HiCON Mach3 Software Integration User Guide

HiCON Mach3 Software Integration User Guide
HiCON Mach3 Software Integration
HiCON Mach3
Software Integration
Ethernet Motion Controller
Data Acquisition System
Logic Controller
User Guide
Document Revision 1.0
(Updated March 19, 2013)
© 2013 Vital Systems Inc
Phoenix, AZ USA
For more information please visit the product web page:
www.vitalsystem.com/hicon
© 2012 Vital Systems, Inc.
1
www.vitalsystem.com
HiCON Mach3 Software Integration
Contents
LICENSE AGREEMENT ............................................................................................................................... 3
MACH3 SOFTWARE INTEGRATION ........................................................................................................... 4
Starting Mach3 with HiCON ..................................................................................................................... 4
MACH3 CONFIGURATION ........................................................................................................................ 6
Mapping Mach3 Input Signals to HiCON OEM Digital Inputs .................................................................. 8
Mapping Mach3 output pins to HiCON OEM Digital Outputs ............................................................... 10
Mapping Mach3 Input Signals to HiCON Integra Digital Inputs............................................................. 12
Mapping Mach3 output pins to HiCON Integra Digital Outputs ............................................................ 14
Getting beyond the basic input/output with Mach3............................................................................. 15
Motor outputs. ...................................................................................................................................... 15
Spindle Setup. ........................................................................................................................................ 16
Setting an Axis as a Spindle ............................................................................................................ 16
Axis Homing and Direction .................................................................................................................... 17
Manual Pulse Generation - MPG ........................................................................................................... 17
OEMDROs and LEDs ............................................................................................................................... 19
HICON PLUGIN CONFIGURATION ........................................................................................................... 19
HiCON Plugin Configuration System Tab ............................................................................................... 21
HiCON Serial Number ..................................................................................................................... 21
Spindle Type and Axis ..................................................................................................................... 22
Max Buffer Level............................................................................................................................. 22
Enable Debug Window ................................................................................................................... 22
Ignore Limit Switches when Homing .............................................................................................. 22
Threading ....................................................................................................................................... 22
Manual Pulse Generation (MPG).................................................................................................... 23
Hardware Encoder Polarity ............................................................................................................ 23
Encoder Debounce ......................................................................................................................... 24
Step Pulse Width ............................................................................................................................ 24
Update HiCON Button (Under System Tab) ................................................................................... 24
HiCON Plugin Configuration Axis Tab .................................................................................................... 25
Test Motion .................................................................................................................................... 25
Control Parameters ........................................................................................................................ 27
Slave Axis Configuration ................................................................................................................. 28
© 2012 Vital Systems, Inc.
2
www.vitalsystem.com
HiCON Mach3 Software Integration
License Agreement
Before using the HiCON and accompanying software tools, please take a moment to go thru this License
agreement. Any use of this hardware and software indicate your acceptance to this agreement.
It is the nature of all machine tools that they are dangerous devices. In order to be permitted to use
HiCON on any machine you must agree to the following license:
I agree that no-one other than the owner of this machine, will, under any circumstances be responsible,
for the operation, safety, and use of this machine. I agree there is no situation under which I would
consider Vital Systems, or any of its distributors to be responsible for any losses, damages, or other
misfortunes suffered through the use of the HiCON board and its software. I understand that the HiCON
board is very complex, and though the engineers make every effort to achieve a bug free environment,
that I will hold no-one other than myself responsible for mistakes, errors, material loss, personal
damages, secondary damages, faults or errors of any kind, caused by any circumstance, any bugs, or any
undesired response by the board and its software while running my machine or device.
I fully accept all responsibility for the operation of this machine while under the control of HiCON, and
for its operation by others who may use the machine. It is my responsibility to warn any others who may
operate any device under the control of HiCON board of the limitations so imposed.
I fully accept the above statements, and I will comply at all times with standard operating procedures
and safety requirements pertinent to my area or country, and will endeavor to ensure the safety of all
operators, as well as anyone near or in the area of my machine.
WARNING: Machines in motion can be extremely dangerous!
It is the responsibility of the user to design effective error
handling and safety protection as part of the system. VITAL
Systems shall not be liable or responsible for any incidental or
consequential damages.
By using the HICON motion
controller, you agree to the license agreement.
© 2012 Vital Systems, Inc.
3
www.vitalsystem.com
HiCON Mach3 Software Integration
Mach3 Software Integration
The Mach3 Software is an off-the-shelf Milling and Lathe machine control software. User can download
the trial version of the software from www.machsupport.com.
The HiCON Integra or HiCON OEM can be integrated with Mach3 to form a high performance machining
center. The HiCON Software Tools provide the necessary drivers and configuration files to interface with
Mach3 software. If you have installed the software tools as explained in the software installations
section of the HiCON User Guide, then you already have all the necessary drivers.
This document assumes that user is familiar with the usage of Mach3 software. This chapter describes
the mapping of Mach3 internal software signals to the HiCON connector.
The general Mach3 software operation remains mostly the same when using HiCON plugin.
Starting Mach3 with HiCON
To launch Mach3 with HiCON plugin, double-click on the Mach3 Mill or Lathe software icon on the
desktop as you would normally run using parallel port. It shows the following dialog box with the option
to select M3HiCON plugin. Make sure this plugin is selected and click ‘OK’.
Make sure the HiCON is powered up and connected to the Ethernet network. The Mach3 software
shows up as follows with a message ‘HiCON Online’ in the Status bar.
© 2012 Vital Systems, Inc.
4
www.vitalsystem.com
HiCON Mach3 Software Integration
Click on the Menu item ‘PlugIn Control’, and then click on the item ‘HiCON Status” which displays the
following screen indicating that the HiCON board is connected with current states of counters and I/O
status.
© 2012 Vital Systems, Inc.
5
www.vitalsystem.com
HiCON Mach3 Software Integration
Outputs can be toggled by clicking on the output LEDs. If an output is defined in Ports and Pins, it will be
controlled by Mach3 and clicking on its LED will have no effect. This window may be left open while
running Mach3.
Mach3 Configuration
If using any of the Mach3 input signals, make sure the pins are ‘Enabled’ and set ‘Active Low’ as shown
in the example figure below.
Ignore the line printed on the above window about pins 10-13 and 15 [email protected]#$. This does not apply to
HiCON based system.
As with the input configuration, if using any of the Mach3 output signals, make sure the pins are
‘Enabled’ and set ‘Active Low’ as shown in the example figure below.
© 2012 Vital Systems, Inc.
6
www.vitalsystem.com
HiCON Mach3 Software Integration
Ignore the line printed on the above window about pins 2-9,1,14… [email protected]#$. This does not apply to HiCON
based system.
© 2012 Vital Systems, Inc.
7
www.vitalsystem.com
HiCON Mach3 Software Integration
Mapping Mach3 Input Signals to HiCON OEM Digital Inputs
The following table shows the mapping from Mach3 input pin numbers to the actual digital input pin
numbers available on the HiCON board.
Mach3 Input
ports and pins
Port #
Pin
Number
11
0
11
1
11
2
11
3
11
4
11
5
11
6
11
7
11
8
11
9
11
10
11
11
11
12
11
13
11
14
11
15
HiCON J8 pin
assignments
J8
Mach3 Input
ports and pins
Port #
Pin
Number
14
0
14
1
14
2
14
3
14
4
14
5
14
6
14
7
14
8
14
9
14
10
14
11
14
12
14
13
14
14
14
15
© 2012 Vital Systems, Inc.
HiCON Basic
MACH3 LED
GetPin Index
OEMLED
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
11, 0
11, 1
11, 2
11, 3
11, 4
11, 5
11, 6
11, 7
11, 8
11, 9
11, 10
11, 11
11, 12
11, 13
11, 14
11, 15
1300
1301
1302
1303
1304
1305
1306
1307
1308
1309
1310
1311
1312
1313
1314
1315
HiCON J12 pin
assignments
J12
HiCON Basic
MACH3 LED
GetPin Index
OEMLED
14, 0
14, 1
14, 2
14, 3
14, 4
14, 5
14, 6
14, 7
14, 8
14, 9
14, 10
14, 11
14, 12
14, 13
14, 14
14, 15
1348
1349
1350
1351
1352
1353
1354
1355
1356
1357
1358
1359
1360
1361
1362
1363
Pin number
Pin number
Lands on J6, J7
Lands on J6, J7
Lands on J6, J7
Lands on J6, J7
Lands on J6, J7
Lands on J6, J7
Lands on J6, J7
17
18
19
20
21
22
23
24
25
8
www.vitalsystem.com
HiCON Mach3 Software Integration
Mach3 Input
ports and pins
Port #
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
Pin
Number
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Mach3 Input
ports and pins
Port #
Pin
Number
13
0
13
1
13
2
13
3
13
4
13
5
13
6
13
7
13
8
13
9
13
10
13
11
13
12
13
13
13
14
13
15
© 2012 Vital Systems, Inc.
HiCON J9 and J11
pin
assignments
J9
Breakout 7535
pin assignments
HiCON Basic
MACH3 LED
GetPin Index
OEMLED
Pin number
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
12, 0
12, 1
12, 2
12, 3
12, 4
12, 5
12, 6
12, 7
12, 8
12, 9
12, 10
12, 11
12, 12
12, 13
12, 14
12, 15
1316
1317
1318
1319
1320
1321
1322
1323
1324
1325
1326
1327
1328
1329
1330
1331
HiCON J11 pin
assignments
J11
Breakout 7535
pin assignments
HiCON Basic
MACH3 LED
GetPin Index
OEMLED
13, 0
13, 1
13, 2
13, 3
13, 4
13, 5
13, 6
13, 7
13, 8
13, 9
13, 10
13, 11
13, 12
13, 13
13, 14
13, 15
1332
1333
1334
1335
1336
1337
1338
1339
1340
1341
1342
1343
1344
1345
1346
1347
Pin number
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
9
www.vitalsystem.com
HiCON Mach3 Software Integration
Mapping Mach3 output pins to HiCON OEM Digital Outputs
The following table shows the mapping from Mach3 output pin numbers to the actual digital output pin
numbers available on the HiCON board.
Mach3 Output
ports and pins
Port #
Pin Number
HiCON J8 pin
assignments
J8
HiCON Basic
SetPin
Index
11, 0
11, 1
11, 2
11, 3
11, 4
11, 5
11, 6
11, 7
Pin number
11
11
11
11
11
11
11
11
0
1
2
3
4
5
6
7
Mach3 Output
ports and pins
Port #
Pin Number
2
3
4
5
6
7
8
9
HiCON J9 pin
assignments
J9
Breakout board 7535
pin assignments
Pin number
12
12
12
12
12
12
12
12
0
1
2
3
4
5
6
7
Mach3 Output
ports and pins
Port #
Pin Number
2
3
4
5
6
7
8
9
0
1
2
3
4
5
6
7
HiCON J11 pin
assignments
J11
Breakout board 7535
pin assignments
Pin number
13
13
13
13
13
13
13
13
© 2012 Vital Systems, Inc.
0
1
2
3
4
5
6
7
2
3
4
5
6
7
8
9
0
1
2
3
4
5
6
7
10
HiCON Basic
SetPin
Index
12, 0
12, 1
12, 2
12, 3
12, 4
12, 5
12, 6
12, 7
HiCON Basic
SetPin
Index
13, 0
13, 1
13, 2
13, 3
13, 4
13, 5
13, 6
13, 7
www.vitalsystem.com
HiCON Mach3 Software Integration
Mach3 Output
ports and pins
Port #
Pin Number
HiCON J12 pin
assignments
J12
dspMacro
SetPin
Index
14, 0
14, 1
14, 2
14, 3
14, 4
14, 5
14, 6
14, 7
Pin number
14
14
14
14
14
14
14
14
© 2012 Vital Systems, Inc.
0
1
2
3
4
5
6
7
2
3
4
5
6
7
8
9
11
www.vitalsystem.com
HiCON Mach3 Software Integration
Mapping Mach3 Input Signals to HiCON Integra Digital Inputs
The following table shows the mapping from Mach3 input pin numbers to the actual digital input pin
numbers available on the HiCON Integra.
Mach3 Input
ports and pins
Port #
Pin
Number
11
0
11
1
11
2
11
3
11
4
11
5
11
6
11
7
11
8
11
9
11
10
11
11
11
12
11
13
11
14
11
15
Mach3 Input
ports and pins
Port #
Pin
Number
14
0
14
1
14
2
14
3
14
4
14
5
Mach3 Input
ports and pins
Port #
Pin
Number
12
0
12
1
12
2
12
3
© 2012 Vital Systems, Inc.
HiCON Integra (J13, J14) pin
assignments
(J13, J14)
HiCON Macro
MACH3 LED
GetPin Index
OEMLED
11, 0
11, 1
11, 2
11, 3
11, 4
11, 5
11, 6
11, 7
11, 8
11, 9
11, 10
11, 11
11, 12
11, 13
11, 14
11, 15
1300
1301
1302
1303
1304
1305
1306
1307
1308
1309
1310
1311
1312
1313
1314
1315
Pin number
INP0
INP1
INP2
INP3
INP4
INP5
INP6
INP7
INP8
INP9
INP10
INP11
INP12
INP13
INP14
INP15
HiCON Integra J10 pin
assignments
J10
HiCON Macro
MACH3 LED
GetPin Index
OEMLED
14, 0
14, 1
14, 2
14, 3
14, 4
14, 5
1348
1349
1350
1351
1352
1353
Pin number
8
15
7
14
6
13
HiCON Integra J7 pin
assignments
J7
HiCON Macro
MACH3 LED
GetPin Index
OEMLED
Pin number
10
11
12
13
12, 0
12, 1
12, 2
12, 3
12
1316
1317
1318
1319
www.vitalsystem.com
HiCON Mach3 Software Integration
12
12
12
12
12
12
12
12
12
12
12
12
4
5
6
7
8
9
10
11
12
13
14
15
Mach3 Input
ports and pins
Port #
Pin
Number
13
0
13
1
13
2
13
3
13
4
13
5
13
6
13
7
13
8
13
9
13
10
13
11
13
12
13
13
13
14
13
15
© 2012 Vital Systems, Inc.
14
15
16
17
18
19
20
21
22
23
24
25
12, 4
12, 5
12, 6
12, 7
12, 8
12, 9
12, 10
12, 11
12, 12
12, 13
12, 14
12, 15
1320
1321
1322
1323
1324
1325
1326
1327
1328
1329
1330
1331
HiCON Integra J8 pin
assignments
J8
dspMacro
MACH3 LED
GetPin Index
OEMLED
13, 0
13, 1
13, 2
13, 3
13, 4
13, 5
13, 6
13, 7
13, 8
13, 9
13, 10
13, 11
13, 12
13, 13
13, 14
13, 15
1332
1333
1334
1335
1336
1337
1338
1339
1340
1341
1342
1343
1344
1345
1346
1347
Pin number
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
13
www.vitalsystem.com
HiCON Mach3 Software Integration
Mapping Mach3 output pins to HiCON Integra Digital Outputs
The following table shows the mapping from Mach3 output pin numbers to the actual digital output pin
numbers available on the HiCON board.
Mach3 Output
ports and pins
Port #
Pin Number
HiCON Integra J15 pin
assignments
J15
Pin number
11
11
11
11
11
11
11
11
0
1
2
3
4
5
6
7
Mach3 Output
ports and pins
Port #
Pin Number
OUT0
OUT1
OUT2
OUT3
OUT4
OUT5
OUT6
OUT7
HiCON Integra J7 pin
assignments
J7
Pin number
12
12
12
12
12
12
12
12
0
1
2
3
4
5
6
7
Mach3 Output
ports and pins
Port #
Pin Number
2
3
4
5
6
7
8
9
HiCON Integra J8 pin
assignments
J8
Pin number
13
13
13
13
13
13
13
13
© 2012 Vital Systems, Inc.
0
1
2
3
4
5
6
7
2
3
4
5
6
7
8
9
14
HiCON Macro
SetPin
Index
11, 0
11, 1
11, 2
11, 3
11, 4
11, 5
11, 6
11, 7
HiCON Macro
SetPin
Index
12, 0
12, 1
12, 2
12, 3
12, 4
12, 5
12, 6
12, 7
HiCON Macro
SetPin
Index
13, 0
13, 1
13, 2
13, 3
13, 4
13, 5
13, 6
13, 7
www.vitalsystem.com
HiCON Mach3 Software Integration
Mach3 Output
ports and pins
Port #
Pin Number
HiCON Integra J12 pin
assignments
J12
Pin number
14
14
14
14
14
3
4
5
6
7
RL1
RL2
RL3
RL4
RL5
HiCON Macro
SetPin
Index
14, 3
14, 4
14, 5
14, 6
14, 7
Getting beyond the basic input/output with Mach3.
When you are done with limit switches and other basic I/O you will probably want to have several
switches on you control panel next to the e-stop such as feed hold, stop, g-Code rewind and other
things. To get this added functionality you will need to learn how to write brains in Mach3. Brains are
used to get access to all of the extra I/O and to work tool changers and just about anything you can think
of.
Here is a pretty basic brain to map input 1 to output 5.
You would setup what wire goes to input 1 and output 5 under the ports and pins tab of Mach3.
After a few tries you will get the hang of it.
For more information: go to www.machsupport.com and then to the video section and look for Brains.
Motor outputs.
On the Motor Ouputs tab, enable the axis that you will be using. Spindle setting in this window is not
used by the HiCON plugin.
© 2012 Vital Systems, Inc.
15
www.vitalsystem.com
HiCON Mach3 Software Integration
Spindle Setup.
When using a VFD or other motor controlling device that uses 0-10v or ±10v control, the following steps
are needed. The spindle setup is done via the Plugin config screen.
Make sure Spindle Relays are enabled in the Port and Pins Spindle window.
Go to the Config tab and then spindle pulleys. Current pulley 1. For this example, set min speed to 0 and
max speed to 100. This will give a 0v output to the spindle at S0 (min speed) and a 10v at S100 (max
speed).
This setting is great for testing. Without the VFD/Drive hooked up, you
can test your output with a digital volt meter to make sure you are
getting 0-10volts for 0 to max speed.
When it all works then put in min 0 and max gets set to the max speed
of your machine, eg, 5000. This will allow you to program S in the Gcode in actual rpm, ie 0 … 5000.
On the Plugin Config System tab, you can configure the spindle to use
±10V or 0-10V by selecting the Spindle Type.
Setting an Axis as a Spindle
You may set any axis (0 – 5) as the spindle axis by specifying from the Spindle Type field and selecting
“GCode Axis”. The Axis number is specified in the Spindle Index field on the System tab. Once the
spindle axis has been set, you may then issue any GCode command (e.g. G0C10) for spindle position
control, as well as Spindle speed commands (e.g. S500M3) to control the spindle speed and direction
© 2012 Vital Systems, Inc.
16
www.vitalsystem.com
HiCON Mach3 Software Integration
using the closed loop axis PID control. The Steps Per, Max Speed, and Acceleration of the spindle is read
from the selected axis motor-tuning configuration.
NOTE: The spindle’s motor-tuning settings are always ignored.
Axis Homing and Direction
In the Config menu, select Homing/Limits. You will see the following window.
To change the axis direction, click on the Reversed column for the axis you want to change the direction.
A green check mark indicates the direction is now reversed.
NOTE: When reversing the axis direction. Make sure that the corresponding Encoder Polarity is changed
in the System Tab if using Encoder Feedback.
Homing Offset lets you define the home position co-ordinates. When homing sequence is complete, the
axis machine position is set to this value. Home Neg, changes the default homing direction.
HiCON offers a number of different homing types for each axis.
Parameters to select the correct homing sequence.
Please review section Control
If you are using Index-Pulse-Only Homing without a home sensor, you must assign an unused digital
input in Mach3 as home sensor. Mach3 software requires a home sensor definition regardless of
homing method.
Manual Pulse Generation - MPG
HiCON allows using a quadrature encoder as a MPG source. The encoder is connected to the dedicated
encoder inputs on J5, J6 and J10 connectors, as well as to the K4 connector (Channel 3) on the breakout
board 7775. Users can configure MPG parameters as explained in Manual Pulse Generation (MPG).
© 2012 Vital Systems, Inc.
17
www.vitalsystem.com
HiCON Mach3 Software Integration
To turn on MPG feature, make sure MPG #1 is checked green as shown above in the Ports and Pins
window. Enter the Encoder resolution in the Counts/Unit field. The rest of the fields in this window are
not used.
You set the encoder multiplier in the General Config setting
as shown below. You can use your own multiplier values in
this window as well as use the standard .1, .01, .001, etc
values.
When MPG mode is selected, and a G-Code file is run, the
HiCON Plugin will switch to jog mode automatically in order
to run the file. Once the file is complete or stopped, the
mode will revert back to MPG.
© 2012 Vital Systems, Inc.
18
www.vitalsystem.com
HiCON Mach3 Software Integration
OEMDROs and LEDs
The following table lists the OEM DROs and LEDs used by the HiCON plugin.
OEMDRO Index
Description
1320 - 1321
Analog Inputs (Channels 0 – 1). Value should be between (0 – 3.3V)
1330 - 1338
Encoder Counter (Channels 0 – 8).
1340
Threading RPM. This RPM is calculated based on the parameters
defined in the Threading section of HiCON Plugin Configuration, and is
used by the Threading Logic.
2000 – 2009
HiCON Basic DRO Inputs. (See HiCON Basic documentation)
2050 – 2059
HiCON Basic DRO Outputs. (See HiCON Basic documentation)
OEMLED Index
Description
1300 – 1363
Input 0 – 63
2035
Launch HiCON Macro from Mach3
2000 – 2031
HiCON Basic LED Inputs. (See HiCON Basic documentation)
2050 – 2081
HiCON Basic LED Outputs. (See HiCON Basic documentation)
HiCON Plugin Configuration
HiCON plugin configuration screens can be launched from Mach3 by navigating to Config -> Config
Plugins and selecting M3HiCON-www.VSi99.com-HiCON-xxx- option.
© 2012 Vital Systems, Inc.
19
www.vitalsystem.com
HiCON Mach3 Software Integration
Once the HiCON plugin configuration is launched you can see seven tabs, these are:
1.
2.
3.
4.
5.
6.
7.
System Tab
Axis X(0)
Axis Y(1)
Axis Z(2)
Axis A(3)
Axis B(4)
Axis C(5)
Each Axis tab represents an axis to be controlled through HiCON. By default, System tab will be
selected, as shown in HiCON Configuration window.
© 2012 Vital Systems, Inc.
20
www.vitalsystem.com
HiCON Mach3 Software Integration
HiCON Plugin Configuration System Tab
Figure: HiCON Configuration window
In the system tab, you can set a number of configurations. Clicking on “Update HiCON” will transmit
these settings to the HiCON controller. Clicking OK will also transmit the data, and also save this data in
selected mach3 profile (e.g. mach3mill, mach3turn etc)
In the following sub sections users can find detailed information about various configuration options
that are provided under the system tab.
HiCON Serial Number
To connect to a specific HiCON device on the network, you must enter the 6-character serial number in
the “HiCON Serial” field. If left blank or ‘0’, the plugin will connect to the first device it can find.
© 2012 Vital Systems, Inc.
21
www.vitalsystem.com
HiCON Mach3 Software Integration
Spindle Type and Axis
Spindle Type
The Spindle Type configuration sets the spindle to either Analog Voltage or to a GCode Axis. Valid values
are:
Undefined: The plugin ignores the spindle commands.
GCodeAxis: Sets the spindle as an axis.
Analog Voltage 0-10V: unidirectional only.
Analog Voltage ±10V: clockwise and counter-clockwise spindle direction.
Spindle Axis
The Spindle Axis field sets the axis number when using “GCode Axis” as the Spindle Type (Valid values
are from 0 – 5).
Analog Spindle Scale
Multiplier to scale the voltage output for the spindle motor. Applicable with Analog Voltage type only.
Max Buffer Level
This parameter defines how much command position buffering will be done inside the HiCON controller.
The size of the buffer can range from 1 – 5000 millisec. These points are consumed by the HiCON at 1
KHz. To get faster response time on feedrate changes, you may select a lower value, but the side effect
is that if the PC software slows down and cannot sustain the motion data rate to the HiCON, then the
motion could be jerky.
Enable Debug Window
By checking this option users can enable debug window for debugging purpose. This option should be
turned on only if directed by a factory personal. The debug window will appear next time you start
Mach3.
Ignore Limit Switches when Homing
HiCON allows Limit switches to be used as Home Sensors. This parameter should be checked to use Limit
switches as Home sensor.
Threading
Following sub sections describes parameters to configure threading in HiCON.
Threading RPM Synch Source
This parameter defines the encoder type for Spindle speed calculation and starting the threading cycle.
The Index pulse from the encoder is used to launch the Z-Axis at the right time in order to position the
tool correctly for Threading in every cycle. The RPM calculation is used to override the feedrate of the ZAxis during the threading cycle.
© 2012 Vital Systems, Inc.
22
www.vitalsystem.com
HiCON Mach3 Software Integration
The possible values for RPM Sync Source parameter are: “HardEncoder” and “Undefined”.
Undefined: When this option is selected, HiCON will not enable threading and value of RPM Synch
Index will be ignored.
When HardEncoder is selected, the spindle feedback encoder must be connected to one of the encoder
inputs on HiCON Integra J6, J8 (Expansion B), J10, or J11 connectors. The encoder’s differential A and B
signals are used to calculate the RPM of the spindle, and Index pulse is used to trigger the threading
cycle.
Threading RPM Synch Index
This parameter defines the encoder index for Spindle speed feedback. Below is the range for this index:
HardEncoder: index range is 0 – 7.
Threading RPM Count/Rev
This parameter defines the encoder resolution in terms of count per revolution for Spindle speed
feedback. For HardEncoder type encoder, the encoder resolution must is multiplied by 4.
Threading RPM Sampling (ms)
This parameter defines the timing window in milliseconds to add the encoder counts for RPM
calculation. For slow pulse train (eg only few ticks per rev), this value should be high enough to
accumulate enough counts to calculate RPM consistently. If the window time is too long, the system
reaction time (regulation of Z-Axis feedrate) to changing RPM will be slow. A higher count/rev encoder
will allow this window time to be very small, which will allow the system to react fast (regulate Z-Axis
feedrate) if RPM changes. The range of this field is from 1 thru 10000 milliseconds.
Manual Pulse Generation (MPG)
MPG Source Type
This section defines MPG (Manual Pulse Generation) Quadrature encoder source. Both Differential and
Single Ended Encoder types are supported. One differential encoder can be hooked up to J11 while
single-ended encoders can be wired to J6, J8 (encoder usage), or J10. These encoders are defined as
Hard Encoder. An Undefined Encoder option causes HiCON to ignore MPG Source values.
MPG Source Index
If Hard Encoder is selected in MPG Source Type, MPG Index denotes the hardware encoder channel.
Hardware Encoder Polarity
The Hardware Encoder Polarity field is used to reverse the direction of the encoder counters. If A/B
signals are connected in reverse such that it does not match the PID control direction, the system will
not be able to arm. To fix this issue, the hardware A and B signals can be reversed using this parameter.
Note that this encoder polarity setting only swaps the A and B signals to change the counter direction.
The Index pulse signal polarity is not affected by this setting.
© 2012 Vital Systems, Inc.
23
www.vitalsystem.com
HiCON Mach3 Software Integration
Encoder Debounce
The Encoder debounce field is used to remove noise from the hardware encoder signals. Setting of
100ns is normally sufficient, but if encoder count is still changing by noise, you can try higher debounce
value. The higher the value in debounce, the maximum frequency of encoder signal will be reduced.
This setting only applies to hardware encoders 0 – 7.
Step Pulse Width
The step pulse width is the amount of time the step signal is held high (measured in microseconds). The
values shown on StepGen 0 – 5 are read-only; – the plugin calculates the values and overwrites any
values entered by the user. The step pulse width value is computed through this formula:
SPW = 1 / (CountsPerUnit * Velocity) * 1,000,000 / 2
The “CountsPerUnit” and “Velocity” variables are retrieved from Mach3 Motor Tuning settings.
Update HiCON Button (Under System Tab)
This button downloads the entire system configuration parameters to the HiCON. If you make any
changes to Controls parameters, you must download the new settings by clicking on this button before
ARMing the HiCON or executing a test motion. To save data to your computer hard-drive, click OK. All
configuration data from all pages is saved in the selected mach3 profile.
© 2012 Vital Systems, Inc.
24
www.vitalsystem.com
HiCON Mach3 Software Integration
HiCON Plugin Configuration Axis Tab
The Axis tabs provide configuration settings that are directly related to each axis. These tabs also
provide motion testing features. The Controls parameters must be transmitted to HiCON manually by
pressing ‘Update HiCON button before the Drive is armed. Clicking on OK or the ‘Save Configuration’
buttons saves the entire configuration to the selected Mach3 profile.
Test Motion
Test Motion options can be used by users to configure Control parameters.
The Ready LED shows if the HiCON is ready to accept motion command. If Ready LED is GREEN, it
implies HiCON is ready to accept new motion command. While executing a motion profile, the Ready
LED turns to RED and HiCON cannot accept a new motion command until the current motion sequence
is complete or cancelled.
Once the test motion is complete, you can see how closely the axis followed the commanded motion
profile on the “Motor/Drive Response” graph. By selecting “AutoReverse” check box, you can make the
© 2012 Vital Systems, Inc.
25
www.vitalsystem.com
HiCON Mach3 Software Integration
axis reverse the direction automatically in next Execute command and thus avoid the axis to keep on
going in one direction during testing.
Position – Test motion final position or displacement in terms of Position Units, e.g. 1.5, 10.093, mm or
inches etc.
Acceleration – Test motion acceleration value in terms of Units per second squared, e.g. inches/second2,
mm/sec2 etc.
Velocity – Test motion velocity value in terms of Units per minute, e.g. inches/minute, mm/minute etc.
Relative and Absolute – These check boxes indicate whether the value in the Position field is either the
distance to travel (relative) or the final position (absolute).
Execute Button – Transmits the Execute-Motion command to the HiCON. User can press ‘Cancel’ button
to cancel the motion execution anytime during the machine operation.
Make sure you have
downloaded the axis controls setting by clicking “Update HiCON” before clicking on Execute.
The Ready LED shows if the current motion command is completed and HiCON is ready for new motion
command. New motion command can be launched by Execute button when the Ready LED is Green. If
the LED goes to Red after click on Execute, but you do not observe any motion, the velocity or
acceleration may be too low.
PID Arm Button – By clicking this button, the Plugin download’s PID Filter parameters and arm or disarm
the PID. If PID is armed, the LED below this button will turn to GREEN, otherwise it will be RED.
Home Button – Executes the Homing sequence based on selected Homing settings. Review section
6.12.3 Control Parameters to configure Mach3 Homing options for each axis before executing Homing.
Reverse - Checking this option will multiply parameter in the position box with -1 and thus direction of
motion will be reversed.
Auto Reverse - Checking auto reverse option will toggle “reverse” option between two consecutive
motion commands, thus the user do not have to manually reverse the direction of motion every time.
Axis Position Display (DRO) – Shows the position of the axis based
on different settings as described below:
Show units - When this option is selected, the data shown will be converted and shown in units
(mm, inches etc), otherwise data will be displayed in raw encoder counts.
Commanded position - Display shows the value of the internal variable for the commanded
position for the selected axis.
© 2012 Vital Systems, Inc.
26
www.vitalsystem.com
HiCON Mach3 Software Integration
Load Encoder - Display shows the axis position derived from backlash count and selected
feedback encoder.
Motor Encoder - Display shows the current value of the axis position derived only from the
encoder feedback.
Note that the actual position may slightly deviate from the Commanded position when PID is enabled.
Control Parameters
Control Input Source - Control Input Source defines the input type (or set-point) for a particular axis.
This should be set to MACHxx. If the axis is not used, it must be disabled by selecting undefined.
Control Input Index - Defines the index of the PID input source. Normally this is equal to the axis
number. For slave axis, it should be set to the number of the master axis.
Control Input Gain – The control input (Commanded) is multiplied by this number before applying to PID
filter.
Control Output Source - Control Output Type defines the output for the PID filter for a particular axis.
The possible values are:
Stepper: Use one of the stepper channels for the Step and Direction signals (range of StepGen0 –
5) used in stepper drives.
Undefined: This setting is used to disable the axis and to ignore the control output index. If the
axis is not used, the Control Output Source must be set to undefined.
Feedback Source - Feedback Source defines the feedback type for the selected axis. The possible values
are:
Encoder: Use one of the encoder channels (Encoder 0 – 7) as the feedback.
Max Follow Error – Maximum deviation allowed between command and actual, above that, the PID
controller shuts down and need to be re-enabled manually. If 0, PID will never shutdown which can be
extremely dangerous in a run-away motor condition. So always use a positive value in this field. This
field can be back calculated from the maximum velocity of the axis, e.g. 600 000 count/sec max velocity
divide by 1000 gives 600 counts per millisecond. So to achieve 600K count/sec speed, the max following
error should be 600 or more. The actual value may be lot more than that based on the mechanical
characteristics of the axis.
Homing Type - Defines homing sequence for each axis. Two types of homing sequence are supported:
1. Home Sensor
(homing with or without Index Pulse)
2. IndexPulseOnly (Use only the Index pulse to Home)
© 2012 Vital Systems, Inc.
27
www.vitalsystem.com
HiCON Mach3 Software Integration
For Home Sensor method, the axis moves in configured direction until home sensor is seen. It then
moves in the opposite direction at 20% of initial speed until the sensor is not seen. At this point the
home position is defined. If Use Index Pulse option is set, the axis then continues to move until Index
pulse clears the position counter and indicate the home position.
For IndexPulseOnly, the axis moves in the configured direction to locate the index pulse to home the
axis. As soon as the index pulse is detected, it clears the position counter to indicate the home position
and stops the axis.
Backlash – This field let you enter backlash amount in terms of units (inches or mm etc). HiCON uses this
value to calculate virtual load position (mill table).
Backlash Speed % – This field let you enter backlash speed percent, 1% to 500%. It defines how fast you
want to apply the backlash. The percentage is applied to the Motor acceleration, eg, if the configured
acceleration for the axis is 10 inch/sec2, and Backlash Speed is 400%, the Backlash motion will be
performed at 40 inches/sec2.
Slave Axis Configuration
To set an axis as a slave axis, set the Control-Input index equal to the master axis, e.g., if A axis is slave
and Y is the master axis, set the control-input index for A equal to 1. Make sure mach3 configuration is
done properly for slave axis. Do not run any test motion command on slave axis tab. Always do testmotions on the master axis. The slave axis always uses the PID values of the master axis automatically.
© 2012 Vital Systems, Inc.
28
www.vitalsystem.com
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement