mm)
    • Min. sheet size: 63” x 2” (1600x50 mm)

Suction Cup Layout - PR 300 L

slide52

Overview: ASIII MP Operation

The ASIII (Automatic Storage with Loading function), which works in conjunction with the PR III UL machine, is adapted to taking care of the automatic loading/unloading of raw material. The use of suction cups enables the ASIII to handle different kinds of material such as steel, aluminium, and plastic.

Features of the ASIII

• Automatic Storage with Loading function.

• Works in conjunction with the PR III UL.

• Automatic loading of NCT: Loading unit with suction cups; Sheet separation; Picks up sheets and loads laser / punching machine.

• Loading of raw material and unloading cut sheets take place to and from the pallet lifter when the pallet lifter is at the pin-table.

• Equipped with pallet lifter: Lifting capacity 3000kg (6613 lbs); Moves pallets to loading position

• Storage capacity of 9 pallets for handling and storing various raw materials.

• 3 pallet configuration depending on customers needs.

• Equipped with pin table for removal of wooden pallet.

• The sheet to be cut is lifted from the raw material pallet in the material shelf and is then loaded to the NCT.

• The sheet thickness is always checked using a double sheet detector. The ASIII has 3 different separation settings that can be selected by the User/PC control system.

ASIII MP specifications

slide53

Getting necessary parameters from PRIII control into Dr.ABE Blank

You’ll either need to get the PRIII parameters from Amada Service Engineer, or get them yourself from the PRIII controller.

After logging on to the PLC for the PRIII-Unloader, access the system parameter page for X and Y-Servo parameters. The Z-Servo parameters are not necessary to be entered into Dr.ABE Blank.

If you need to get the parameters yourself, the login password is “78963”

Sample collected PRIII parameters

Switch to METRIC display units, and then enter the PRIII parameters into Machine Settings / Peripherals / Take-out Information.

X Home = 7270X Wait = 750X Stack 0 = 4079X Pickmin = 70YA Home = 40YB Home = 1305YB Pickmax = 1305Min arm opening = 210

slide55

Because of the travel limitations of the LKI part removal arms, it is necessary to install the PR OT-Check Module. This is a small executable that gets called when saving the Schedule to SDDJ/File. Before the NC code and SY2 files are saved, the module will examine for invalid arm assignments or stacking locations, based on the travel ranges for each arm.

The PR OT-Check Module requires a special license, so you’ll need to make sure that the module is enabled by your DAT-file license. If you go to Status Check from License Management in ASIS100PCL, you should see “PR OT Check Add-on” listed.

After installing the module, you’ll need to go to System Settings / Option tab and specify the location of the OT Check executable. Make sure to select the checkbox for “Carry Out Conversion When Saving Schedule”, and then point to the file “CompOtCheck.exe” in the AIC_PrAddOn subfolder in the Dr.ABE folder environment.

slide56

Other than the sections highlighted in yellow (which will be unique to each install), these are current ideal Take-out Information settings for EML-PRIII customer, not ACIES.

Note: the YAHome value for the PRIII itself (at the machine) is actually from the bottom of the sheet (Y 0.00”), however Dr.ABE Blank uses this value to limit how low on the part (in the Y) the arm can be placed from the bottom of part. This would unnecessarily restrict the ability to pickup smaller parts.

To address this issue, I have lowered the YAHome and XpickMin values to allow the arm to pick up smaller parts. There is no danger in doing this, unless a part is placed at Y 0.00” on the sheet, which is highly unlikely…most customers nest parts at 1.500” in the Y or higher. These altered values were tested onsite and work fine. (ET)

slide57

Dr.ABE Blank Loading/Unloading Device settings

You shouldn’t need to change many settings in this section.

I’ve been told by Machine Service Engineer that M56 is used for EML + PRIII, and it works well, so set it up as below for End Position M-Code.

slide58

Dr.ABE Blank NC Code Preference settings

The items highlighted in yellow are critical for proper NC code generation for the ACIES-PRIII system.

Note: The M104 Z height does need to be in the code for the last cut when taking out parts with the PRIII, but we will turn that output setting on in the Peripherals preference…not here.

However, if you want the Z-value output for other functionality (workchute, etc.) in Process After Rules then you’ll need to turn the “Z HEIGHT M104Zx” checkbox on.

slide59

Dr.ABE Blank Peripherals Preference settings

Take Out tab

Parts Removal Sequence tab

Make sure to set the Laser Z Axis Reference Point to 12 inches!

Regarding the “Auto Stack On” setting, it has been recommended by LKI/AEE to turn that setting off…but doing so will result in the DoStack (Unloading Table) being loaded with parts in the same layout manner as the ACIES sheet. This is fine for a single-sheet program, but for multiple-sheet nests the customer will want the parts Stacked on top of one another. Also, if the user is in the habit of pressing Reset and doing the DoStack manually…it doesn’t matter what this setting is set to. The PR OT-Check module will force you to correct any problematic stacks created by having Auto Stack On.

slide60

M383 and M384 Take-Out methods

There are 2 methods of taking parts out with the PRIII.

The other method, less commonly used, is M383…in which the perimeter cut is partially finished, and then the head raises and the arms come in and secure the part…then the final cut is made while the arms are already holding the part. This is useful for parts that have intricate notches making a successful pickup with M384 method difficult.

The most commonly used one is M384, in which the part perimeter is cut out completely…and then the head raises and the arm comes in to remove the part.

The method that is used is controlled by the Peripherals preference

slide62

PR OT-Check Module functionality

The PRIII OT Check Module works with SDDJ or File Method. When clicking “Save Schedule /Output Report” from the Result Area’s right-click menu to save the NC/SY2 file a window will open and allow setting the correct alternative take-out for every invalid part on the nesting, similar to “Begin TK/IJP edit”.

The module only triggers the TK Edit window or DoStack when the travel zones of the pick up arms (A & B) are exceeded (assigned incorrectly / out of pick up range). When the pick up arms are within tolerance (valid pick up range) any saved Schedules/NC to SDDJ/File will not trigger the PR OT-Check Module.

slide63

How to manually re-do the Stacking

2. Place parts from Parts List onto

Unload Table

3. Do this for each program by using the Program Name drop-down, clicking Change Table when Unload Pallet is filled (if necessary)

1. Click “Reset”

4. Click “OK” when finished

slide66

Miscellaneous DoStack information (cont’d)

  • Click the Layouts button to choose from different Unload Pallet configurations.

Note: If the Layouts button is disabled, you’ll need to run the SS32X25 OCX* batch file patch. These files were contained in the old “DoStack StackingModule fix” from 2008.

Once you have these files, place them in the “\Windows\System32 “ folder and run the “SS32X25.bat” file.

*These files will be provided to you along with this document.

  • From v2.xx onwards, the DoStack Pallet config is not setup in the Schemes.xml file anymore. It is done in the Peripherals preference, via the TK SkidLayoutEdit button.
  • Unless you are running 2.12.05P3 (special patch), you’ll need to enter all of the values in the SkidLayoutEdit in METRIC units.
  • The upcoming v2.12.06 will resolve this issue so Inch values can be used.
slide67

DoStack documentation from AEE/Computes

The stacking dialog is divided into three parts:

1. To the left, there is the list of all the parts to produce with the currently selected program.

2. Top right, you can see the current unloading layout for the selected table.

3. Bottom right, there is a tree showing the contents of each stack you have positioned so far.

The pallet used for the last job in your list is visualized by default but you can view any of the pallet set for the selected job sequence. Note that the placement of parts that is displayed the first time reflects the settings you specified to nest the sheet. However, you can change the position and the number of stacks in any of the existing pallets.

If you wish to rearrange all the pallets used for the current job list, click the RESET button from the toolbar. Stacking module automatically clears all the pallets in use and highlights the first job in the list. The table to the left shows all the parts produced with the selected job, including external or internal subprograms.

• Red: the part has not been stacked yet.

• Yellow: the part is present in at least one stack but more stacks can be created (the maximum number of stacks for a single part corresponds to its quantity for the current job)

• Green: the part has already been stacked and all the possible piles have been created.

To place a part on the pallet, just click it with the mouse left button and drag it to the chosen position. The module automatically creates a stack with the dropped part and updates stack data (height, total weight, part code, number of stacked parts and their position on the pallet).

To remove a stack, just click on it and then choose REMOVE STACK.

The DEFAULT button allows you to rearrange all the parts of the current job by applying the same layout you used for this job within the CAM.

The parts represented to the right can be displayed in different ways:

• Blue: the parts belonging to the current program have been placed correctly on the pallet without overlapping other work pieces or the pallet edges.

• Red: the parts belonging to the current program have not been positioned correctly and may overlap other work pieces (for example, those included in a bounding box) or exceed the loading area.

• Dashed lines: all the parts that do not belong to the currently selected program.

• White dashed lines: all the parts that required a change of pallet. Remember that these parts cannot be moved, unless you RESET all the layouts or restart positioning pieces from the current pallet.

slide68

DoStack documentation from AEE/Computes (cont’d)

When you have positioned all the parts for the current job, you can continue by selecting the next job from the Program Name combo-box.

If some parts are misplaced, you will be prompted to correct their position but you can ignore the prompt and continue anyway (it is your choice, just remember that placement errors may make it impossible to unload parts correctly).

After selecting the new program, the list of parts underneath the Program Name box is automatically refreshed. You can place parts on the same pallet you used for the previous job (if there is enough space left) or activate the CHANGE TABLE command to bring up a new pallet.

You can also take advantage of the REUSE command that lets you pile up parts automatically by adding them to the existing stacks. This is only possible when stacks include similar parts (i.e., parts with the same code, shape and unloading angle). If there is no compatible stack, you will

have to position parts manually.

You can change the type of pallet in use at any time. Just click the PALLET SCHEMES button to bring up the list of pallets available in SCHEMES library (file SCHEMES.XML, no longer valid…use the TK SkidLayoutEdit button instead now).

When you have defined the layout of all the parts to produce for the current job list, click the OK button. The files associated with each job are automatically updated to reflect the new settings.

Stacks exceeding the maximum admitted height are marked with an exclamation mark.

It is recommended that you rearrange incorrect stacks, for example by creating a new one.

However, if you want to keep the current layout, click OK or select the next job. The module will automatically add all the pallets required.

slide69

OT-Check: Pickup Edit & DoStack information

  • For OT Module Pickup Edit window:
  • If you ever see a red exclamation point icon on a part in the DoStack module, this is because of Part Stack Height/Weight. Create more stacks of that part on the Unload Pallet to get rid of the error.
slide70

Miscellaneous Dr.ABE Blank tips for EML+PRIII usage

  • “Return to Home” reposition is not necessary for the EML when used with the ASIII tower. The sheet remover mechanism will automatically adjust when coming in to remove the finished sheet.
slide71

The following slides will explain the SY2 file format and also how to examine an SY2 file to see if its content is valid.

This content was prepared for EML-PRIII system, but is still valid for ACIES-PRIII system.

slide72

SY2 format

Detail

For EML+PRIII

slide73

Dual (A and B-arm) SY2 code example and illustrative diagram

[PD_0005]

HNO=5

HNAME=EMLPRIIICUPTEST-M384-ET

HKIND=1

HWGT=3.5076

HCMT=

HPRNO=

HSZX=30.2061

HSZY=19.8298

HSX=30.2061

HSY=19.8298

P98DT=0,1,1,0.0000,0.0000

PBX=0.6334

PBY=26.1952

PBAX=0.6334

PBAY=26.1952

PANG=0.0000

U1=

U2=

U3=

U4=

U5=

HORD=

AWAY=0

CFLG=1

CNUM=0

INUM=0

FCUTX=0.0000

FCUTY=19.8298

FTY=0.0000

RXPICK=4.3912

RYPICK=38.4684

RARMO=9.2170

RACUPS=1023

RBCUPS=1023

RH1=4097

RH2=3

RS1=0

RS2=0

RIX=1

AID=2

AX=16.5799

AY=28.8197

AHIGT=0.0480

ASKID=0

AMAXN=287

slide74

Single (B-arm) SY2 code example and illustrative diagram

[PD_0004]

HNO=4

HNAME=EMLPRIIICUPTEST-M384-ETsingle

HKIND=1

HWGT=2.1541

HCMT=

HPRNO=

HSZX=30.2061

HSZY=12.0747

HSX=30.2061

HSY=12.0747

P98DT=0,1,1,0.0000,0.0000

PBX=49.1401

PBY=46.7918

PBAX=49.1401

PBAY=46.7918

PANG=0.0000

U1=

U2=

U3=

U4=

U5=

HORD=

AWAY=0

CFLG=1

CNUM=0

INUM=0

FCUTX=0.0000

FCUTY=12.0747

FTY=0.0000

RXPICK=8.389

RYPICK=48.2791

RARMO=9.6555

RACUPS=0

RBCUPS=511

RH1=4097

RH2=3

RS1=0

RS2=0

RIX=-1

AID=3

AX=6.2098

AY=15.7299

AHIGT=0.0480

ASKID=0

AMAXN=287

slide75

Unload Stacking Location (from DoStack)

SY2 code example and illustrative diagram

[PD_0001]

HNO=1

HNAME=CSINK_assign_test_Pilots_ONLY

HKIND=1

HWGT=0.3921

AID=1

AX=5.8697

AY=33.5

AHIGT=0.0480

ASKID=0

AMAXN=287

[PD_0004]

HNO=4

HNAME=EMLPRIIICUPTEST-M384-ETsingle

HKIND=1

HWGT=2.1541

AID=3

AX=6.2098

AY=15.7299

AHIGT=0.0480

ASKID=0

AMAXN=287

[PD_0005]

HNO=5

HNAME=EMLPRIIICUPTEST-M384-ET

HKIND=1

HWGT=3.5076

AID=2

AX=16.5799

AY=28.8197

AHIGT=0.0480

ASKID=0

AMAXN=287

slide76

With the latest PR-OT-Check Module (v1.10.14), there should no longer be any bad data written to the SY2 file.

With previous versions of the OT Check module, depending upon how you did the Stacking in the DoStack module (when it was triggered by OT Check module when saving NC) it would sometimes write bad AX & AY stacking locations. This problem was easy to check inside of the SY2.

First, let’s take a look at how to easily see (based on sample truncated SY2 data) which arm is used:

A-arm only

B-arm only

Both A and B-arms

RXPICK=4.4258

RYPICK=42.0695

RARMO=8.2677

RACUPS=63

RBCUPS=0

RH1=4097

RH2=3

RS1=0

RS2=0

RIX=1

AID=4

AX=3.122

AY=2.6287

AHIGT=0.0600

ASKID=1

AMAXN=229

RXPICK=22.0473

RYPICK=49.7022

RARMO=10.886

RACUPS=0

RBCUPS=36183

RH1=4097

RH2=3

RS1=0

RS2=0

RIX=-1

AID=1

AX=5.9161

AY=37.8028

AHIGT=0.0600

ASKID=1

AMAXN=229

RXPICK=4.3912

RYPICK=38.4684

RARMO=9.2170

RACUPS=1023

RBCUPS=1023

RH1=4097

RH2=3

RS1=0

RS2=0

RIX=1

AID=2

AX=16.5799

AY=28.8197

AHIGT=0.0480

ASKID=0

AMAXN=287

After verifying what arm is used, you can determine if the Stacking Location is valid by looking at the AX and AY values.

Here is one example of bad data from old OT Check module. Notice that the B-arm is assigned and the Stacking Location on the Unload Pallet is at 1” in the Y. This is invalid and will cause a PR alarm when the program is run, because B-arm cannot go that low.

** B-arm minimum Y location is 9.8425” (250mm)

RXPICK=5.2845

RYPICK=46.1078

RARMO=8.2677

RACUPS=0

RBCUPS=255

RH1=4097

RH2=3

RS1=0

RS2=0

RIX=-1

AID=9

AX=83.8067

AY=1

AHIGT=0.1350

There is no way the B-arm can go down to 1” in the Y

slide77

PRIII suction cup alignment test program instructions

  • If you are ever onsite and need to make a suction cup alignment program, here is how to do so:
  • Make sure to get the PR parameters from the PR control (as mentioned earlier in this document) and import them in Dr.ABE Blank.
  • Make sure that the holes get etched. If you set the Etch Layer in Laser Tool Assign preference to “ETCH”, then the holes will be automatically etched.
  • Examine the cup locations with Amada Service engineer and make Machine (PR) adjustments if necessary. If the PR values are adjusted you may need to change them accordingly in Dr. ABE Blank and make another test program.

Note: I’ll provide (2) Cup Alignment dxf files, with the holes placed on a layer called “ETCH”, along with this document.

One will be for A-arm test and other will be for both arms.

slide78

Getting Ready to Run a Program

  • Overview : Prepare Line for FMS Mode
  • Before starting the Line (Automation) the following should be checked:
  • NCT (LC2415NT/EML/EM) must be in memory mode with E-DNC selected and Line Control on
  • PRIII must be read to receive data (waiting mode)
  • ASIII MP must be in FMS (Auto) Mode
  • AMNC-IT – Operation Start
  • When any of the above conditions are not met, the Line (automation) will fail to run. Please make sure the above conditions are met for a successful Line operation. Detailed instructions for these steps are below:
  • NCT Ready Mode
  • Ensure that AMNC-F control is ready to run with FMS-C (AMNC-IT)
    • Must be in MEMORY mode
    • E-DNC mode must be active
slide79

Line Operation key must be turned to the LINE position

  • Clamps must be closed by using ASIII control panel (before putting ASIII in AUTO mode), or from LC2415/EML/EM control panel near back of machine
  • Machine must be at origin
  • Make sure PRIII is in ”Waiting for Data” Mode
    • Make sure START button is ready (green)
    • Origin the PR (press ”To Home”)
    • Press ”AUTO”  ”FMS”  ”OK”  and then ”START”
    • The PRIII PCL control module will then be ready (”Waiting for data” mode)
slide80

NOTE: To dry-run a program and turn OFF the PR arm vacuum, follow these additional steps:

  • (If you are not dry-running a program, ignore these steps)
  • Press the START and STOP buttons at the same time, and continue to hold them down
  • While still holding down the START & STOP buttons, turn the Vacuum switch to the right
  • Release all of the buttons
  • The small light above the Vacuum icon/button should now be blinking, indicating that vaccum is deactivated.
  • Press STOP button once (making sure it is in the ”up” or ”raised” position)
  • Press START button. It should be lit green . PR arm is now ready for dry-run program test.
  • Once dry-run is completed and you want to switch PR arm vacuum back to regular operation mode, turn the Vacuum switch on the PRIII control panel to the right. The Vacuum switch light will stop blinking and the PR will be in ”Vacuum On” mode again.
slide81

ASIII MP Ready Mode

    • Select the ”Home Run” button to origin the tower, followed by the ”Auto” mode from the main menu of the ASIII MP screen
  • Select ”FMS Mode New”. The ASIII is now ready for automatic FMS operation.
slide82

FMS-C (AMNC-IT) Ready to Transfer Data

  • Make sure the Material for the job being run is registered in the STORAGE section of the AMNC-IT control. If it is not, make sure to register/add it before loading the program(s) into AMNC_IT control.
  • Go to the PRE-EDIT from AMNC-IT control. Click the ”OPEN” button to load your program(s).The programs may be loaded from a local directory, Shared folder or SDDJ, depending on how AMNC-IT is configured.
  • Highlight the desired program from the list and click ADD button.
slide83

After clicking”ADD” from the Pre Edit Menu, the ”Production qty entry” dialog must be completed.

    • Specify the information in Material Name section. This data should correspond to the laser cut condition used by the machine’s AMNC-F control to cut the parts.
    • Enter the Material Shelf number
    • Enter the PR Shelf number for unload parts
    • Enter the UL Shelf number (unload pallet).
    • Click OK to exit
slide84

Select the Schedule button (next to Pre Edit). The added program(s) will be displayed in ascending order (order in which they were loaded). Press the ”OperationStart”button to begin the processing of the program(s) in the queue.

Note: If you get ”Line Not Ready” error message after selecting ”Operation Start”, go to the Animation screen and look for ”green light” on PR and Line PLC areas. The AMNC-F light is only green when receiving a program.

slide85

AMNC-IT WORK ON SET

  • The Work On feature of FMS-C (AMNC-IT) allows the operator to be able to recover from the following instances.
    • The PRIII fails a part pickup after 3 tries or the pickup arm sensors are not enabled well
    • Loading a sheet manually onto NCT (Not available on Tower)
  • The above cases are typical examples that will require a ”Work On” set function.
  • Case A & B:
  • To recover using the ”Work On” function:
  • The NCT has to be reset on the controller by pressing the NC Reset tab.
  • Use the Utility tab on the NCT controller to access the Utility1 menu and press the G50 button to origin the sheet and retract the laser head to home position.
  • Reset the PRIII PLC controller by pressing the stop button first, disabling pickup arm vacuum (off), acknowledge the alarm, origin the arms to waiting position for new pick up data (The PRIII PLC controller will be waiting for data).
slide86

FMS-C (AMNC-IT) Schedule menu will be showing the schedule aborted. Click the ”Work On” button to change the status of the program and confirm it by the ”OK” button.

The color of the ”WORK ON ” button will switch from white to green confirming the state change. Click the ”OPERATION START” button to begin processing.

slide87

On the ASIII MP controller, do not abort the loaded schedule. The state of the schedule should also be green as displayed below.

  • There may be instances where the ”WORK-ON” button will fail to change colors from white to green. To resolve this problem, please make sure all the above condition have been met, check Animation screen for ”green lights” and then try the following:
    • if AMNC-F does not have green light in Animation, perform Retract X/Y/Z origin of LC2415NT/EML, by switching the Line key off of LINE mode and switch to Manual mode. Slightly jog X, Y, and Z axis and then perform Retract Origin. After ”Retract” origin is complete, put LC2415NT/EML back into LINE mode (key turned to LINE, Memory mode, E-DNC virtual button active)
    • manually bring the Gauge Blocks up to detect the material. If Work Set button turned green, lower gauge blocks and select Operation Start.
  • Every time a sheet is manually loaded onto the NCT all the above conditions must be met and the Gauge Blocks will have to be manually enabled up and down from the NCT, before a ”WORK ON” may be achieved.
  • When operation begins for a ”WORK ON” job, the ASIII MP will automatically unload the skeleton.
slide88

ASIII MP Material Database

Please do not make any changes to the built in database of the ASIII MP Database after the Amada Installation Engineer sets it up. All material storage information will be maintained in AMNC-IT. Any changes will require a password from the installation Engineer. Please contact the Amada Engineer should any modifications be needed.

The display below will be coming up frequently when any of the material shelves are loaded with new material, the Skeleton Shelves are full or emptied, or Shelves removed / placed back into tower.

PLEASE SAY ”NO” TO EVERY TIME THE ABOVE MANUAL MENU APPEARS !!! Answering ”Yes” to the above question will cause the database to be reconfigured, and will require a password from your Amada Installation Engineer.

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