The Series 16i-MB CNC is a powerful, compact control useful for five-axis milling machines used in die/mold and aerospace applications. The increased functionality provided by its features eliminates the need for qualified tooling with dynamic cutter compensation and tool length offset within the control.

Part programming is simplified because the CNC calculates the compensations as the tool rotates to a new vector, rather than relying on an expensive CAM system to process all of the length offsets and cutter compensation at each new vector. The operator can change the tool length offset and/or cutter compensation values at the CNC without re-posting the part program. Part programs also support “machine anywhere”–once posted, they can be executed on any five-axis machine regardless of the machine configuration. Whether the axis pivots the spindle, the workpiece or both is irrelevant to the program, and CNC parameters allow the machine configuration to be easily defined.

Additional functions include machine configuration, definable by CNC parameters to allow for variability; dynamic tool length compensation in tool axis direction, which allows non-qualified tooling without requiring reprocessing of parts programs in the CAM system; tool center point control, which enables programming from the center point of the tool rather than the pivot point of the tool; and 3D cutter compensation, which rotates the cutter compensation as the tool rotates to a new vector.

Tormach LLC, innovators of personal CNC technology, announced today the release of its new CNC Machine Control software.Based on a platform of widely popular CNC controller Mach 3 from ArtSoft, the M3 release contains new modifications that allow direct integration with a variety of CAM applications.

With its mid-size, affordable, and highly accessible PCNC 1100 mill equipment, Tormach has finally brought the benefits of precise computerized cutting to individual craftsmen and small to medium-sized businesses. Besides well-designed hardware, easy-to-use PC-based software controls have been a critical element in the personal CNC trend.

"Our mission has always been to make the transition to CNC milling easy and affordable," says Tormach CEO Greg Jackson. "Our M3 release takes a big step toward lowering the barrier to CNC. Every machine we ship now includes CAD, CAM, and the new Machine Control program. This is unheard of for a $6800 CNC mill, but we felt that full integration was part of our goal."

Tormach customers receive access to 3D CAD with Alibre Design Xpress, a user-affable mechanical modeler. CAM software, which converts CAD drawings and models into machine-read toolpaths, is included with the PCNC 1100 mill in the form of a starter edition of SheetCAM. CNC Machine Control converts CAM-produced g-code instructions as machine movements. The M3 modifications allow the program to work directly with SheetCAD, as well as TurboCADCAM and SprutCAM.

Other features of the new controller include a 'feed & speed' calculator, pre-programmed M-codes for tapping head, improved tool path displays, a maintenance hour log, and extended conversational programs, in addition to new user definable G28 operation.

The M3 release has been coordinated with the release of Tormach's Jog/Shuttle Controller, a low cost accessory for manual motion control. The Jog/Shuttle controller is considered "plug and play" through a standard USB connection.

"Legacy electronic hand wheels, commonly known as MPGs, or Manual Pulse Generators, are clumsy in comparison to a Jog/Shuttle interface," says Jackson. "Instead of a simple wheel-controlling position, the Jog/Shuttle method has two concentric wheels controlling both position and velocity dynamically."

The M3 release requires Windows XP or Vista and is available as a free upgrade for all past Tormach mill users. It can also be downloaded for trial use in an offline mode when a PCNC 1100 mill is not available.

About Tormach

The people at Tormach are dedicated to delivering tools, accessories, and components of unprecedented value in the world of CNC and motion control. Whether customers are involved in R&D, education, short run production, or simply entrepreneurs with new ideas, Tormach products allow them to make what they need easier, quicker, and more affordably. Tormach is headquartered in Waunakee, Wisconsin.

Kimray Inc. in Oklahoma City manufactures control valves and related equipment for oil and gas-producing companies. It reports a 40% to 50% increase in machining efficiency due largely to CNC-based production machines.

Siemens CNC-and-drive packages power the Emco Maier Emcoturn 420 MC Plus (above) and Hyperturn 665 MC Plus lathes at Kimray (below).

The company's turnkey manufacturing facility houses dozens of lathes, grinders, and turning, milling, sawing, and bore-finishing/honing machine tools. Nearly all have CNC systems, including its Emco Maier Emcoturn 420 MC Plus and Hyperturn 665 MC Plus lathes, which sport Siemens Sinumerik 840D CNCs and Simodrive 611D drive packages.

"I can do so much more with the Sinumerik 840D, such as programming and cut-and-paste operations, while the machine is running," reports one of Kimray's lathe operators. "Each screen lets me go into a lot of detail for such tasks as separating mains from subs with part and workpiece programs."

The operator uses the Siemens CNC for axis and spindle movements on both Emco machines. He easily accesses programs and data and transfers it back to the machines (from the company's main host system) as needed.

He also comments that on a typical setup, he "likes the sensitivity — the ability to move the axis a ten-thousandth to a hundred-thousandth at a time." He goes on to say that "the control's program-test feature is useful for new programs. Each tool has its own geometry page and up to four offsets, which makes my job less complicated."

According to Tom Jackson, director of sales-support operations for Emco Maier USA, the company's 420 machine permits simultaneous production of two parts without interruption or collision. The Siemens digital drives produce dynamic performance in both the main spindle and X/Y axes.

GE Fanuc says it has developed the world`s fastest CNC controller, capable of controlling the largest number of axes. The company`s Series 30i controller, unveiled at the recent EMO show in Milan, can supervise up to 40 axes - 24 of them simultaneously - and can execute up to ten different CNC programs at a time.

The controller, which uses a new high-speed processor, takes 25ns to perform ladder program steps, and can execute three ladder programs simultaneously. It provides nanometre interpolation and is said to deliver interpolation cycle times eight times faster than earlier models. It has a 1,000-block look-ahead for accurate contour control, and takes 0.4ms to process a block.

GE Fanuc expects the new controller to be used for high-end machines - such as five-axis milling machines and those using linear motors -- that demand high-speed, multi-axis, multi-path, controls. It could help to produce high-quality finishes on complex die moulds, minimising the need for polishing after cutting.

One of the benefits of an Internet-enabled CNC is the potential to reduce the cost and delay associated with service calls, In many cases a machine may not be down because of a mechanical or hardware failure, but instead it may be a programming or parameterizing problem that causes a machine to stop. Problems of this type can often be addressed remotely. Communicating with the CNC across the Internet, using security protocols to protect against authorized access, offers a readily available way to perform this remote service.

But providing the CNC with an Internet connection opens up new possibilities not just for the CNC supplier's service department, but also for the service department of the company using the machine. Thanks to the Internet access, the CNC can be equipped to send e-mails automatically in response to faults or other control-related events. The CNC can even send text alerts via SMS (Short Message Service) to mobile phones.

CNC technology supplier Siemens (U.S. office in Elk Grove Village, Illinois) has developed software called "@Event" for exactly this purpose. The software links a Siemens Sinumerik control to a commercially available e-mail program such as Microsoft Outlook Express. The control can then send e-mails to various addresses selected by the user in response to specific alarms.

The software runs on Windows NT. For a given CNC alarm, the software searches through a pre-configured list for the receivers associated with that alarm. It then establishes the link to the e-mail server and sends the receivers the appropriate email or SMS message.

E-mail messages can contain file attachments, so a log or trace file indicating operator actions or states preceding the fault can go out with the message. To assist quick troubleshooting, all of the relevant machine data can also be sent as a sort of identity card for the machine tool.

Other options for defining how the e-mail or SMS messages are sent are also available. For example:

* Every alarm can be transmitted as a separate message, or all simultaneous alarms can be grouped into a single message.

* A complete list of alarms can be sent cyclically, at a predefined interval.

* Messages can be sent only when an alarm occurs, or they can be sent in response to every further status change after that alarm.

The user also has the option to decide which alarm sources trigger any message at all.

Associating alarms with distinct receivers can allow all alarm messages relating to the control to be routed directly to a system specialist at a remote location for immediate analysis. Meanwhile, alarm messages that indicate mechanical faults can be sent to a local service technician, perhaps as an SMS message to a mobile phone, while these same messages are also sent via e-mail to a production manager's PC.

Find these related articles on the Web:

Connecting Your Legacy CNC Machine Tool To The Internet

This article looks at some of the technical challenges involved with this link.

What Does It Take To Internet-Enable Machine Tools?

It takes data. That is, it takes machine and process data that are easily exported and linked to a factory network.

A "Significant Event" At Cessna Here is a real-world application of remote CNC monitoring.

PC based CNC machine tool controllers are starting to become the trend in CNC machining. Retrofitters and OEMs are looking toward the PC as the new machine tool controller platform to accommodate today's need for "high-speed" machining. More and more retrofitters and OEMs are starting to switch from a pre-fabricated controller to a PC based CNC controller for a variety of positive reasons. The most common reasons are described below.

PC based CNC machine tool controllers are less expensive than pre-fabricated controllers. You can replace your existing pre-fabricated control with a PC based controller at a fraction of the cost when compared to replacing your control with another pre-fabricated controller. This cost savings is accomplished because a PC based CNC controller uses a standard Windows based 95, 98, ME, NT or 2000 personal computer, motion control board, digital I/O card and CNC machine tool control software, which are relatively inexpensive components.

If you don't want to build your own PC based CNC machine tool controller, you don't have to. Today, there are several different companies manufacturing various ready-to-go, bolt-on professional PC based CNC controller enclosures. Most of these controller enclosures include all the hardware and software necessary to control your machine including the amps and motors. Users can also purchase separate high-quality hardware and software components and use their own personal computer.

PC based CNC machine tool controllers are easy to install. The idea behind advanced PC based CNC machine tool controllers is to eliminate the need for tracing wires to the PLC or write ladder logic. Rather, the computer becomes the PLC and does the logic thus eliminating the need for PLCs and writing ladder logic. PC based CNC machine tool controller software generally comes equipped with several ready-to-go operator screens to choose from and even customize for ease of use and to get you up and going in minimal time. The software generally allows you to mix and match physical buttons, knobs, gauges, switches, lights and displays with virtual ones.

PC based CNC machine tool controllers are also easy to use. A well designed PC based CNC controller software package generally has the ability for a user to fully customize the control's user interface without being a C++ or VB programmer. For example, the control's user interface is able to be designed by dragging and dropping control objects around the operator screen and then setting each control object's size, caption and functions with fill-in-the-blank or check boxes within Windows. The user interface can be as simple or as feature rich as the operator desires. Control operators are no longer subject to the rigid design of pre-fabricated controllers. PC based CNC machine tool controllers also offer various programming styles such as G code, conversational or CAD to motion.

PC based CNC machine tool controllers are quickly retrofitted. Most companies cannot afford to take months off to get a machine on-line and productive. A good PC based CNC machine tool controller's learning curve is only about 1/5 of the time needed when compared to most controllers that still use PLCs. On average, installation is capable of being done in three days for the most common types of knee mills, bed mills, lathes, lasers, water jets, plasmas and punch presses.

PC based CNC machine tool controllers are capable of stilling running a customer's old G code programs. A state-of-the-art PC based machine tool controller, for example, allows flexibility to run a Fanuc G code program in the morning and then an Allen Bradley in the afternoon. Definable G code and M code tables are generally built into the control to allow configuring the new controller to understand pre-existing programs.

Real time solid modeled or wireframe tool path simulation while the machine is cutting is one of the features a good PC based CNC machine tool controller contains. Being able to perform tool path animation and CNC verification prior to pressing Cycle Start is also an important feature. Simulation provides step-by-step control over each move graphically, moving the light source, solid model rotation and viewing angles.

PC based CNC machine tool controllers are user customizable and are considered an open system. The best software allows screens to be customized without having to be a VB or C++ programmer. Typical Windows-style fill in the blanks and check boxes are used on well-organized screens so that even novice Windows users can drag and drop objects into place and set their properties. More advanced users are able to configure the controller routines to support new processes and new technologies with well-documented software application program interfaces (APIs) made available to all customers as well as source code for ActiveX and DLLs.

All good software supports the ability to integrate third-party applications. PC based CNC machine tool controller software contains, at a minimum, machine maintenance software, remote diagnostics via a modem, self-diagnostics and remote machine tool monitoring via RS232, ActiveX or a Network card. This includes automatic collection of manufacturing data in real time without operator intervention as a standard feature.

PC based CNC machine tool controllers are fast and can easily accommodate today's "high speed" machining requirements. With over 200,000 motion cards shipped to date these cards can achieve 62.5 microsecond servo update times per axis, which result in cutting feedrate velocities of up to 122,000 IPM. Some digital I/O cards can detect a change of state at rates in the 10 KHz range. DSP microprocessors close the servo loop using dual 32 bit micro processors to increase productivity, feedrates, accuracy and cut quality. Multiple events and multiple position motions can happen simultaneously. 3D profiles can even be cutting while the tool is changing. The extra processor on the motion card is not only the best way to close the servo loop with the motors, it is also the fastest method known to date to produce the fastest block-to-block cutting speeds.

With PC based CNC machine tool controllers, maintenance and repair are no longer an issue. Machine operators are now the masters of their own machine. Self-diagnostics are generally a part of every system. When it comes to parts, off-the-shelf Windows 95, 98, ME, NT or 2000 personal computers and brand name hardware purchased from local sources can be used. Are your parts now either so proprietary or hard to find that they do not exist anymore? How long can you be down? PC based CNC machine tool controllers eliminate the need to rely on others. Machine operators can learn how to service, support, maintain and upgrade the complete control and replace any part themselves.

PC based CNC machine tool controllers help eliminate downtime. No more waiting for proprietary parts that can only be obtained through the control's manufacturer. Generally, there is a terminal strip and cable that connects the machine wiring to the computer. All that needs to be done is to unplug the cable from the computer. This will not disturb the wiring to the machine. Next, restore the screens, G codes, M codes and logic files within 10 seconds from a saved backup on a floppy disk. The backup file is also small enough to be emailed. If the problem is the motion or I/O card, either of these can be replaced by anyone without disturbing the wires. If a control breaks, swap out another computer to replace any control for any machine type at anytime.

PC based CNC machine tool controllers are easier and quicker to service. Manufacturers of PC based CNC controller software hire qualified technicians to immediately answer technical questions via phone, fax or email. If application assistance or custom logic is needed, the PC based CNC controller software manufacturer has qualified in-house staff and local reps that can fulfill these needs either on-site or via the internet. Also, most PC based CNC machine tool control software manufacturers do not detach themselves from the hardware boards and takes responsibility for all of the hardware boards they sell.

PC based CNC machine tool controllers allow use of your existing motors and amplifiers. This holds down the cost and labor plus ensures that the motors and amps are sized right for the machine. Good hardware can control existing motors that are: Brush or brushless, AC or DC, servo, stepper, PWM or hydraulic. The amps or drives can be either current driven or velocity type. Spindle drives use current mode or inverters. Feedback can be closed or open loop. Closed loop systems use encoders or resolvers. There are a number of companies that also make digital I/O cards.