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SM2 & SM3 Knee Mill Programming Manual (6.6MB PDF)

1. New Name New Extension swi PT4 7 2 Fi L H F5 6 F Fe DATA DATA OPEN RENAME RENAME TAB FWD BACK FOLDER FOLDER FILE RETURN FIGURE 14 7 Renaming a file Press the Help hard key to call up the alpha keys Additional parts of the screen appear once the RENAME softkey is pressed New Name When a file or folder is highlighted the name will appear here When the TAB the RENAME FILE or RENAME FOLDER softkey is pressed the highlight will move here and you will then be able to write in a new name 102 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual New Extension A new extension can be given to the file picking from the ones available If the file name already contains an extension you will have to erase the old one before giving it a new one Additional softkeys RENAME FOLDER Press once a new name has been entered into the New Name and New Extension areas to change the name of the folder RENAME FILE Press once a new name has been entered into the New Name and New Extension areas to change the name of the file RETURN Returns to the Program In Out Mode screen 14 8 Backing Up In order to protect your important programs it is a good idea to back them up regularly That way if a floppy disk or hard drive becomes unusable you will not have to re write the program To back up your files press the BACK UP softkey from
2. Most places in the ProtoTRAK SM CNC we refer to the program or part In Program In Out Mode this program or part is called a file Filenames are program names or part names They are the name you give to the programs you write on the ProtoTRAK SM CNC plus a file extension Although the ProtoTRAK SM CNC can have program names up to 25 characters that use letters and special symbols most other CNC s must have file names that are eight or fewer characters using numbers only File extensions are part of filenames that help describe the file They appear after the filename and are composed of three letters following a period For example doc is the extension that appears after a file name for a file stored using Microsoft Word 97 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual Usually but not always the file name indicates what program was used to create the file Sometimes this is not the case Some programs like those found in early models of CNC do not attach a file extension to a file name at all Also a user may attach his own extension to a file name for his own purposes ProtoTRAK and TRAK A G E CNC s always attach an extension to every file that is stored The extension mx2 is used for files or programs written and stored on a ProtoTRAK MX2 ProtoTRAK M2 or TRAK A G E 2 CNC The extension mx3 is used for the ProtoTRAK MX3 ProtoTRAK M3 and T
3. ProtoTRAK SM CNC Itis treated in its own section because it works differently than the other event types Unlike other events the A G E allows you to e Enter the data you know and skip the prompts you don t e Use different types of data like angles that may be available from the print e Enter guesses for the X and Y ends and centers not available on the print With the A G E you can easily overcome limitations in the data the print provides without having to spend time in laborious calculations 10 1 Starting the A G E The A G E is started automatically when you enter the Irregular Pocket or Irregular Profile event The first set of prompts you encounter will be the header information Once that information is entered you will see the following screen PROG PIN PIN 0812 2 TOOL 1 3 AXIS INCH EVENT 1 IRR PROFILE EVENT 2 X BEGIN 0 0000 abs Y BEGIN 0 0000 abs Z RAPID 0 0500 abs Z END 0 2500 abs TOOL OFFSET RIGHT PASSES Z FIN CUT 0 0100 Z FEEDRATE 4 0 XYZ FEEDRATE 15 0 FIN FEEDRATE 10 0 TOOL 1 Fi F2 F3 F4 F5 F F FB AGE AGE END ABORT MILL ARC AGE AGE FIGURE 10 1 Once the profile header screen is finished you choose between an A G E Mill and an A G E arc to define the shape The screen above shows three axis CNC programming Where A G E Mill A straight line from one X Y point to another A G E Arc Any part of a circle 69 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM
4. Radius 175 abs Known print dimension Chord Length Press Page Forward now as no further Chord Angle data is required EVENT 8 AGE MILL NOTES Tangent X End Y End Conrad Angle End Length Line Angle Selects tan mill Press Page Forward now as no further data is required Tangent Direction X End Y End X Center Y Center Conrad Radius Chord Length Chord Angle 1 2 data forward data forward 0 abs 0 abs data forward 4 85 abs Selects tan arc CCW Unknown value not required Unknown value not required Known print dimension Known print dimension Known print dimension Press Page Forward now as no further data is required Tangent X End Y End Conrad Angle End Length Line Angle AGE MILL Selects tan mill Press Page Forward now as no further data is required Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual EVENT 11 AGE ARC NOTES Tangent 1 Selects tan arc Direction 1 CW X End data forward Unknown value not required Y End data forward Unknown value not required X Center 2 43 abs Known print dimension Y Center 4 55 abs Known print dimension Conrad data forward Radius 0 175 abs Known print dimension Chord Length Press Page Forward now as no further Chord Angle data is required EVENT 12 AGE ARC NOTES Tangent 1 Selects tan arc Direction 1 CW arc X End Data
5. arrow followed by two periods The root directory will disappear when the most basic organization for the drive in the Look In box is reached Opening a File To open a program file from a storage location press the OPEN softkey from the Program In Out Mode screen The ProtoTRAK SM CNC will always default to the last folder you had open Find the file using the softkeys as described above in the section on basic navigation In addition to the basic parts of the screen described above two additional parts of the screen appear in the open operation File Name displays the name of the file that is highlighted from the list Open As lists the formats for which the file may be opened The default is PT4 Two additional softkeys appear OPEN FILE Opens the highlighted program file and puts it in current memory Only one file may be in current memory at a time if one is there already a warning message will appear before that file is overwritten RETURN Returns to the Program In Out Mode screen When the open operation is finished the system will return to the Select Mode screen Saving Programs To save a program file to a storage location press the SAVE softkey from the Program In Out Mode screen Find the drive and folder you want to save the program file in using the softkeys as described above in the section on basic navigation Three additional parts of the screen appear once the SAVE softkey is pressed 99 Southwester
6. right angles Prompts for the rectangular profile X1 is the X dimension to any corner Y1 is the Y dimension to the same corner as X1 X3 is the X dimension to the corner opposite X1 incremental is from X1 Y3 is the Y dimension to the same corner as X3 incremental is from Y1 60 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual Z Rapid is the Z dimension to transition from rapid to feed Z End is the Z dimension at the bottom of the frame incremental is from the previous event Conrad is the value of the tangential radius in each corner Direction is the clockwise input 1 or counterclockwise input 2 direction for milling Tool Offset is the selection of the tool offset to the right input 1 offset to the left input 2 or tool center no offset input 0 relative to the programmed edge and direction of the cutter movement Passes is the number of cycles to machine to the final depth spaced equally from Z Rapid to Z End hint keep Z Rapid small Fin Cut is the width of the finish cut If 0 is input there will be no finish cut Z Feedrate is the Z feedrate from Z rapid to Z end XYZ Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Fin Feedrate is the milling feedrate for the finish cut if programmed Tool is the tool number you assign 9 8 3 Irregular Profile Press the IRREG PROFILE soft key if
7. the ProtoTRAK will construct a box to contain the text you define This box is oriented along the X axis like the text in this sentence and you may program up to 40 characters per event although you will only be able to see 20 characters on the prompts screen To machine text in a direction other than the X axis simply use multiple Engrave Events and place the lower left corner of the box wherever you would like The numbers and letters you program will always have a standard orientation like the letters on this page you cannot program tilted or inverted letters with the Engrave Event The letters are of the font shown in the figure and all capitals Prompts for the Engrave Event First define the lower left corner of the box that will contain your text X BEGIN The X coordinate of where you want your text to begin Y BEGIN The Y coordinate of where you want your text to begin HEI GHT The height of your text Each character varies in width the set height of the character will change the width in order to keep the overall size of the character proportional TEXT The text to be milled When you get to this prompt the Alpha keys will automatically pop up to allow you to enter the text Once you have finished entering text you must press End F8 and then any of the SET keys to successfully enter your text into the event The alpha keys will appear automatically if the text field is blank If you have already entered text but wish to make
8. 0000 x 0 0000 ABS Y 0 0000 ABS z 00000 ABS X OFFSET FROM FIXTURE 1 TO 3 My Ta a a R Fr B OO R re DATA DATA DATA DATA ERASE DOWN UP LEFT RIGHT TABLE Soe PETER Figure 12 4 The Fixture Offset screen 90 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual Setting up fixtures is easy First establish your base by setting your X Y and Z absolute zero You can do this in the DRO Mode but the X Y and Z Absolute position dimensions are also on this screen for your reference Fixture 1 is always the base Once you set your absolute zero on the base it is simple a matter of entering the distance from the base to up to five other fixture locations You can do this one of two ways By entering the numbers with the keypad or by positioning to the next fixture putting the cursor on the correct offset value and then pressing ABS SET 12 5 Service Codes These are special codes that may be entered into the ProtoTRAK SM CNC to call up routines used in installation setting of preferences machine checkout and service The following is a summary of the service codes available WARNING Before using service codes be aware that some of the routines are very powerful and may change system settings in a way you don t want Some of the routines cause the servos to come on and move at rapid speed Category Service Code Com
9. 1 2 2 0 2 1 2 2 2 3 3 0 3 1 w w w AUN w w w w onou Table of Contents 1 0 Introduction Models 1 Manual Organization 1 Safety Safety Publications 3 Danger Warning Caution and Note Labels and Notices Used in this Manual 3 Safety Precautions 6 Description of the ProtoTRAK SM CNC Display Pendant Front 9 3 1 1 Keyboard Hard Keys 9 3 1 2 Soft Keys 10 3 1 3 Emergency Stop Switch 10 3 1 4 The Liquid Crystal Display 11 Pendant Left Side 11 Pendant Right Side 12 Optional Equipment 12 3 4 1 Position Encoders 12 3 4 2 Power Draw Bar 12 3 4 3 Remote Stop Go Switch 12 3 4 4 Work Light 13 3 4 5 Coolant Pump 13 3 4 6 Auxiliary Functions 13 3 4 7 Limit Switches 13 Ballscrews 13 Servo Motors 13 Z Axis Glass Scales 13 Z Axis Ballscrew amp Motor Assembly 13 Basic Operation Switching the ProtoTRAK SM CNC on 15 Shutting down the ProtoTRAK SM CNC 16 Emergency Stop 16 Switching Between 2 amp 3 Axis Operation 16 Help Functions 16 4 5 1 Math Helps 17 Windows Up or Down 18 Definitions Terms amp Concepts ProtoTRAK SM CNC Axis Conventions 19 Part Geometry amp Tool Path Programming 19 Absolute amp Incremental Reference 20 Referenced amp Non Referenced Data 20 Incremental Reference Position in Programming 20 Tool Diameter Compensation 21 Connective Events 21 Conrad 22 Memory amp Storage 22 Planes amp Vertical Planes 23 Tool Diameter Compensation when Contouring in Z with Part Geometry 23
10. 100 or mm min from 5 to 2540 Finish Feedrate is the milling feedrate for the finish cut Tool is the tool number you assign 8 7 2 Rectangular Profile Press the RECTANGLE soft key if you wish to mill a rectangular frame all corners are 90 right angles Prompts for the rectangular profile X1 is the X dimension to any corner Y1 is the Y dimension to the same corner as X1 X3 is the X dimension to the corner opposite X1 incremental is from X1 Y3 is the Y dimension to the same corner as X3 incremental is from Y1 Conrad is the value of the tangential radius in each corner Direction is the clockwise input 1 or counterclockwise input 2 direction for milling Tool Offset is the selection of the tool offset to the right input 1 offset to the left input 2 or tool center no offset input 0 relative to the programmed edge and direction of the cutter movement Fin Cut is the width of the finish cut If 0 is input there will be no finish cut Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Fin Feedrate is the milling feedrate for the finish cut if programmed Tool is the tool number you assign 8 7 3 Irregular Profile Press the IRREG PROFILE soft key if you wish to mill a profile other than a rectangle or circle The Irregular Profile event gives you the powerful Auto Geometry Engine to define a shape made up of straight lines Mills and arcs The Irregular Profile is a ser
11. 100 base T Ethernet Ports available COM1 LPT 1 COMI LPT 1 System software Not available to user Instead Full Windows distribution on use second flash drive hard drive in C WIN98 Network or LPT CDROM System and network set up Default password PT4 Default user name PT4 Default computer name PT4SN0001 Default work group SWI Network settings Client for MS Networks File and print sharing Default protocols Net beui TCP IP Network log in Windows log in Enabled share level access control TCP IP set up Obtain IP address automatically Dns Disabled Gateway Not used Wins configuration Use DHCP for wins resolution do not change 118 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 14 13 RS232 Interface While networking and floppy disks are more modern reliable and convenient methods the RS232 protocol may also be used to transfer files between the ProtoTRAK SM CNC and other controls and computers The ProtoTRAK SM CNC will support RS232 file transfer for Open and Save operations in the Program In Out Mode The other operations such as Back up cannot be done through RS232 14 13 1 Connections To transfer a file between the ProtoTRAK SM CNC and a remote computer or control the two systems must be connected to each other with an RS232 cable On the ProtoTRAK SM CNC plug the cable into the connector on the left side
12. 5Hp 5 Hp Voltage 220 440V 220 440V 220 440V Phase Cycle 3 Phase 50 60 Hz 3 Phase 50 60 Hz 3 Phase 50 60 Hz Current 4 3 Amp 4 3 Amp 7 Amp Maximum Weight of Workpiece 750 Ib 850 lb 850 lb 16 5 Maximum Machining Capacities Drilling Mild Steel Tapping Milling metal removal rate mild steel 1 in min 1 5 1n min 16 6 Machine Options The following options are available for TRAK K Mills See Section 3 for a list of the CNC options Chip Pan Halogen Work Lamp Power Draw Bar for K4 CAT 40 or NMTB 40 Power Draw Bar K2 and K3 R8 Riser Block 4 6 or 8 Knee Power Feed 16 7 Lubrication 16 7 1 Manual Lubrication The TRAK Knee Mill X Y Z way surfaces and ball screws are lubricated manually with the lubrication pump located on the left side of the knee Pull the handle fully and release 4 to 6 times at the beginning of each shift and once every four hours of operation thereafter 137 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 1 At the beginning of each day check the oil level in the pump If low fill with SAE 30 or 30W oil 2 Every six months of operation apply a liberal coating of Mobile Grease MP or equivalent to the Z Axis ACME screw CAUTI ON Failure to manually activate the pump at the beginning of each day may cause severe damage to the TRAK Knee Mill way s
13. 9 10 10 10 11 11 0 11 1 11 2 11 3 11 4 Copy Events Finishing Teach Events Three Axis CNC Program Events Posn Position Events Drill Events Bolt Hole Events Mill Events Arc Events Pocket Event 9 6 1 Circle Pocket 9 6 2 Rectangular Pocket 9 6 3 Irregular Pocket 9 6 4 Tool Path in Pocket Events 9 6 5 Zigzag Z Depth Cuts 9 6 6 Conrad in Pocket Events 9 6 7 Bottom Finish Cut Islands 9 7 1 Circular Island 9 7 2 Rectangular Island 9 7 3 Irregular Island Profile Events 9 8 1 Circle Profile 9 8 2 Rectangular Profile 9 8 3 Irregular Profile Helix Events Subroutine Events 9 10 1 Repeat 9 10 2 Mirror 9 10 3 Rotate Copy Events Thread Mill Event Pause Events Engrave Event Finishing Teach Events Auto Geometry Engine A G E Programming Starting the A G E A G E Mill Prompts A G E Arc Prompts Skipping Over Prompts The OK NOT OK Flag Ending A G E Guessing Data Look amp Guess Calculated Data Arcs and Conrads Tangency Edit Mode Delete Events Spreadsheet Editing 11 2 1 Selecting Data to be Displayed on the Search Edit Table 11 2 2 Sorting Data 11 2 3 Making Global Changes to Data Erase Program Clipboard 79 12 0 12 1 12 2 12 3 12 4 12 5 13 0 13 1 13 2 13 3 13 4 13 5 13 6 13 7 13 8 13 9 13 10 14 0 14 1 14 2 14 3 14 4 14 5 14 7 14 8 14 9 14 10 Set Up Mode The Tool Table 83 12 1 1 The Tool Table Screen 84 12 1 2 Simple Tool Set Up f
14. A Dial and TRAK products are warranted to the original purchaser to be free from defects in work manship and materials for the following periods Warranty Period Popu Materials Factory Labor New TRAK 1 Year 1 Year Any EXCHANGE Unit 90 Days 90 Days The warranty period starts on the date of the invoice to the original purchaser from Southwestern Industries Inc SWI or their authorized distributor If a unit under warranty fails it will be repaired or exchanged at our option for a properly functioning unit in similar or better condition Such repairs or exchanges will be made FOB Factory Los Angeles or the location of our nearest factory representative or authorized distributor Disclaimers of Warranties This warranty is expressly in lieu of any other warranties express or implied including any implied warranty of merchantability or fitness for a particular purpose and of any other obligations or liability on the part of SWI or any producing entity if different Warranty repairs exchanges do not cover incidental costs such as installation labor freight etc SWI is not responsible for consequential damages from use or misuse of any of its products Trav A Dial TRAK products are precision mechanical electromechanical measurement systems and must be given the reasonable care that these types of instruments require Replacement of chip scrapers and wipers is the responsibility of the customer Consequently the warran
15. Allows a scale factor between 1 and 10 An input of 5 means the part will be 5 times as big as the programmed dimensions A value of 1 0000 is assumed if nothing is input Dwell Request Allows you to input a dwell at the bottom of a drill bolt hole or bore cycle for events you select Select the appropriate YES or NO soft key If you select YES you will be prompted to input a dwell time in seconds from 1 to 99 9 when appropriate to the event being programmed Auxiliary Function Request Asks if you wish to activate any of the optional auxiliary functions see Section 7 4 at any time during the program Select the appropriate YES or NO soft key If you select YES you will be prompted to input the type and sequencing of the auxiliary functions during event programming Event Comments f you select Yes for event comments you will have the opportunity to insert a comment in each event For Irregular Pocket and Irregular Profile events you will be able to enter a comment at the header event but not for each A G E Turn and A G E Arc event The comment you insert will appear in the RUN mode on the screen just above the X position dimension as the event begins to run Comments may be composed of letters numbers and some symbols and may be up to 20 characters While programming the event with the Event Comments set to Yes when the highlight is on the Event Comments prompt you may enter a comment using the same methods used to enter a progr
16. Forward Unknown data Y End Data Forward Unknown Data X Center Data Forward Unknown Data Y Center Data Forward Unknown data Conrad Data Forward Radius 9 abs Radius of Arc Chord Length Press Page Forward now as no further Chord Angle data is required EVENT 13 AGE ARC NOTES Tangent 1 Selects tan arc Direction 2 CCW X End 1 02 abs Known print dimension Y End 5 505 abs Known print dimension X Center 1 17 abs Known print dimension Y Center 5 505 abs Known print dimension Conrad Press Page Forward now as no further Radius data is required Chord Length Chord Angle EVENT 14 AGE MILL NOTES Tangent 1 Selects tan mill X End 0 inc X value is unchanged Y End Guess 6 6 abs Unknown value Guess Conrad 0 15 Known print value Angle End Press Page Forward now as no further Length data is required Line Angle Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual EVENT 15 AGE ARC NOTES Tangent Direction X End Y End X Center Y Center Conrad Radius Chord Length Chord Angle Selects tan arc CW Known print dimension Known print dimension Known print dimension Known print dimension Press Page Forward now as no further data is required EVENT 16 AGE MILL NOTES Tangent X End Y End Conrad Angle End Length Line Angle Selects tan mill off the part Known value Value unchanged Press Page Forward now as no further
17. Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual X1 POCKET X dimension for one corner of the rectangular pocket that surrounds the island Y1 POCKET Y dimension for one corner of the rectangular pocket that surrounds the island X3 POCKET X dimension for the opposite corner of the rectangular pocket that surrounds the island Y3 POCKET Y dimension for the opposite corner of the rectangular pocket that surrounds the island CONRAD PCKT the value of the tangential radius in the corners of the rectangular pocket that surrounds the island FIN CUT PCKT finish cut along the perimeter of the pocket If 0 is input there will be no finish cut See the previous section for a bottom finish cut Z FEEDRATE is the Z feedrate from Z rapid to Z end XYZ FEEDRATE the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 FIN FEEDRATE the finish milling feedrate for both the island and pocket finish cuts TOOL is the tool number you assign 9 7 2 Rectangular Island Press the RECT ISLAND softkey if you wish to machine a rectangular island Prompts for the RECT ISLAND X1 I SLAND X dimension for one corner of the rectangular island Y1 I SLAND Y dimension for one corner of the rectangular island X3 ISLAND X dimension for the opposite corner of the island Y3 ISLAND Y dimension for the opposite corner of the island Z RAPID is the Z dimension of the transition from rapid to feed Z E
18. ProtoTRAK SM you are not likely to be able to use this benefit with a very large or complex file anyway To run the G Code file directly open the file using OPEN AS G Code GCD The entire program will be brought into current memory You will be able to view the tool path when you run the program in the Run Mode but you will not be able to edit the program or view it in the Program Mode In order to edit the program you will have to use the same application usually CAM that you used to write the program originally 14 11 1 G Codes Recognized by the ProtoTRAK SM CNC G00 positioning rapid G01 linear interpolation feed G02 circular interpolation CW G03 circular interpolation CCW G06 CW Helix G07 CCW Helix G16 Selects a vertical plane via a bearing angle value in D word from the x axis G17 Selects the XY plane for circular interpolation G18 Selects the XZ plane for circular interpolation G19 Selects the YZ plane for circular interpolation G20 input in inch G21 input in mm G40 cutter compensation cancel for SWI it means center G41 cutter compensation left G42 cutter compensation right G61 exact stop check mode G64 cutting mode no hesitation between events NOHES true G80 Hole machining canned cycle G81 Drill canned cycle G82 Spot drilling canned cycle G83 Peck drilling canned cycle G84 Tapping canned cycle G85 Boring canned cycle 14 11 2 M Codes Supported by the ProtoTRAK SM CNC M00 program sto
19. SM A G E programming system A basic rule of thumb for A G E programming e When you have unknown tangent elements you may skip data e When you have unknown non tangent elements you use the Guess feature The Program All programs start by first selecting Program from the front panel softkeys You may enter in an alphanumeric program description or simply press Go to Begin to get started Be certain to start your program by selecting Profile Sample Drawing 2 a 100851 127 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual EVENT 1 IRREGULAR PROFILE NOTES X Begin Y Begin Tool Offset Finish Cut Feedrate Fin Feedrate Tool 1 abs 6 66 abs 2 Inc Set 100 abs Inc Set abs set Leads into part no witness mark Leads into part no witness mark Sets tool offset LEFT Means no finish cut Sets feedrate to 100 ipm Means no finish feedrate Sets tool to default 1 Tangent X End Y End Conrad Angle End Length Line Angle AGE Mill Selects Tan Mill Known print value Known print value Press Page Forward now as no further data is required Tangent 1 Selects Tan Arc Direction 1 abs Selects CW arc direction X End 1 02 abs Known endpoint Y End Guess 6 6 abs Unknown endpoint guess X Center Abs set Defaults to 0 known print dimension Y Center Abs se
20. a change you will see a blue question mark appear on the lower left corner of the screen when you scroll to this field press the Help button and the alpha keys will appear FEEDRATE The feedrate of XYZ along the path of the text Tool is the tool number you assign 46 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual PROG INOS TOOL PAKS om EVENT 0 EVENT1 ENGRAVE PROGRAM NAME 0 SCALE AUXILIARY FI EVENT COMA MULTIPLE FD DIMENSION X BEGIN w nram 0 0000 abs abs Text Length 3 0 000000 Fa F5 F Fr F8 Fi F2 FR BACK CLEAR SPACE y A lt gt ENTER END FIGURE 8 8 The above figure shows the text and special characters available for the Engrave event 8 9 Notice the field that is labeled Text Length This field will display the total length of your programmed text and will update as you enter each character Subroutine Events The Subroutine Events are used for manipulating previously programmed geometry within the XY plane The Subroutine Event is divided into three options Repeat Mirror and Rotate Repeat and Rotate may be connective As long as the rules of connectivity are satisfied see Section 5 9 the ProtoTRAK SM CNC will continue milling between preceding and subsequent events REPEAT allows you to repeat an event or a group of events up to 99 times with an offset in X and or Y This can be usefu
21. available to calculate missing print data For example Math Help type 28 enables you to solve an entire right triangle by giving two known pieces of data To exit from the Math Help press the Mode key MATH PINBRKTOOS Ci CSS AXIS INCH Triangle 1 6000 IonoU gt 27 5000 Solution 1 of 1 1 6000 3 0736 3 4651 27 5000 62 5000 I0 H F2 B FH F5 F Fr FS EDIT RETURN 17 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual FIGURE 4 5 2 Math Help 28 In this example by entering the length of line A and the value of 4 6 angle G the other values are calculated You may have the Math Help solutions load directly into your program This saves you from having to write down the solution and then key it in While you are programming the event that needs the data from Math Help simply press the HELP key to start the Math Help Once a solution is obtained you will have the following soft key selections Load Begin will load the displayed solution into the event as the X and Z beginning Load End will load the displayed solution into the event as the X and Z end Load Center will load the displayed solution into the event as the X and Z center Next Solution when there is more than one solution to the problem this will display the alternative solutions Edit this allows you to go back to the data you entered in order to ma
22. backwards through the event inputs DATA BOTTOM puts the Highlight on the last input INSERT EVENT use this to insert a new event into the program This new event will take the place of the one that was on the right side of the screen when you pressed the INSERT EVENT key That previous event and all the events that follow increase their event number by one For example if you started with a program of four events if you were to press the INSERT EVENT key while Event 3 was on the right side of the screen the previous Event 3 would become Event 4 and the previous Event 4 would become Event 5 If you insert a Subroutine event the event numbers will increase by one as when you insert another kind of event If you insert a copy event the event numbers will increase by the number of events that are copied DELETE EVENT this will delete the event on the right side of the screen 7 9 Programming Events Once you press the appropriate GO TO soft key you will begin to define your part as a series of Events For the ProtoTRAK SM CNC an Event is a geometry or a feature of a part PROG PINO TOOL 1 3AXIS INCH EVENT 0 EVENT 1 PROGRAM NAME 0 SCALE 1 000 DWELL REQUEST NO AUXILIARY FUNCTION NO EVENT COMMENTS NO MULTIPLE FIXTURES NO DIMENSION DEFINITION PART GEO i01052 FIGURE 7 9 1 The header screen has been completed and is on the left side Select an event type from the soft keys Shown here are the events for three a
23. below AUX END options None No Auxiliary functions will turn off at the end of this event Coolant off Turns the coolant or air solenoid off at the end of this event 3 Pulse Indexer Activates a 0 3 second electronic pulse at the end of this event See note below Coolant Air on and off is automatically programmed for tool changes If you want the air or coolant pump on while cutting the entire part you need only program the Aux begin in the first event and Aux end in the last event The coolant pump or air solenoid will turn on at the beginning of the programmed event and will turn off during tool changes The Pulse Indexer function is designed to operate with a standard indexer Programming an Aux 3 at the end of an event will cause the ProtoTRAK SM CNC to stop machining at the end of the event and wait for a signal from the indexer or rotary table that it has finished its programmed move then it will resume machining at the next event If you want the ProtoTRAK SM CNC to return the head to the Z retract position before moving to the next event put the Aux 3 command in a Pause event The ProtoTRAK SM CNC will interpret the signal from the indexer or rotary table as a GO command and continue machining without you having to press the GO key 7 5 Multiple Fixtures You may run your program using up to six fixtures plus a base A fixture is a location on you your machine with a defined offset from your absolute 0 When
24. cut is programmed it will be made at the completion of the final pass The cutter will arc in and arc out of the finish cut and position itself the finish cut dimension away from the part before moving the tool out of the part The factory setting for tool stepover while machining a pocket is 70 This may be changed When you first enter the pocket event the blue will appear next to the help key Pressing Help will give you the choice of entering a new tool stepover percentage The value you enter here will remain the same until you change it again 40 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 8 5 1 Circular Pocket Press the CIRCLE PCKT soft key if you wish to mill a circular pocket Prompts for the circle pocket X Center is the X dimension to the center of the circle Y Center is the Y dimension to the center of the circle Radius is the finish radius of the circle Direction is the clockwise input 1 or counterclockwise input 2 direction for milling Fin Cut is the width of the finish cut If 0 is input there will be no finish cut Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Fin Feedrate is the milling feedrate for the finish cut Tool is the tool number you assign 8 5 2 Rectangular Pocket Press RECTANGLE soft key if you wish to mill a rectangular pocket all corners are 90 right angles and the
25. data is required Press the Look Key Now If all is OK press Look key again to return to program and End the AGE Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 15 2 Sample Program No 2 Basic 2 1 2 Axis This program is designed to give you practice on programming 2 axis Program events for 3 axis CNC programming To practice on 2 axis CNC simply ignore the Z prompts The Program All programs start by first selecting Program from the front panel softkeys You may enter in an alphanumeric program description or simply press Go to Begin to get started Start your program by selecting Pocket and then Circle Pocket Sample Drawing 2 132 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual EVENT 1 CIRC PCKT NOTES X Center abs set Sets the pocket center to X zero Y Center abs set Sets the pocket center to Y zero Z Rapid l abs Sets the Rapid plane to 0 1 Z End 6 abs Sets the pocket depth to 0 6 Radius 1 25 abs Sets radius of pocket to 1 25 Direction 2 abs Makes the cut direction CCW of Passes 2 abs Cuts the pocket using two 2 depths Entry Mode 1 abs Makes the tool ramp into the material Fin Cut 01 abs Takes a 0 01 cut to finish the pocket Z Feedrate 5 abs Sets the ramp feedrate to 5 ipm XYZ Feedrate 20
26. each event in a long program to make the changes on that event type In order to make global changes 1 Sort the data in a way that groups together the things you want to change 2 Highlight the data value that is highest on the table nearest to the top that you want changed 3 Press the CHANGE ALL softkey All the inputs that are the same as the one you highlighted and are listed together below the data you highlighted will then be highlighted 4 Enter the new value then press set All the highlighted data will be changed to the value you just input Example From the screen shown in Figure 11 2 1 we will change the Z Feed for each of the mill events in the program 1 Sort by event type to get all the Mill events together 2 Highlight the Z Feed in the first Mill event Event 8 See Figure 11 2 3 3 Press the CHANGE ALL softkey All the Z Feeds in the Mill events are highlighted See Figure 11 2 4 4 Type in the new Z Feed value and press INC SET or ABS SET See Figure 11 2 5 79 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual In this example the Z feed is changed from 5 0 to 7 0 for all the Mill Events ep PNR TSS AXIS INCH FA EVT TYPE TOOL FEED Z RAPID CONRAD 14 BOLT HOLE 3 0 1875 5 0 0 1000 abs al 5 0 0 1000 abs 5 0 0 1000 abs MILL 2 0 3750 5 0 10 0 0 0000 inc 0 0000 MILL 2 0 3750 0 00
27. either INC SET or ABS SET Tool Offset f the first event with an offset CENTER If not the first event with an offset the same as the last event if that event was a Mill or Arc event Feedrate same as last event if that event was a Mill Arc Pocket Frame or Helix Tool same as last event or Tool 1 if the first event DRILL OR BORE Drill PECKS FOR DRILL 1 peck CONRAD 0 You may change these assumed inputs by simply inputting the desired data when the event is programmed Z Rapid Positioning Three axis CNC programming only Between any two events the head will always move to the higher of the Z rapid of the event just completed or the Z Rapid of the next event unless the two events are connective see Section 5 7 Remember when using part geometry programming two milling events are not connective unless they lie in the same plane 34 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 7 8 Softkeys within Events Once a geometry Event such as Mill or Bolt Hole is selected the softkeys will change See Figure 7 8 FIGURE 7 8 Soft keys used while programming an event PAGE FWD moves forward through the programmed events PAGE BACK moves backwards through the programmed events DATA FWD moves forward through the event inputs Note use the DATA FWD key and not a SET key when you do not want to input a value DATA BACK moves
28. feed speed The options are 002 inches per revolution of the spindle 004 inches per revolution and 006 inches per revolution 142 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual To change speeds pull the knob out and rotate the selector to the proper position It is generally easier to change speeds with the spindle running or rotated by hand Do not force the lever 17 10 4 Feed Trip Lever The Feed Trip Lever stops the quill feed motion when the quill stop knob reaches the quill micrometer dial Move the lever to the left to engage or to the right to disengage 17 10 5 Fine Hand Quill Feed 1 Disengage the Power Feed Engagement Lever See 17 10 1 2 Set the fine feed direction shaft to the neutral position See 17 10 2 3 Rotate the Fine Feed handwheel 17 10 6 Fine Automatic Quill Feed 1 Be certain the quill lock is off 2 Set the quill micrometer dial to the proper depth See 17 10 4 3 Engage the Power Feed Engagement lever when the motor is stopped See 17 10 1 17 Select proper quill feed See 17 10 3 143 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 144 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual Checklist Full name of person to receive certification Com
29. file is opened 070501 MXx3 FIGURE 14 9 2 Use the Open As box to tell the ProtoTRAK SM CNC what kind of file it is 105 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual Use the Open As box to tell the ProtoTRAK SM CNC what format the file is in so that it knows how to convert it to the ProtoTRAK SM CNC format In Figure 14 9 1 the ProtoTRAK SM CNC could guess that the file to be converted was from a previous version of ProtoTRAK because of its file extension mx3 But since file extensions may be missing or may not really describe the file format correctly you can use the Open As box to declare the file type All files or programs open on the ProtoTRAK SM CNC as a PT4 file with one exception G Code files see below Once the file is opened as ProtoTRAK SM CNC file you may store it as ProtoTRAK SM CNC file with the same filename and the extension PT4 The drop down menu in the Open As box shows which converters are available Open As types that are grayed out indicate converters that are available for purchase 14 9 3 Converting From the ProtoTRAK SM CNC to a Different Format Files or programs are converted from the ProtoTRAK SM CNC to a different format using the Save function of Program In Out Mode PROG 11 PIN BRKTOOS F B AXIS INCH SAE Lookin fia FileName 00254 j Save As SWI MX3 Fi F2 F3 F4 FS F FF Fe pata DAT
30. informed competitors would have you believe This restriction is a matter of practicality Because the ProtoT RAK allows you to program in part geometry and therefore will figure out the tool path for you the process of converting a three axis program gives the ProtoTRAK a tool position problem that it cannot resolve without a lot more data from you The other reason is that the output from a CAM systems for three axis shapes is in the form of thousands and thousands of straight line GO1 moves that would convert into the equal number of ProtoTRAK Mill events This is hardly a manageable program Instead of forcing the issue in a silly way we give you the more elegant solution of running GCD files To our competitors we respectfully point out that the thread and helix milling canned cycles of the ProtoTRAK are three axis simultaneous interpolation In order to run a CAM program the program must be posted through a post processor that makes some adjustments to the output of the CAM software so that it is understood by the ProtoTRAK The ProtoTRAK uses a post processor that is very similar to the Fanuc 6M 121 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual If you are not familiar with writing a post processor we recommend that you contact your CAD CAM supplier We will be happy to work with him to get you the post processor you need 14 14 1 Writing a Post Pro
31. into the ProtoTRAK SM CNC format and put into the current memory Once the transfer is complete the Select a Mode screen will appear 14 13 3 Sending a File Sending a file via the RS232 is done through the file Save command Transfer will take place only with a program that is in the ProtoTRAK SM CNC s current memory As with receiving the file the RS232 port must be selected in the Look In box Since the file name does not transfer with the program through RS232 you can ignore the file name box Place the cursor into the Save As box and select a file format The ProtoTRAK SM CNC will convert the file to the format that you select as it is being sent to the remote computer or control Once the transfer is set up press the Save soft key The ProtoTRAK SM CNC will be placed in a ready state for transferring the file to the remote computer or control A second Save key press is required to go from this ready state to actually sending 120 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual The remote computer or control must be set up to receive the file If the remote computer or control is a TRAK or ProtoTRAK CNC or is a computer that is running ProtoT RAK or TRAK A G E offline software you can receive the file by simply using the Open softkey via the RS232 in the Program In Out Mode If the remote computer or control is not a TRAK or ProtoTRAK CNC consult y
32. is run e The SHOW PROG soft key will show the programmed data for the event being run and the next event as the part is run The run procedure is very simple Follow the instructions on the conversation line and proceed by pressing the GO key Once the STOP hard key is pressed additional softkeys will be available Program Run Messages During Program Run all messages that will help you to run the part will appear in the data input line The messages you will usually see are Load Tool ___ Means to load the tool requested and press GO to continue Stop At any time the program may be halted by pressing the STOP key This freezes the program at that point You may choose to continue running the program by pressing the CNC RUN softkey or pressing the GO key You may also run the program by using the table or saddle handwheels by pressing the TRAKing softkey Feedrate Override The run feedrate may be changed at any time by pressing the FEED or FEED keys Each press modifies the programmed feedrate as well as rapid by 10 Trial Run Trial Run allows you to quickly check out your program with no Z movement before you actually start to make parts In trial run the table will move at rapid speed regardless of what feedrates are programmed the rapid speed may be overridden with FEED 4 and FEED keys The table will stop at each stop location for example at each drill location but immediately continue on without your inp
33. is selected Special attention must always be paid to tool offsets when machining with a ball end mill The reason for this is that the tool diameter changes in the bottom part that portion equal to the tool radius of the tool The tool is always positioned at the beginning of a milling operation so that the correct point on the ball end of the tool is tangent to the beginning point and offset perpen dicular to the machined edge by the radius of the tool Consider the example below of milling a ramp in the XZ plane from point B to point C see Figure 5 11 23 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual Z XZ VERTICAL PLANE A X FIGURE 5 11 1 Ball end mill position with respect to program points Tool starts so end mill is tangent to BC R from center of tool is perpendicular to BC Note how the tool at the beginning point point B starts below in the Z direction point B so that it can actually touch this point If this were not true a cusp would remain to the left of point B Now consider a similar example milling from A to B to C in the XZ plane Z XZ VERTICAL PLANE t X FIGURE 5 11 2 In order to respect the lines defined by the programmed points the ball end mill never touches point B Tool starts centered over A offset up by the tool radius R It moves right until it is tangent to both AB and BC Then moves to point C as in the
34. known point in the previous event Following are the positions for each event type from which the incremental moves are made in the subsequent event Position X Y and Z programmed Drill X Y Z RAPID and Z END programmed Bolt Hole X CENTER Y CENTER Z RAPID and Z END programmed Mill X END Y END Z RAPID and Z END programmed Arc X END Y END Z RAPID and Z END programmed 20 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 5 6 5 7 Circle POCKET or FRAME X CENTER Y CENTER Z RAPID and Z END programmed Rectangle or Irregular POCKET or PROFILE X1 and Y1 corner Z RAPID and Z END programmed Helix The X END Y END Z RAPID and Z END programmed Sub The reference position as defined for the specific events above for the event prior to the first event that was repeated A G E PROFILE The appropriate reference position as defined for the specific events above for the last event that is programmed For example if an ARC event followed a MILL event a 2 0 inch incremental X BEG would mean that in the X direction the beginning of the ARC event is 2 0 inches from the end of the MILL event Tool Diameter Compensation Tool diameter compensation allows the machined edges shown directly on the print to be programmed instead of the center of the tool The ProtoTRAK SM CNC then automatically compensates for the programmed geometry so that th
35. mm min from 5 to 2540 Tool is the tool number you assign When the initial screen is complete you will define the perimeter of the pocket with a series of A G E Mills and A G E Arcs Programming with the Auto Geometry Engine is explained in Section 10 0 No islands may exist in an irregular pocket 9 6 4 Tool Path in Pocket Events In Program Run the pocket path will be either the plunge or zigzag cuts to Z depth along either the X or Y followed by the required number of cuts to clear out the interior material and then the rough cut along the inside of the perimeter This will be repeated for each pass and then followed by a finish pass if FIN CUT was not zero along the inside of the perimeter at the Finish Feedrate and final depth If a bottom finish cut was programmed it will be machined before the perimeter finish cut Whether the cuts to clear the interior material of the irregular pocket are along the X or Y axis depends on if there are hidden areas of the pocket The ProtoTRAK SM CNC always looks to cut along the X axis first If there are areas that are hidden to the X axis it will machine along the Y axis If there are hidden areas that cannot be machined continuously in the X or Y axis the tool will return to Z retract and then reposition to machine the hidden area 9 6 5 Zigzag Z Depth Cuts In programming pocket events you have a choice to program the cuts to Z depth either as a plunge or a zigzag ramp For rectan
36. numbers letters spaces and other characters When the Program name prompt is highlighted the Data Input Line will show Program Name At this point you may e Press number keys e Press Help to access alpha keys and special characters in the ProtoTRAK SM CNC e Use a keyboard plugged into the ProtoTRAK SM CNC to name the program To use the alpha keys and special characters on the ProtoTRAK SM CNC e Use the Clear softkey to erase the entire line the Backspace softkey to erase the last character or number e Use the arrow softkeys to move around the table e Once the character you want is highlighted use the Enter softkey to load the character into the program name 30 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual e Use the blank space on the lower right of the table to insert a space into the program name e Once you finish entering the letters and special characters press the End softkey This tells the ProtoTRAK SM CNC that you are finished with the alpha table Numbers may still be added to the program name When you are finished with the program name press SET to enter it into the current memory Note It is not necessary to enter a part number If none is entered and a GO TO soft key is pushed the system will assume a part number 0 7 3 2 General Program Options Use the DATA FWD softkey to select general programming options Scale
37. o W o DRO Mode Enter DRO Mode DRO Functions Jog Power Feed Do One Teach 6 6 1 Entering Teach Data Return to Absolute Zero Tool Program Mode Getting Started amp Some General I nfo Programming Overview Enter Program Mode Program Header Screen 7 3 1 Program Name 7 3 2 General Program Options 7 3 3 Program Header Softkeys Auxiliary AUX Functions Multiple Fixtures 7 5 1 The Default Fixture 7 5 2 Fixtures amp Running the Program 7 5 3 Editing Fixtures Assumed Inputs Z Rapid Positioning Softkeys within Events Programming Events Editing Data While Programming Look Finish Cuts Two Versus Three Axis Programming Two Axis Program Events Posn Drill Bolt Hole Events Mill Events Arc Events Pocket Event 8 5 1 Circular Pocket 8 5 2 Rectangular Pocket 8 5 3 Irregular Pocket 8 5 4 Tool Path in Pocket Events 8 5 5 Conrad in Pocket Events Islands 8 6 1 Circular Island 8 6 2 Rectangular Island 8 6 3 Irregular Island Profile Events 8 7 1 Circle Profile 8 7 2 Rectangular Profile 8 7 3 Irregular Profile Engrave Event Subroutine Events 8 9 1 Repeat 8 9 2 Mirror 8 9 3 Rotate TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 29 29 30 30 31 32 33 34 34 34 34 35 35 36 37 38 8 10 8 11 9 0 9 1 woo OUA W 9 7 9 8 9 11 9 12 9 13 9 14 9 15 10 0 10 1 10 2 10 3 10 4 10 5 10 6 10 7 10 8 10
38. occur when the GO key is pressed after the Load Tool ___ prompt 12 2 Tool Path When the TOOL PATH soft key is pressed the program is processed and the tool path graphics are displayed SET UP PIN RO424 11 a INCH Fi F2 F3 F4 F5 FG FT FS ADJUST FIT view praw STEP XY YZ XZ 3D FIGURE 12 2 The Tool Path graphics show the program and tool positions Most programming errors that would prevent the program from running are detected when the tool path graphics are selected For example if you were to have omitted a 88 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual minus sign from a Z End dimension the system would give you an error message that the Z End should not be higher than the Z Rapid The displayed graphic is automatically sized to fit the screen and an icon that represents the X Y and Z orientation is placed at the program s absolute 0 reference point The path shown on the screen represents the center of the tool e Position and drill events are drawn in yellow e Rapid moves are in red e Programmed geometry is in blue 12 2 1 Soft keys in Tool Path ADJ UST VIEW calls up additional softkeys to adjust the view See below FIT DRAW will re draw automatically sizing to fit the screen necessary only if an adjustment changed the drawing from its initial sizing STEP each press of the STEP button shows the next
39. of the pendant see Figure 3 2 On the remote computer or control the cable may go to any available serial port The baud rate for the ProtoTRAK SM CNC is set at 4800 use Service Code 37 to reset the baud rate The pin out for the 9 pin connector is the standard RS232 PC PC Laplink Interlink cable PC 9 way female PC 9 way female 9D Female 9D Female RS232 signal Pin Pin RS232 signal GND Case Case Gnd TxD 3 2 RxD RxD 2 3 TxD RTS 7 6 DSR CTS 8 4 DTR DSR 6 7 RTS SG 5 5 SG DTR 4 8 CTS 14 13 2 Receiving a File Receiving a file via the RS232 is done through the file Open command See Figure 14 13 1 gt Fal PT4 Faili PT4 T4 2T4 anents I PT4 ter PT4 H PT4 HJIHICH F 14 B Cons PT4 File Name O PT4 Open Ag Swi PT4 gt EWU PBREBRuUuvLe A FPR FR A TAB DATA DATA OPEN FWD BACK FOLDER Figure 14 13 1 The RS232 port is selected in the Look In box 119 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual Once the RS232 port is selected pressing the Tab key will position the cursor in the now empty list of contents A message window will appear prompting you to enter the file name of the file you wish to receive Press Tab again to move the cursor to the File Name box You may name the file the same name as the one it has on the remote co
40. opened If these tools were not set very recently we recommend that you check them before running the program The Ref row will read NOT SET A reference may be set at this point If you do not go into the tool table after opening a program and before running you will get a reminder message to check your tools 87 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 12 1 12 Making Tool Set Ups Easy We highly recommend the following to make tool set ups easy 1 Always use the same tool to set your reference Preferably you should use a tool you don t use to machine something that you keep in your toolbox 2 Don t use a tool that you use to machine your part as a reference If your reference tool breaks you have to reset all your tools 3 Always use the same surface for touching your tools to Use the machine table a gage block or the vice something you can always count on being there If you use the top of the part your reference is changing all the time 12 1 13 The Tool Table and Two Axis CNC Operation The information entered in the tool table will also be used when operating the ProtoTRAK SM CNC as a two axis CNC Instead of positioning the head the DRO information seen in the Run Mode will be adjusted for the differences in tools When a new tool is loaded the Z dimension will change according to the offsets in the tool table This change will
41. pocket finish cut 8 6 1 Circular Island Press the Circle Island soft key if you wish to mill a circular island Prompts for the Circle Pocket X CENTER is the dimension of the center of the Island Y CENTER is the dimension of the center of the Island 42 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual RADI US is the finish radius of the Island DIRECTION is the milling direction clockwise or counterclockwise FIN CUT ISL Finish cut for the Island If 0 is input there will be no finish cut X1 POCKET X dimension for one corner of the rectangular pocket that surrounds the island Y1 POCKET Y dimension for one corner of the rectangular pocket that surrounds the island X3 POCKET X dimension for the opposite corner of the rectangular pocket that surrounds the island Y3 POCKET Y dimension for the opposite corner of the rectangular pocket that surrounds the island CONRAD PCKT the value of the tangential radius in the corners of the rectangular pocket that surrounds the island FIN CUT PCKT finish cut along the perimeter of the pocket If 0 is input there will be no finish cut FEEDRATE the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 FIN FEEDRATE the finish milling feedrate for both the island and pocket finish cuts TOOL is the tool number you assign 8 6 2 Rectangular Island Press the RECT ISLAND softkey if you wish
42. pocket finish cuts TOOL is the tool number you assign When the initial screen is complete you will define the perimeter of the island with a series of A G E Mills and A G E Arcs Programming with the Auto Geometry Engine is explained in Section 10 0 PROFILE Events This event allows you to mill around the outside or inside of a circular or rectangular frame or an irregular profile The irregular profile may be closed or open When the irregular profile event is started the ProtoTRAK SM CNC will automatically initiate the powerful Auto Geometry Engine See Section 10 0 for programming with A G E 8 7 1 Circle profile Press the CIRCLE soft key if you wish to mill a circular frame Prompts in the Circle Profile event X Center is the X dimension to the center of the circle Y Center is the Y dimension to the center of the circle Radius is the finish radius of the circle Direction is the clockwise input 1 or counterclockwise input 2 direction for milling 44 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual Tool Offset is the selection of the tool offset to the right input 1 offset to the left input 2 or tool center no offset input 0 relative to the programmed edge and direction of the cutter movement Fin Cut is the width of the finish cut If 0 is input there will be no finish cut Feedrate is the milling feedrate in in min from 1 to
43. pocket other than a rectangle or circle The Irregular Pocket event gives you the powerful Auto Geometry Engine to define a shape made up of straight lines Mills and arcs The first screen in an irregular pocket event will define the beginning point and some of its general parameters The last event of the irregular pocket must end at the same point as defined in the first event X Begin is the X dimension of the beginning of the pocket Y Begin is the Y dimension of the beginning of the pocket Z Rapid is the Z dimension to transition from rapid to feed Z End is the Z dimension of the depth of the pocket Passes is the number of cycles to machine to the final depth spaced equally from Z rapid to Z end hint keep Z Rapid small Entry mode choose between a zigzag ramp and a plunge The plunge will machine straight down Z to the appropriate Z depth The zigzag ramp will move in a zigzag pattern to depth See Section 9 6 5 for more information about the zigzag ramp Z Feedrate is the Z feedrate from Z rapid to Z end XYZ Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 55 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual Fin Cut is the width of the finish cut If 0 is input there will be no finish cut See Section 9 6 7 for a bottom finish cut Fin Feedrate is the finish cut milling feedrate in in min from 1 to 100 or
44. power feed Press GO to resume Repeat the process beginning at c above as often as you wish Press RETURN soft key to return to manual DRO operation Do One The Do One routines in the DRO mode allow you to do one CNC operation while machining manually without having to write a program The programming and tool path of the events in Do One are nearly identical to those in the Program Mode See Section 8 and 9 for programming instructions Teach Teach gives you the ability to enter X and Y dimensions into a program It can bea useful way of entering a few manual moves for operations like clearing out excess material or remembering a few hole locations The process of using Teach is in two parts The first part takes place in the DRO Mode This is where you start the Teach program establish the program events and enter the X and Y dimensions The second part is in the Program Mode This is where you complete the Teach events that you began in the DRO Mode by entering the rest of the data Once the data is entered the Teach events become just like the other events that make up a program 6 6 1 Entering Teach Data From the DRO screen press Teach On the top of the screen you will see the message Teach and an event counter When you enter Teach you are actually programming events If there is already a program in current memory Teaching will add events to the end of the program If there is not already a program in current memory
45. program events already in current memory when you change the multiple fixture from NO to YES they will all receive the default fixture number automatically When you change the default fixture number in the program header screen from one fixture to another all the events that had the previous default fixture number will be changed to the new default fixture number If there are no program events in current memory when you change the multiple fixture feature from NO to YES the prompt will be added to the end of every event you then program The default fixture number will be assumed if you press SET without specifying a different number If you do specify a different fixture number that fixture number will become the assumed input for subsequent events when SET is pressed 7 5 2 Fixtures and Running the Program To run the program first go to the DRO mode and set absolute 0 at the base fixture fixture 1 In the Run mode the SHOW ABS displays the absolute position relative to the fixture in the event being run that is the absolute dimension that was programmed 7 5 3 Editing Fixtures With the Multiple Fixtures featured turned to YES you may edit the fixture number in the Program Mode event by event You may also use the Search Edit feature in the Edit Mode to change fixture numbers See Section 11 4 for setting up fixture offsets Assumed I nputs The ProtoTRAK SM CNC will automatically program the following when you simply press SET
46. programmed using A G E Mill and A G E Arc events Programming with the Auto Geometry Engine is explained in Section 10 0 61 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 9 9 9 10 Helix Events The Helix Event is found after you press the MORE softkey from the Select Event screen It allows you to machine in a circular path in the XY plane while you simultaneously move the Z axis linearly Press the HELIX soft key X Center is the X dimension to the center of rotation of the helix Y Center is the Y dimension to the center of rotation of the helix Z Rapid is the Z dimension to transition from rapid to feed Z Begin is the Z dimension to the beginning of the helix Z End is the Z dimension at the end of the helix Radius is the radius from the center of rotation to the helix Angle is the angle from the positive X axis that is 3 o clock to the starting position of the helix Rev is the number of revolutions in the helix for example 0 75 would be 270 degrees or 3 25 would be three times around plus 90 degrees Direction is the clockwise input 1 or counterclockwise input 2 direction of the helix Tool Offset is the selection of the tool offset to right input 1 offset to left input 2 or tool center no offset input 0 relative to the programmed edge and direction of the cutter movement XYZ Feedrate is the feedrate from beginnin
47. sides are parallel to the X and Y axes The prompts for the rectangular pocket X1 is the X dimension to any corner Y1 is the Y dimension to the same corner as X1 X3 is the X dimension to the corner opposite X1 incremental is from X1 Y3 is the Y dimension to the same corner as X3 incremental is from Y1 Conrad is the value of the tangential radius in each corner Direction is the clockwise input 1 or counterclockwise input 2 direction for milling Fin Cut is the width of the finish cut If 0 is input there will be no finish cut XY Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Fin Feedrate is the milling feedrate for the finish cut Tool is the tool number you assign 8 5 3 Irregular Pocket Press the IRREG PCKT soft key if you wish to mill a pocket other than a rectangle or circle The Irregular Pocket event gives you the powerful Auto Geometry Engine to define a shape made up of straight lines Mills and arcs The first screen in an irregular pocket event will define the beginning point and some of its general parameters The last event of the irregular pocket must end at the same point as defined in the first event X Begin is the X dimension of the beginning of the pocket Y Begin is the Y dimension of the beginning of the pocket Fin Cut is the width of the finish cut If 0 is input there will be no finish cut Feedrate is the milling feedrate in in min from 1 to 100 or mm m
48. the A G E events don t have to be fully defined before you can go to the next one You can skip the data you don t know by using the DATA FWD softkey After you press the DATA FWD key at the last prompt the event will move to the left side of the screen and the Select Event screen will appear When skipping over prompts or editing always use the DATA FWD or DATA BACK key Using INC SET or ABS SET will change the data If you want the event back on the right side use the BACK hard key The OK NOT OK Flag Each A G E event has a flag that tells you if it has been fully defined Sometimes data from later events is needed to define previous events To the immediate right of the event type the words OK or NOT OK appear depending on whether that particular event is defined Once the OK flag appears for the event you do not need to enter more information Skip past the rest of the prompts with the DATA FWD softkey If you leave the Program Mode and then return pressing the GO TO END softkey will take you automatically to the first NOT OK event 71 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 10 6 Ending A G E 10 7 Any time all the events are of an Irregular Profile are OK the A G E may be ended If you are programming an Irregular Pocket there is an additional requirement that must be satisfied before the A G E may be ended the X and Y end p
49. the Program In Out Mode screen PROGWO Pno H BAXS INCH BACKUP lookin Ba FS RETURN F2 F3 Fa F5 F F DATA DATA OPEN Ta BACKUP Fi TAB FWD BACK FOLDER FROM TO FIGURE 14 8 Backing up The top part of the screen shows all the items in Drive A The bottom part shows the items that have been picked for backing up The basic procedure for backing up is 1 Use the navigation procedure described in Section 14 2 above and highlight the program file or folder you wish to back up 2 Press the BACKUP FROM softkey You will see the item appear along with its directory path in the new listing area under the main listing area 3 Repeat the above for as many items as you wish 103 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 14 9 4 Use the navigation procedure to select a different drive or a different folder 5 Open the drive or folder using the Open folder key 6 Press BACKUP TO When the back up operation is completed you will see the items and their directories in the new location Note You must set an absolute zero reference in the DRO Mode before machining the part You may use any tool that you have set up with the above procedure to set your reference and the ProtoTRAK will automatically compensate for the difference in the rest of the tools Converters Converters are programs within the ProtoT
50. the Z feedrate from Z rapid to Z end XYZ FEEDRATE the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 FIN FEEDRATE the finish milling feedrate for both the island and pocket finish cuts TOOL is the tool number you assign 9 7 3 Irregular Island Press the IRREG ISLAND key if you wish to mill an island other than a rectangle or circle The Irregular Island gives you the powerful Auto Geometry Engine to define a shape made up of straight lines and arcs The first screen in an Irregular Island event will define the beginning point and some of its general parameters The last event of the irregular pocket must end at the same point as defined in the first event Prompts for the Irregular Island event X BEGIN X dimension to the beginning of the island Y BEGIN Y dimension to the beginning of the island Z RAPI D is the Z dimension of the transition from rapid to feed Z END is the Z dimension at the bottom of the pocket incremental is from the previous event PASSES the number of roughing passes to the depth ENTRY MODE choose between zigzag ramp and plunge The plunge will machine straight down Z to the appropriate Z depth The zigzag ramp will move in a zigzag pattern to depth See the previous section for more information about the zigzag ramp FIN CUT ISL Finish cut for the Island If 0 is input there will be no finish cut See the previous section for a bottom finish cut X1 POCKET X dimension for on
51. the computer s that you are currently networked to Double click on the one you wish to map to and when opened you should see a list of all folders that we enabled sharing Right click on one of these folders and select Map Network Drive you should get a window like the one below Map Network Drive N 2 x ia Path A Csal d Cancel M Reconrectat logan Figure 14 12 5 7 Mapping 115 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 20 Choose an available drive letter of your choice make sure that the Reconnect at logon option is checked and click OK From now on the drive letter that you chose will be assigned as a shortcut to the shared folder which is actually a folder stored on the networked computer On your ProtoTRAK you will be able to see this drive when you go to PROG IN OUT and attempt to OPEN or SAVE your files Using the TAB button to move to the LOOK IN window you should now be able to save retrieve to and from your newly mapped network drive aL lt K EE Se SS Sc ci oe lt K lt lt lt DESKTOP PC DESKTOP Pe o 900000 oo Hub ROTO TRA YM A N a Wik HE SES ORS RE Eee O ee e ee DESKTOP PC FIGURE 14 12 6 Peer to Peer 3 desktop PC s and 1 SM CNC control hooked to a hub 14 12 6 Server and Client Net
52. then delete the original Use the Clipboard to paste previously stored events from another program into the current program After you press the Clipboard key you will enter the offset from the previous program s absolute zero to the current program s absolute zero see figure below For information about putting events into the clipboard see Section 11 4 SOURCE PROGRAM DESTINATION PROGRAM i00965 Figure 9 10 In the above example the offset that puts the group of holes in the desired location is X 1 50 and Y 1 00 Thread Mill Event To program a Thread Mill event press the Thread mill soft key This event includes an automatic move in and out of the thread Prompts in the Thread Mill event X CENTER the X dimension of the center of the thread Y CENTER the Y dimension of the center of the thread Z RAPID the Z dimension where the Z rapid feed slows to Z program feed Z BEGIN the Z dimension where the threading pass begins Z END the Z bottom of the thread 65 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual PITCH the distance from one thread to the next in inches or mm It is equal to one divided by the number of threads per inch For example the pitch for a 1 4 20 screw is 1 20 05 inches MAJOR DIA the largest diameter of the thread the root for an ID thread the crest for an OD thread MINOR DIA the smallest diameter of the thre
53. this window and go back to the first Network window 7 Highlight the line which reads TCP IP Realtek PCI Fast Ethernet 8 Click on Properties under the IP address tab select Specify an IP address Now type in an IP address making sure to match the first set of numbers with the IP address of the computer that you are connecting to You can obtain your computer s current IP number by going to START gt RUN gt WINIPCFG Otherwise you can manually enter one TCP IP Properties Figure 14 12 5 3 9 Click on the DNS Configuration tab and make sure that it is disabled 10 Click on the WINS Configuration tab and make sure that is disabled as well 11 Click on the Bindings tab and make sure that you have Client for Microsoft Network and File and printer sharing checked You will need these in order to log on correctly as well as be able to transfer files from one computer to the other 113 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual TCP IP Properties DNS Configuration Gateway WINS Configuration IP Address Bindings Advanced Nemos Click the network components that will communicate using this protocol To improve your computer s speed click only the components that need to use this protocol MV Client for Microsoft Networks WI Microsoft Family Logon Figure 14
54. to copy from Selects the last event to copy to Does not offset the pattern in X Offset the pattern in Y by 0 5 Does not change the Z Rapid plane Does not change the Z depth Copies the selected events 6 times Leaves the feedrate where it was Leaves the previous tool as the current tool Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual Select More then Copy then Repeat to do the drilling using Event 3 thru 9 info EVENT 10 COPY REPEAT NOTES for the drill 0 1 operation First Event Last Event X Offset Y Offset Z Rapid Offset Z Offset Repeats Feed Tool EVENT 17 3 abs 9 abs 5 5 inc set inc set inc set inc set 1 inc set inc set inc set BOLT HOTE Selects the first event to copy from Selects the last event to copy to Offset the pattern in X by 5 5 Does not offset the pattern in Y Does not change the Z Rapid plane Does not change the Z depth Copies the selected events 1 time Leaves the feedrate where it was Leaves the previous tool as the current tool NOTES drill for 0 5 bolt pattern Drill or Bore of Holes X Center Y Center Z Rapid Z End Radius Angle of Pecks for Drill Z Feedrate Tool 1 5 abs abs abs 1 abs 75 abs 1 625 abs 9 abs 6 abs 10 abs 3 abs Selects Drill Function Known print value Defaults to X zero Defaults to Y zero Set
55. tool move You may hold the STEP button down to draw the graphic without repeated button presses To complete the drawing automatically press FIT DRAW XY YZ XZ 3D shows the same drawing on the screen with adjustments in the view you select Soft keys in ADJ UST VIEW FIT same as the FIT DRAW va 4 gt moves the drawing in that direction ZOOM IN ZOOM OUT resizes the drawing RETURN returns to the previous soft keys retaining the adjustments that were made to the drawing 12 3 Reference Positions REF POSN The Reference Positions screen shows the retract status the home locations and software limits for all axes SET UP PINROAZA 17 CUd Tt ooo POSITION STATUS Z RETRACT X HOME 0 0000 abs Y HOME 0 0000 abs Z LOWER LIMIT OFF X LIMIT OFF X LIMIT OFF Y LIMIT OFF f Y LIMIT OFF Fi F2 F3 Fa F5 F A FE LIMITS DATA DATA ONIOFF FWD BACK siana FIGURE 12 3 Reference positions The Z Retract is not set Position the head and press a SET key 89 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 12 4 12 3 1 Z Retract three axis CNC The Z Retract is where the quill will go for a tool change or at the end of running a program Programs may not be run in three axis CNC until the Z Retract is set Since the Z axis quill is operated manually in two axis CNC it is not necessary to set the Z retract to run a two axis CNC pa
56. well Press the SYS hard key Softkey F2 will read GO TO 2 AXIS when the ProtoTRAK SM CNC is currently operating in three axis and it will say GO TO 3 AXIS when the ProtoT RAK SM CNC is currently operating in two axis See Figure 4 4 i01063 FIGURE 4 4 You will see this screen when the SYS hard key is pressed The choice GO TO 2 AXIS shows that the CNC is currently in 3 Axis operation Help Functions 16 Southwestern Industries Inc TRAK Knee Mill amp Proto TRAK SM CNC Retrofit Safety Programming Operating amp Care Manual When a blue question mark appears next to the HELP hard key that means special functions or configuration settings are available for the current operation For example at the program header with the highlight on the program name the blue question mark appears Pressing the HELP key at that time will call up a table with alpha and special characters you can use to name your program 4 5 1 Math Helps When the blue question mark does not appear pressing HELP will initiate the Math Helps MATH PINBRKTOOS BAXS INCH Line Line Intersection Line Arc Intersection Arc Arc Intersection Line Arc Tangency Centers Points Radius Angles Polar Cartesian Transformation Calculator OommoQgmr FIGURE 4 5 1 The first Math Helps screen Choose among the alternatives based on the information you need to calculate Math Helps are powerful routines that enable you to use the data you have
57. you program an event to have a fixture it will treat the offset as if it were absolute zero shift The programmed X Y and Z absolute dimensions are relative to the absolute reference for the specified fixture For example say you had two vises on the table On the first vise you established the lower left jaw as the absolute 0 At the same time you measured the distance between the absolute zero you just established and the lower left jaw of the other vise You entered that measurement as an offset from your base vise the first one and the other vise which is fixture 2 Any events that you programmed using fixture 2 would treat the lower left corner of that second vise like the absolute 0 for the X Y and Z dimensions in the events Fixture offsets are handy for combining different programs together to run at the same time or to make multiple parts by repeating the events with different fixtures The fixture offsets are entered in the Set up mode There is a base fixture called fixture number one We recommend that event 1 in your program uses fixture number one It doesn t have to we just believe it is clearer that way 33 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 7 6 7 7 7 5 1 The Default Fixture In the program header screen you entered a default fixture number if you didn t it assumed fixture 1 as the default fixture If there are
58. you wish to mill a profile other than a rectangle or circle The Irregular Profile event gives you the powerful Auto Geometry Engine to define a shape made up of straight lines Mills and arcs The Irregular Profile is a series of events that are programmed to machine continuously The first event of the series will be called an IRR PROFILE and it will define the beginning point of the profile and other information that applies to the entire profile X Begin is the X dimension of the beginning of the profile Y Begin is the Y dimension of the beginning of the profile Z Rapid is the Z dimension to transition from rapid to feed Z End is the Z dimension of the depth of the profile Tool Offset is the selection of the tool offset to right input 1 offset to left input 2 or tool center no offset input 0 relative to the programmed edge and direction of tool cutter movement Passes is the number of cycles to machine to the final depth spaced equally from Z rapid to Z end hint keep Z Rapid small Z Feedrate is the Z feedrate from Z rapid to Z end XYZ Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Fin Cut is the width of the finish cut If 0 is input there will be no finish cut Fin Feedrate is the finish cut milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Tool is the tool number you assign When the initial Irregular Profile screen is complete the rest of the profile is
59. yourself using a simple procedure 1 Go to Set Up Mode Service Codes then A Software 2 Press the soft key for Service Code 318 3 A screen will appear that lists all the converters available for the version of ProtoTRAK SM CNC software that you have The converters that are active are listed in black the inactive converters are grayed out See Figure 14 9 1 4 Place the cursor over the inactive converter you want 5 Press the Install soft key 6 There is a password that enables you to use the converter Enter the password in the Data Input Line and press Set If you do not have the password call the SWI Customer Service Group at 800 367 3165 You will need to make arrangements to pay the fee for the converter before you are given the password 104 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual Southwestern Industries Inc Southwestern Industries Inc Southwestern Industries Inc F6M Haas Automation Inc Southwestern Industries Inc GCD AutoDesk Inc AutoCad DXF i01056 FIGURE 14 9 1 Service Code 318 displays a list of converters available on the ProtoTRAK SM CNC software version you are running On this list the first three converters are active the rest are not active 14 9 2 Converting From a Different Format into a ProtoTRAK SM CNC Conversions from a different format into a ProtoTRAK SM CNC occur when the
60. 00 abs TANGENT Y BEGIN 0 0000 abs X END SSS Z RAPID 0 0250 abs YEND Z END 0 8560 abs CONRAD TOOL OFFSET RIGHT ANGLE END PASSES 4 LENGTH FIN CUT 0 0100 LINE ANGLE Z FEEDRATE 3 0 XYZ FEEDRATE 17 5 FIN FEEDRATE 20 0 TOOL 1 Guess for X END l ia Fi F2 F3 F4 FS F6 FT FS PAGE PAGE DATA DATA DATA INSERT DELETE GUESS FWD BACK FWD BACK BOTTOM EVENT EVENT Figure 10 8 1 When the Data Input Line says Enter Guess pressing LOOK gives you the ability to use graphics to make your guesses On the screen shown in the figure above the Data Input Line says Enter Guess for X BEG Pressing LOOK at this point will take you to a special version of the LOOK graphics Using a mouse or the cursor keys you may move a point around the screen When you come to the place where your point is use the Enter key The softkeys for this special version of the LOOK graphics gt M V move the cursor around the screen ZOOM IN makes the drawing larger ZOOM OUT makes the drawing smaller ENTER END when the cursor is at the point you want to use as a guess use this to enter the end point of a line or an arc ENTER CENTER use this to enter a guess for the center of an arc You can enter a combination of guessed and non guessed data For example if you were to enter the dimension for X End without guessing you would still be able to enter the dimension of Y End using guess 73 Southwestern Industries Inc TRAK Knee Mill am
61. 00 inc 0 0000 0 0000 inc 0 0000 inc 0 0000 inc 5 0 10 0 0 0000 inc 0 0000 ZFEEDRATE N o F2 F3 F4 FS F FF Fa PAGE PAGE anor CHANGE wo pack Y a 4 p SORT ALL FIGURE 11 2 3 After sorting by Event Type the highlighter is placed on the Z feed of the first Mill Event EDIT PIN R0424 11 3 AXIS INCH EVT TYPE TOOL A NE FIN Z RAPID CONRAD FEED FEED FEED Cu Bon HOLE 3 01075 25 BOLT HOLE 1 0 2500 50 36 BOLT HOLE 3 0 1875 5 0 4 MILL 2 0 3750 BER 10 0 s m 20 3750 RQ 100 6 MILL 2 0 3750 SEO 0 0000 inc MILL 3 0 1875 EO 0 0000 ine 5 0 0 0000 inc 0 0000 0 0000 0 0000 0 0000 inc 0 0000 inc 0 0000 j ZFEEDRATE ERO Fi F3 Fa FS Fi Fr FS RETURN FIGURE 11 2 4 Pressing the Change All softkey highlights the Z feed for all the Mill events 80 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual SS AXIS INCH EDI l PIN R0424 11 Z XYZ T EVT TYPE TOOL FEED FEED 14 BOLT HOLE 3 0 1875 50 25 BOLT HOLE 1 0 2500 36 BOLT HOLE 3 0 1875 4 Mut 2 0 3750 MILL 2 0 3750 MILL 2 0 3750 3 0 1875 3 0 1875 3 0 1875 MILL 2 0 3750 MILL 2 0 3750 MILL FIGURE 11 2 5 Type the new Z Feed and then SET to change all the highlighted values from 5 t
62. 000 12 Posmon 3 0 1875 0 1000 abs al 7 TOA O o Fi F2 F3 F4 F5 FG Fr FS PAGE PAGE CHANGE rwo pack 4 P SORT au FIGURE 11 2 1 The Search Edit softkey launches Spreadsheet Editing View the entire program by the variables you select 77 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual The first time the screen appears the data is sorted by event number Each row represents the data for the event number shown in the first column on the left The event number is always displayed in the first column but the other data displayed on the table can be changed Soft Keys in Search Edit PAGE FWD pages forward through the table PAGE BACK pages backwards through the table va 4 gt highlights data for editing Only data that is highlighted and appears in the Data Input Line may be edited Note the EVT event number and event TYPE may not be edited in Search Edit so the highlighter will not go there SORT enables you to change the sort to any of the data displayed See Section 11 2 2 CHANGE ALL enables you to make global changes of data See 11 2 3 11 2 1 Selecting Data to be Displayed on the Search Edit Table In order to change the data selected in the table press the HELP hard key There will be a listing of all the data types that may be edited in Search Edit Press the RETURN soft key and the table will be r
63. 11 G Code Description G00 Rapid positioning G01 Linear interpolation G02 Circular interpolation CW G03 Circular interpolation CCW G20 Input in inch G21 Input in metric G40 Cutter compensation cancel G41 Cutter compensation left G42 Cutter compensation right G54 Work coordinate system 1 selection G55 Work coordinate system 2 selection G56 Work coordinate system 3 selection G57 Work coordinate system 4 selection G58 Work coordinate system 5 selection G59 Work coordinate system 6 selection G73 Peck drilling cycle G80 Hole machining canned cycle cancel G81 Drilling cycle spot boring G82 Drilling cycle counter boring G83 Face hole machining cycle G84 Tapping canned cycle VM only G85 Face boring cycle G89 Boring cycle dwell at bottom G90 Absolute programming G91 Incremental programming G98 Return to initial point in canned cycle G99 Return to point R in canned cycle 14 14 3 Supported Addresses CAM information is communicated through the use of ADDRESS WORD pairs For example in the line NO1GOX1 Y2 N G X and Y are addresses The other information 01 1 and 2 are Data Words The line starts with the Address N and the data word 01 The N address is defined as meaning LINE NUMBER therefore NO1 means Line 1 and so on 123 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manu
64. 12 5 4 TCP bindings 12 Close this window and return to the original Network window Click on the Identification tab 13 Compare these settings to the ones on your computer and make sure that workgroup is the same for both and that they each have unique computer names See Figure 14 12 5 5 Configuration Identification Access Control Windows uses the following information to identify your SS computer on the network Please type a name for this Computer the workgroup it will appear in and short description of the computer Computer name PT4 Workgroup sii Computer Description 1T Figure 14 12 5 5 Identification 14 Finally close the windows Restart the ProtoTRAK 15 On your computer you want to make sure using the same steps that you have TCP IP installed matching workgroups unique computer names unique IP addresses that will work together 192 162 0 1 amp 192 162 0 2 for example Client for Microsoft Windows and file and printer sharing enabled 16 Restart both the computer and your ProtoTRAK To verify that we have successfully networked both computers together on your desktop double click on Network Neighborhood You should see each other s computer name here If not contact SWI customer service or your systems administrator for technical support 114 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual No
65. 212 MILLING MACHINES Ta SOUTH WESTERN INDUSTRIES E 2615 HOMESTEAD PLACE RANCHO DOMINGUEZ CA 90220 voL O O RE S E a ER ELECTRICAL RATINGS IELTS es jamps 3 PHASE 60_ Hz FLA OF LARGEST MOTOR AMPS SHORT CIRCUIT INTERRUPT AMPS ELECTRICAL DRAWING 20598 1 CNC CONTROL ELECTRICAL RATINGS IF APPLICABLE VOLTS _8 JAMPS 1 PHASE C60 Hz k MACHINE ONLY MADE IN XXXXXX O i00902 Safety amp Information Labels Used On The TRAK Knee Mills It is forbidden by OSHA regulations and by law to deface destroy or remove any of these labels Retrofit customers please see the manual that came with your machine for information about safety and information labels 4 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual HIGH VOLTAGE 230 VOLTS WARNING IMPROPER INSTALLATION OR OPERATION OF THIS MOTOR MAY CAUSE INJURY TO PERSONNEL OR MOTOR FAILURE READ OPERATING INSTRUCTIONS MOTOR MUST BE INSTALLED AND GROUNDED PER LOCAL AND NATIONAL ELECTRICAL CODES TO REDUCE POTENTIAL OF ELECTRICAL SHOCK DISCONNECT ALL POWER SOURCES BEFORE INITIATING ANY MAINTENANCE OR REPAIRS KEEP FINGERS AND FOREIGN OBJECTS AWAY FROM VENTILATION AND OTHER OPENINGS KEEP AIR PASSAGES CLEAR EYEBOLTS OR LIFTING HOOKS WHEN SUPPLIED ARE INTENDED FOR LIFTING THE PRODUCT ONLY AND MUST NOT BE
66. 9 degrees negative angles measured clockwise Pecks is the number of tool withdrawal cycles each cycle drills progressively less and retracts to the Z Rapid position The factory setting is for each peck to be successively smaller taking the largest cuts at the beginning and the smallest at the end When the highlight is on this prompt you may change this setting by pressing the HELP key This will take you to a screen where you may choose to have the same amount of material taken per peck Z Feedrate is the drilling feedrate Tool is the tool number you assign MILL Events This event allows you to mill in a straight line from any one XYZ point to another including at a diagonal in space It may be programmed with a CONRAD if it is connective with the next event this next event must lie in the same plane as the Mill event Prompts for the Mill event X Begin is the X dimension to the beginning of the mill cut Y Begin is the Y dimension to the beginning of the mill cut Z Rapid is the Z dimension to transition from rapid to feed Z Begin is the Z dimension to the beginning of the mill cut X End is the X dimension to the end of the mill cut incremental is X Begin Y End is the Y dimension to the end of the mill cut incremental is Y Begin Z End is the Z dimension to the end of the mill cut incremental is Z Begin Conrad is the dimension of a tangential radius to the next event that must lie in the same plane for part ge
67. A OPEN CREATE SAVE TAB FWD BACK BEP Ee FILE rerun FIGURE 14 9 3 Use the Save As box to tell the ProtoTRAK SM CNC what file format you want to end up with Use the Save As box to tell the ProtoTRAK SM CNC what kind of file you want the current program in the PT4 format to be converted into In Figure 14 9 3 the file name 070501 is being saved on drive A as a mx3 file Note that although the program or part name as shown in the status line is BRKT005 the file name given for converting the file conforms to the mx3 format fewer than eight characters long and consisting of numbers 14 10 ProtoTRAK and TRAK CNC Compatibility File exchange between the ProtoTRAK SM CNC and other ProtoTRAK and TRAK CNC s is possible because the ProtoTRAK SM CNC is backward compatible In other words the ProtoTRAK SM CNC can store and retrieve other ProtoTRAK and TRAK CNC files The actual transfer of the files can be accomplished by using a floppy disk zip disk RS232 and or Ethernet cable In order to 106 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual transfer files between the ProtoTRAK SM CNC and previous generations of ProtoTRAK and TRAK CNC you must have the MX2 and MX3 converters activated See Section 14 9 above Note Previous ProtoTRAK and TRAK CNC s allow numeric filenames of eight 8 characters or less while the ProtoTRAK SM CNC allow alphanumeric f
68. CNC Retrofit Safety Programming Operating amp Care Manual End A G E Ends the A G E programming for the Irregular Pocket or Irregular Profile Abort A G E Aborts all A G E events The data for all the events is lost 10 2 A G E Mill Prompts Press the A G E Mill key PROG PIN PIN 0812 2 TOOL 1 3 AXIS INCH EVENT 1 IRR PROFILE EVENT2 A G E MILL bet X BEGIN 0 0000 abs TANGENT Y BEGIN 0 0000 abs XEND 0 0000 abs Z RAPID 0 0500 abs Y END Z END 0 2500 abs CONRAD TOOL OFFSET RIGHT ANGLE END PASSES 2 LENGTH FIN CUT 0 0100 LINE ANGLE Z FEEDRATE 4 0 XYZ FEEDRATE 15 0 FIN FEEDRATE 10 0 TOOL FIGURE 10 2 A G E Mill prompts Enter what you know skip or guess the ones you don t Prompts in A G E Mill programming Tangent this refers to the tangency of the mill to the previous event See Section 10 11 for a discussion of tangency X END is the X dimension to the end of the mill cut incremental is X Begin Y END is the Y dimension to the end of the mill cut incremental is Y Begin CONRAD is the dimension of a tangential radius to the next event ANGLE END is the angle measured counterclockwise from this mill event to the next Do not input if the next event is an arc LENGTH is the length of the mill from beginning to end LINE ANGLE is the angle of this mill line moving from begin to end measured counterclockwise from the positive X axis that is 3 o clock GUESS This softkey wi
69. EGIN 0 0000 abs XEND G 1 0000 abs Z RAPID 0 0500 abs Y END Z END 0 2500 abs CONRAD TOOL OFFSET RIGHT ANGLE END PASSES 2 LENGTH FIN CUT 0 0100 LINE ANGLE Z FEEDRATE 4 0 XYZ FEEDRATE 15 0 FIN FEEDRATE 10 0 TOOL 1 YEND i Fi F2 F3 F4 F5 F FT FS PAGE PAGE DATA DATA DATA INSERT DELETE FWD BACK Fwo BACK Bottom event Event SUESS FIGURE 10 7 The X End dimension has been entered as a guess note the letter G Guesses should always be entered as absolute dimensions Once entered the system labels the guessed data by placing a G next to it Guessed data will be labeled this way in all the events that are flagged NOT OK Once an event is OK the guessed data will be 72 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual replaced by calculated data If you wish to edit your guesses placing it on the right side of the screen will cause your original guessed data to reappear 10 8 LOOK and Guess Guessed data may be entered by pressing the number keys and then SET However you may find it more convenient to use the LOOK graphics to enter guesses When the highlight is on the prompt for which you wish to enter a guess press the Guess key The Data Input Line will say Enter Guess for X END for example At this point press the LOOK key PROG PIN SWIG17KL 3 AXIS INCH Nol EVENT1 IRR PROFILE EVENT2 AGE MILL P X BEGIN 0 00
70. Engrave Event allows you to machine numbers letters and special characters as part of a part program See figure 9 14 below for the letters and special characters that are available in the Engrave Event When programming with the Engrave Event the ProtoTRAK will construct a box to contain the text you define This box is oriented along the X axis like the text in this sentence and you may program up to 40 characters per event although you will only be able to see 20 characters on the prompts screen To machine text in a direction other 66 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual than the X axis simply use multiple Engrave Events and place the lower left corner of the box wherever you would like The numbers and letters you program will always have a standard orientation like the letters on this page you cannot program tilted or inverted letters with the Engrave Event The letters are of the font shown in the figure and all capitals Prompts for the Engrave Event First define the lower left corner of the box that will contain your text X BEGIN The X coordinate of where you want your text to begin Y BEGIN The Y coordinate of where you want your text to begin Z RAPID The Z dimension where the Z rapid feed slows to Z program feed Z END The Z dimension to the bottom of your text HEI GHT The height of your text Each character varies in width t
71. Input the number of the first event you wish to run and press SET If the START EVNT is a Repeat or Rotate the conversation line will prompt Starting Repeat Number asking which repeat or pass you wish to start 13 4 Program Run When you have started by any of the means above the display will show RUN PIN R0424 11 TOOL 1 3AXIS INCH Event 1 RUN Repeat 0 X 0 0000 ss Y 0 0000 ss Z 0 0000 s geag Feed Rate 100 0 M Override 100 Fi F2 F3 Fa F5 Fe FT FS SHOW SHOW SHOW SHOW ABS INC PATH PROG FIGURE 13 4 Press the GO feed key to start running Where The part number being run is shown in the status line 94 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 13 5 13 6 13 7 13 8 e A S F message will appear in the status line when the Scale Factor is not set at 1 0000 e The event number and type and the repeat number if applicable being run is shown at the top of the screen e The current X Y Z absolute positions are shown in the information area e The SHOW ABS soft key which is automatically assumed if one of the other 3 show keys are not selected will show the absolute X Y Z positions as the part is run e The SHOW INC soft key will show the incremental or distance to go within the event X Y Z positions as the part is run e The SHOW PATH soft key will show the tool path graphics as the part
72. ND is the Z dimension at the bottom of the pocket incremental is from the previous event CONRAD ISL the value of the tangential radius in the corners of the island DIRECTION is the milling direction clockwise or counterclockwise PASSES the number of roughing passes to the depth ENTRY MODE choose between zigzag ramp and plunge The plunge will machine straight down Z to the appropriate Z depth The zigzag ramp will move in a zigzag pattern to depth See the previous section for more information about the zigzag ramp FIN CUT ISL Finish cut for the Island If 0 is input there will be no finish cut See the previous section for a bottom finish cut X1 POCKET X dimension for one corner of the rectangular pocket that surrounds the island Y1 POCKET Y dimension for one corner of the rectangular pocket that surrounds the island X3 POCKET X dimension for the opposite corner of the rectangular pocket that surrounds the island Y3 POCKET Y dimension for the opposite corner of the rectangular pocket that surrounds the island 58 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual CONRAD PCKT the value of the tangential radius in the corners of the rectangular pocket that surrounds the island FIN CUT PCKT finish cut along the perimeter of the pocket If 0 is input there will be no finish cut See the previous section for a bottom finish cut Z FEEDRATE is
73. NLY AVAILABLE ON K2 AND K3 K2 Figure 16 3 Machine dimensions K3 100252 K4 Table Size 9 x 49 10 x 50 10 x 50 T Slots number x width x depth 5 8 x3 x2 1 2 5 8 x3 x2 1 2 5 8 x3 x2 1 2 Dimension A Dimension B Min 85 54 86 54 92 56 Dimension B Max 68 78 80 Dimension C Min Dimension C Max 30 46 30 46 33 50 Dimension D 102 102 102 Dimension E Dimension F 38 24 40 25 45 26 Weight approx net 2400 Ib 3060 Ib 3630 Ib Weight approx shipping Pallet Size 1 machine pallet 2700 Ib 3360 Ib 4290 lb 70 x70 70 x70 70 x70 2 machines pallet 90 x66 136 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 90 x66 90 x66 16 4 Machine Specifications K2 K3 K4 Movement amp Ranges X Y Z axis 33 x12 x16 32 x16 x16 32 x16 5 x16 5 Quill Travel maximum 5 Spindle Head a Quill Diameter 3 15 16 b Spindle Taper R8 NST40 d Spindle Nose to Table max part ht 16 16 16 e Quill Feeds Per Rev of Spindle 0 0015 0 008 0 006 Tilt 452 Forward 452 Back 902 Right Tit Forward 902 Right 902 Left 902 Left Spindle Motor
74. Only one file may be copied at a time using this operation To copy multiple files or folders see Section 14 8 100 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 14 6 PRs O O TOO TOO A BAS INCH COPY Look In fea Captsisv TEST PROGRAMS t E BALLBAR PT4 E DPMV3 EXERCISE PT4 B DPMVS5 EXERCISE PT4 B EUCLD PT4 B TAP ALUMINUM PT4 H TAP STEEL PT4 H XREPEAT PT4 B Y REPEAT PT4 H ZREPEAT PT4 File Name Fi F2 F3 Fa FA F F a DATA DATA OPEN copy PASTE TAB FWD BACK Ea FILE FILE RETURN FIGURE 14 5 The Copy screen The copy operation is in two parts First use the navigation procedure described in Section 14 2 above and highlight the program you wish to copy Press the COPY FILE softkey to copy the file Then go to the new file or drive open it using the Open Folder softkey and press Paste file Once the file has been copied it can be pasted to as many other locations as you want Additional softkeys in COPY COPY FILE Makes a copy of the highlighted file PASTE FILE Writes a copy of the file to the location shown in the Look In box RETURN Returns to the Program In Out Mode screen When the pasting operation is finished you will see the file name added to the listing area Deleting Programs Programs in current memory are removed from current memory in Edit Mode See Section 11 3 To remove a program file
75. Operating amp Care Manual In addition you may want to modify this program in order to get all the events you want together For example if you want to copy events 2 5 and 7 12 you may want to modify the program to delete events 1 and 6 first That way you can copy the all the events as they are now numbered from 1 to 10 Remember that you can modify this program just for this purpose and it will not affect the original program unless you save it with the modifications in the Program In Out Mode When the source program is ready press the CLIPBOARD softkey A message will appear that says Copy Events Onto Clipboard and the Data Input Line will read From Event Enter the number of the first event that you want copied and press SET The Data Input Line will read To Event Enter the number of the last event you want copied and press SET The group of events that you have specified is now on the clipboard and will remain there until you replace it with something else by going through the same procedure When power is turned off to the CNC the clipboard information will also be lost The events on the clipboard are inserted into a program in the Program Mode See Section 9 10 82 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 12 0 Set Up Mode The Set Up Mode contains the tool library the tool path graphics and the machine s reference positions Ent
76. RAK A G E 3 CNC s The ProtoTRAK SM CNC uses the extension PT4 whether the program is two or three axis Before opening the file the ProtoTRAK SM CNC is able to determine what kind of file it is A file extension that is unique to the ProtoTRAK SM CNC is GCD The GCD extension tells the ProtoTRAK SM CNC that a particular program is a standard RS274 or G Code program When you specify this extension the ProtoTRAK SM CNC will treat that program in a special way This is explained in Section 14 9 2 14 1 Softkey Selections in the Program In Out Mode YES to display only supported programs NO to display all files OPEN to bring a program from storage into the current memory SAVE to save the program that is in current memory to storage COPY to select and make a copy of a file in storage for pasting in another storage location DELETE to remove a file from a storage location without altering the current memory RENAME to rename a file or folder BACK UP to perform a convenient back up of program files to another storage location 14 2 Basic Navigation of Program I n Out Mode Screens The screens in the Program In Out Mode do not have the normal ProtoTRAK look and feel because they are derived from the Windows operating system Most functions may be performed using a mouse or keyboard Softkeys are provided to operate the system through the control s keys 14 2 1 Basic Parts of the Program In Out Mode Screens The status line a
77. RAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual Section 2 of this manual provides important safety information It is highly recommended that all operators of this product review this safety information Section 3 provides a description of the ProtoTRAK SM CNC Section 4 describes the operation of the milling machine and some basic operations of the ProtoTRAK SM CNC Section 5 defines some terms and concepts useful in learning to program and operate the ProtoTRAK SM CNC The ProtoTRAK SM CNC is organized into six Modes of operation that are described in the following sections Section 6 DRO Digital Readout jog and powerfeed operations Section 7 Program Mode Getting Started covers some general programming information and instructions on starting new programs Section 8 Two Axis Program Events instructions for the canned cycles or events used to program the ProtoTRAK SM as a two axis CNC Section 9 Three Axis CNC Program Events instructions for programming in three axis CNC Section 10 Auto Geometry Engine Programming instructions for programming profiles and pockets using the powerful Auto Geometry Engine Section 11 Edit Mode for routines to make large scale changes to programs in current memory including the powerful Spreadsheet Editinge Section 12 Set Up Mode Tool information part graphics and special codes Section 13 Run Mode Instructions on running a program to mach
78. RAK SM CNC that translate CNC program files of another format into a ProtoTRAK SM CNC file or a ProtoTRAK SM CNC file into a different format With converters you can run programs written on the ProtoTRAK SM CNC on a machine that does not have a ProtoTRAK SM CNC and vice versa Each ProtoTRAK SM CNC comes with converters for other ProtoTRAK and TRAK CNC s Converters for other brands of CNC s are sold separately Program conversions take place by first translating the file into a neutral run engine then from neutral to the desired file format For this reason you should think of conversions as being only one way The conversion process changes the file in ways that are harmless and so the results are correct However when converted back it will not be the same as it was originally written it will create the same part but some of the lines of code will be different 14 9 1 Activating Converters Converters must be activated before you can use them Standard converters include those that handle the translation between the ProtoTRAK SM CNC and other TRAK CNC s Optional converters are purchased separately Standard converters and optional converters that are ordered and shipped with the machine are activated at the factory You can tell which converters are activated by looking in the Open As see Figure 14 9 3 or Save As windows see Figure 14 4 If you purchase a converter after you have installed your machine you must activate it
79. STR Restore Then input the correct number and press SET If incorrect data has been entered and SET you may correct it as long as you are still programming that same event Press the DATA BACK or DATA FWD Forward soft key until the incorrect prompt and data are highlighted and shown in the conversation line Enter the correct number and SET The ProtoTRAK SM CNC will not allow you to skip past prompts by pressing DATA FWD which need to be entered to complete an event except when using the A G E in the Irregular Pocket or Irregular Profile event Previous events may be edited by pressing the BACK hard key to the left of the soft keys The previous event will be shifted from the left side of the screen to the right and may be edited The BACK key may be pressed all the way to the Program Header Screen the PAGE BACK softkey will work as well 36 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 7 11 LOOK 7 12 As you program each event it is helpful to see your part drawn For quick graphics while in the Program Mode press the LOOK hard key This function is active at the end of each event or whenever the conversation line is prompting Select Event Press the LOOK key and the ProtoTRAK SM CNC will draw the part Press LOOK again or BACK to bring back the Select Event screen You may also select a new view or adjust the view Softkeys in LOOK ADJ US
80. T VIEW gives additional options for adjusting the view of the drawing See below FIT DRAW automatically resizes the drawing to fit the entire part program on the screen LIST STEP displays the list of events on the left side of the screen and with a purple highlight on the first event As LIST STEP is pushed the highlight shifts to the next event As this happens that event is also highlighted in the graphics by having its color change to purple START EVENT NUMBER will prompt you to enter an event number for highlighting This is useful for moving quickly to a particular event in a large program XY displays a view in the XY plane YZ displays a view in the YZ plane XZ displays a view in the XZ plane 3D displays an isometric view Softkeys in Adjust view FIT DRAW automatically resizes the drawing to fit the entire part program on the screen v shifts drawing down a shifts drawing up 4 shifts drawing to the left gt shifts drawing to the right ZOOM IN makes the drawing larger ZOOM OUT makes the drawing smaller RETURN returns you to the first LOOK screen The adjustments you made will stay on the screen until you press another selection that overrides those adjustments The LIST STEP function may be used with the adjustment unaltered Note The LOOK routine does not check for programming errors Use Tool Path in the SET UP Mode to check movement of the tool Finish Cuts The Pocket and Profile events
81. TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual Document P N 23243 Version 071204 Covers models e Retrofit PTSM2 PTSM3 e TRAK Knee Mill with 2 Axis CNC TRAK K2S TRAK K3S TRAK K4S e TRAK Knee Mill with 3 Axis CNC TRAK K2S 3 TRAK K3S 3 TRAK K4S 3 Southwestern Industries Inc P O Box 9066 Compton CA 90224 9066 USA T 310 608 4422 F 310 764 2668 Service Department 800 367 3165 e mail sales southwesternindustries com service southwesternindustries com web southwesternindustries com Copyright 2004 Southwestern Industries Inc All rights are reserved No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means mechanical photocopying recording or otherwise without the prior written permission of Southwestern Industries Inc While every effort has been made to include all the information required for the purposes of this guide Southwestern Industries Inc assumes no responsibility for inaccuracies or omission and accepts no liability for damages resulting from the use of the information contained in this guide All brand names and products are trademarks or registered trademarks of their respective holders Southwestern Industries Inc 2615 Homestead Place Rancho Dominguez CA 90220 Phn 310 608 4422 Fax 310 764 2668 Service Department Phn 800 367 3165 Fax 310 886 8029 1 1
82. TRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 8 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 3 0 Description of the ProtoTRAK SM CNC The ProtoTRAK SM CNC is available as either a two axis CNC or as a three axis CNC both with three axis DRO For work typically done on knee mills the two axis CNC is usually preferred because of its simplicity and ease of use 3 1 Display Pendant Front see Figure 3 1 ROTO TRA SM a PROTO AUTO GEOMETRY ENGINE oo a 100741 FIGURE 3 1 The ProtoTRAK SM CNC front panel 3 1 1 Keyboard Hard Keys Feed Keys GO initiates motion in Run The green LED on the GO key will be lit when the servomotors are moving the machine either in jog or when the program run has been initiated by the GO key STOP halts motion during Run The red LED on the STOP key will be lit when the servos motors are not moving the machine FEED feedrate override to increase feedrate up to 150 FEED W feedrate override to decrease feedrate down to 10 ACCESSORY This key is used only for controlling a coolant pump or mister through the optional auxiliary functions box If you do not have the optional Auxiliary functions available for the three axis CNC only this key is not used When the switch is in the On position the coolant pump or mister will come on and stay on during machining operations In t
83. Teaching will start a new program For example if you already had a program in current memory that had 10 events when you press Teach the event counter will say EVENT 11 If there was no program the event counter will say EVENT 1 The event counter shows the event for which data is being entered You may teach in position drill and mill events only On the first Teach screen the softkeys are POSN a position move For two axis programming the POSN and DRILL events are combined DRILL a drill or bore MILL BEGIN the beginning of a straight line or MILL event END TEACH ends the teaching process and returns you to the main DRO screen 27 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 6 7 6 8 If you press the POSN or DRILL key the event counter will go up by one and the screen remains the same If you press the MILL BEGIN key the event counter stays on the same number That is because you have given the beginning point of the line but not yet the end The softkey selections will change to MILL END the last point of the Mill event Press this to end the Mill event and select a POSN DRILL or new MILL event MILL CONT the last point of the current Mill event but the beginning of the next Mill event You may enter successive Mill events by pressing the MILL CONT key Pressing either of the above softkeys will cause the event counter to
84. USED TO LIFT ADDITIONAL WEIGHT USE ONLY GRADE 5 SHOULDER EYEBOLTS WITH MINIMUM THREAD LENGTH OF 1 1 2 TIMES DIAMETER Safety amp Information Labels Used On The ProtoTRAK SM CNC It is forbidden by OSHA regulations and by law to deface destroy or remove any of these labels 5 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 2 3 Safety Precautions L 10 11 12 13 Do not operate this machine before the ProtoTRAK SM CNC Safety Installation Maintenance Service and Parts List Manual and the this Safety Programming Operating amp Care Manual have been studied and understood Do not run this machine without knowing the function of every control key button knob or handle Ask your supervisor or a qualified instructor for help when needed Protect your eyes Wear approved safety glasses with side shields at all times Don t get caught in moving parts Before operating this machine remove all jewelry including watches and rings neckties and any loose fitting clothing Keep your hair away from moving parts Wear adequate safety headgear Protect your feet Wear safety shoes with oil resistant anti skid soles and steel toes Take off gloves before you start the machine Gloves are easily caught in moving parts Remove all tools wrenches check keys etc from the machine before you start Loose items can become dan
85. abs Sets the pocket cutting feedrate to 20 ipm Fin Feedrate 15 abs Sets the finish pocket feedrate to 15 ipm Tool abs set Sets tool to default 1 EVENT 2 Bolt Hole NOTES drill for 0 1 bolt pattern Drill or Bore 1 Selects Drill Function of Holes 5 abs Known print value X Center abs Defaults to X zero Y Center abs Defaults to Y zero Z Rapid l abs Sets the rapid plane to 0 1 Z End 6 abs Sets the drill depth to 0 6 Radius 1 625 abs The radius of the bolt hole circle Angle 45 abs Angle of first hole from zero 0 degrees of Pecks for Drill 6 abs Sets drill function for 6 pecks Z Feedrate 10 abs Sets Z plunge rate to 10 ipm Tool 2 abs Selects Tool 2 0 1 drill EVENT 3 DRILL NOTES center drill for 0 1 hole patterns Drill or Bore 1 abs Selects Drill Function X 2 75 abs Known print value Y 1 5 abs Known print value Z Rapid l abs Sets the rapid plane to 0 1 Z End 6 abs Sets the drill depth to 0 1 of Pecks for Drill 6 abs Sets drill function for 6 pecks Z Feedrate 5 abs Sets Z plunge rate to 5 ipm Tool inc set Keeps Tool 2 0 1 drill Select More then Copy then Repeat to do the drilling using the previous event info EVENT 4 COPY REPEAT NOTES for the drill 0 1 operation First Event Last Event X Offset Y Offset Z Rapid Offset Z Offset Repeats Feed Tool 3 abs 3 abs inc set 5 inc set inc set inc set 6 abs inc set inc set Selects the first event
86. ad the root for an OD thread the crest for an ID thread SIDE input 1 for inside 2 for outside ANGLE the angle the tool feeds into the beginning depth PASSES the number of passes to cut the thread to its final depth DIRECTION clockwise or counterclockwise Z FEEDRATE the feedrate from Z Rapid to Z Begin XYZ FEEDRATE the feedrate of XYZ along the path of the helix FIN CUT width of the finish cut If 0 is input there is no finish cut If something other than 0 is input for finish cut the following prompt appears FIN FEEDRATE the milling feedrate for the finish cut 9 13 PAUSE Events 9 14 The purpose of the Pause Event is to allow you to program a stop condition within the program The effect of this event is to turn off the spindle move the head to the Z retract location with the X and Y position corresponding to the end of the previous event and stopping the program run Pause events are useful if you want to stop the program to activate an indexer make a measurement change a fixture etc NOTE In general you should avoid programming a PAUSE event between two connective events The Pause event will cause the events to NOT be connective To program a Pause Event press the PAUSE soft key Because there is no input required simply press SET to load and the event counter will advance by one and the Select Event screen will reappear In run press the GO key after a pause to continue Engrave Event The
87. afety Programming Operating amp Care Manual 9 15 Finishing Teach Events Teach events are either POSN DRILL or MILL events that are originated in the DRO Mode see Section 6 6 The Teach events that are started in the DRO Mode must be finished in the Program Mode before running Teach events are of these different types TEACH POSN for two axis operation the Position and Drill event types are combined See Section 8 1 for a description of Position event prompts TEACH DRILL this may also be made into a bore event See Section 8 2 for a description of Drill event prompts TEACH MILL a straight line that specifies the beginning and the end When TEACH MILL events are defined using the CONT MILL softkey the prompts for information that cannot change will be suppressed See Section 8 4 for a description of Mill event prompts When a Teach event is unfinished the words NOT OK will appear next to the event type Once the prompts are completed the words NOT OK and Teach will disappear The event will become a normal MILL DRILL or POSN event 68 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 10 0 Auto Geometry Engine A G E Programming When you program an Irregular Pocket or an Irregular Profile the Auto Geometry Engine or A G E is automatically started The A G E is powerful software that works behind the easy to use geometry programming of the
88. al Dimensions along the specified axis Distance to arc center X J Y K Z Tool Diameter Miscellaneous Functions Preparatory Function Tool Length Offset Selector silently ignored Line Number silently ignored Tool Number Feedrate Dwell time for drill bore canned cycles Repetition count for drill bore canned cycles Depth of cut for drill bore canned cycles Reference point for drill bore canned cycles Spindle Speed D M G H N T F P DIO wn 14 14 4 Format Terms and Definitions Number formats A preparatory function number denoted lt prep func gt 1 format dd 2 leading 0 suppression 3 range 0 to 99 B sequence or line number denoted lt seq number gt 1 format independent of units dddd 2 leading 0 suppression 3 range 1 to 9999 C Unsigned coordinate word denoted lt coord gt 1 format metric ddddd ddd inch dddd dddd 2 the sign is implied and therefore may be omitted leading 0 suppression 4 if no decimal point is given the supplied number will be interpreted as an integer i e a whole number 5 Fractional portion is optional 6 Range metric 0 to 99999 999 inch 0 to 9999 9999 w D signed coordinate word denoted lt scoord gt 1 format negative number lt coord gt positive number lt coord gt or lt coord gt 2 range metric 99999 999 to 99999 999 inch 9999 9999 to 9999 9999 E tool function denoted lt tool gt 1 fo
89. ally belong together This eliminates the need to memorize operations just select a mode and choose among the soft keys Most operations will be discussed within the section that treats the mode later in this manual The operations described in this section either don t fit in a particular mode or they are relevant to more than one mode 4 1 Switching the ProtoTRAK SM CNC On To turn the ProtoTRAK SM CNC on move the toggle switch on the display side panel to the Up position The Windows operating system and the ProtoTRAK SM CNC software will take a few seconds to load from the system s flash memory If you have connected the ProtoTRAK SM CNC to a network it may take as long as 90 seconds for the communications to be established When complete the ProtoTRAK SM CNC Select Mode screen will appear Select the Mode of operation by pressing the soft key beneath the labeled box Notice that the EDIT and RUN soft keys are grayed out when the system is first turned on They will not function because there is no program in the ProtoTRAK SM CNC Once a program is entered the EDIT key will function Once a program is entered and the necessary SET UP operations are complete the RUN key will function A F2 F3 F4 F5 F FF FS PROG DRO PROG EDIT SET UP RUN IN OUT FIGURE 4 1 1 The main select a mode screen Shown here the Edit and Run Modes are grayed out because there is no program in current memory The ProtoTRAK SM CNC has a s
90. am name as described above Multiple Fixtures Asks you if you wish to turn on the multiple fixtures offset Answering Yes will cause a prompt to appear at each event asking which fixture the event was referenced from If you select Yes the Data Input Line will ask you to enter a fixture default number from one to six The fixture default number is the fixture that will be applied to all the events in current memory when Multiple Fixtures is turned on or when a new event is programmed without another event being specified Enter the default fixture or leave the number unchanged and press SET Multiple Fixtures are explained more fully in Section 7 5 Dimension Definition The ProtoTRAK SM CNC gives you a choice in programming either tool path or geometry Part Geometry programming allows you to define the geometry you want your part to have and then the CNC does the difficult job of calculating tool path for you automatically This is a great benefit for most parts most of the time because it means that the CNC is doing the hard work of determining tool position 31 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual One restriction to part geometry programming is that for events to be connective they must lay on the same vertical plane see Section 5 10 for a definition of vertical planes For this reason the ProtoTRAK SM CNC gives you the option of entering your ow
91. and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual CNC flash memory a floppy disk or an offline computer connected to the ProtoTRAK SM CNC via the RS232 or network connection 5 10 Planes and Vertical Planes Three axis programming A plane is any flat surface If that surface lies flat on the table it is the XY plane That is if you move your finger along that surface or plane you are moving in the X and or Y direction but not in Z or at least not until you pick your finger up If you tilted that surface think of it as a piece of paper straight up so that it faces the front of the machine it would be in the XZ plane If you tilted it up so that it faced left or right it would be in the YZ plane A vertical plane is any plane or surface tipped up on its edge on the table see below Unlike most CNC controls z the ProtoTRAK SM CNC can machine arcs in any vertical plan rather than just XZ or YZ FIGURE 5 10 Vertical planes 5 11 Tool Diameter Compensation when Contouring in Z with Part Geometry Three axis programming Left and right tool diameter offsets are always those projected into the XY plane Tool offsets in the Z direction are always up and assume the use of a ball end mill When contouring in the Z axis this up tool offset is always activated regardless of left right center if the Part Geometry option is selected There is no Z axis up tool offset applied when the Tool Path option
92. and in the most direct path possible from the previous location You would use this event type to program a hole for drilling In program run the CNC will move to the dimension you program and will wait for you to press GO before moving to the next event You may also use this event type to position the table for some other purpose such as to avoid a clamp or to move off the workpiece for a tool change To program a Position event press the POSN DRILL soft key Prompts for the Position event X END is the X dimension to the position Y END is the Y dimension to the position Tool is the tool number you assign SET will use the tool number of the previous event BOLT HOLE Events This event allows you to program a bolt hole pattern without needing to compute and program the position of each hole Prompts for the Bolt Hole event Holes is the number of holes in the bolt hole pattern X Center is the X dimension to the center of the hole pattern Y Center is the Y dimension to the center of the hole pattern Radius is the radius of the hole pattern from the center to the center of the holes Angle is the angle from the positive X axes that is 3 o clock to any hole positive angle is measured counterclockwise from 0 000 to 359 999 degrees negative angles measured clockwise Tool is the tool number you assign MILL Events This event allows you to mill in a straight line from any one XYZ point to another including at a diagona
93. ant Left Side See Figure 3 2 for a description of the left side panel of the display ELECTRIC HANDWHEEL PARRALLEL PORT LPT PORT UMBILICAL 2 k x g Z 2 UMBILICAL 1 100871 FIGURE 3 2 The ProtoTRAK SM CNC left side with connectors labeled 11 Southwestern Industries Inc TRAK Knee Mill amp Proto TRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 3 3 Pendant Right Side See Figure 3 3 for a description of the connectors and features located on the right side of the display panel DRIVE MODULE FLOPPY DRIVE 1 AMP FUSE 8 AMP FUSE AC ON OFF i00903 FIGURE 3 3 The ProtoTRAK SM CNC right side 3 4 Optional Equipment 3 4 1 Position Encoders The ProtoTRAK SM CNC may be configured to run either with or without independent position encoders for X and Y travel Optional encoders include the TRAK sensors or glass scales each with 0002 underlying resolution 3 4 2 Power Draw Bar A manual draw bar of the NMTB or NST type comes standard with the machine A power draw bar option may be ordered The draw bar included in the option may be CAT or NMTB NST An NMTB NST type of draw bar is the appropriate length to fit tool holders that have a threaded tang on the top The CAT type is longer to thread into CNC tool holders that have the tool changer grip or retention knob removed 12 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safe
94. ar profile event is started the ProtoTRAK SM CNC will automatically initiate the powerful Auto Geometry Engine See Section 10 0 for programming with A G E 9 8 1 Circle profile Press the CIRCLE soft key if you wish to mill a circular frame Prompts in the Circle Profile event X Center is the X dimension to the center of the circle Y Center is the Y dimension to the center of the circle Z Rapid is the Z dimension to transition from rapid to feed Z End is the Z dimension to the bottom of the frame incremental is from the previous event Radius is the finish radius of the circle Direction is the clockwise input 1 or counterclockwise input 2 direction for milling Tool Offset is the selection of the tool offset to the right input 1 offset to the left input 2 or tool center no offset input 0 relative to the programmed edge and direction of the cutter movement Passes is the number of cycles to machine to the final depth spaced equally from Z Rapid to Z End hint keep Z Rapid small Fin Cut is the width of the finish cut If 0 is input there will be no finish cut Z Feedrate is the Z feedrate from Z rapid to Z end XYZ Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Finish Feedrate is the milling feedrate for the finish cut Tool is the tool number you assign 9 8 2 Rectangular Profile Press the RECTANGLE soft key if you wish to mill a rectangular frame all corners are 90
95. ards Institute 1430 Broadway New York New York 10018 Concepts And Techniques Of Machine Safeguarding OSHA Publication Number 3067 Available from The Publication Office O S H A U S Department of Labor 200 Constitution Avenue NW Washington DC 20210 2 2 Danger Warning Caution and Note Labels and Notices As Used In This Manual DANGER mmediate hazards that will result in severe personal injury or death Danger labels on the machine are red in color WARNING Hazards or unsafe practices that could result in severe personal injury and or damage to the equipment Warning labels on the machine are orange in color CAUTION Hazards or unsafe practices that could result in minor personal injury or equipment product damage Caution labels on the machine are yellow in color NOTE Call attention to specific issues requiring special attention or understanding 3 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual i iy ALWAYS WEAR SAFETY GLASSES AND i NEVER WEAR GLOVES RINGS WATCHES LONG SLEEVES SAFETY SHOES NECKTIES JEWELRY OR OTHER LOOSE ITEMS ALWAYS STOP THE SPINDLE AND CHECK TO ENSURE THE A i USE ADEQUATE POINT OF OPERATION SAFEGUARDING IT CNC ORIOLE 3 J IS THE RESPONSIBILITY OF THE EMPLOYER TO PROVIDE NG Soe Nhe Ola eae BEFORE CHANGING l AND ENSURE POINT OF OPERATION SAFEGUARDING OR ADJUSTING THE TOOL OR WORKPIECE OSHA 1910
96. are designed with built in finish cut routines because they are complete and stand alone pieces of geometry Shapes machined with a series of Mill or Arc events either with or without A G E Profile don t have an automatic routine for making finish cuts There is however a very simple technique that can be used 37 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual a Program the shape using the print dimensions and ignore the need to leave material for a finish cut b Using a subroutine event Repeat all the events in a but call out a different tool number C In Set Up Mode lie about the tool diameter for the tool called out in events in a Input a tool diameter equal to the actual tool diameter plus 2 times the finish cut you wish to leave The ProtoTRAK SM CNC will think the tool is bigger than it really is and therefore shift a little further away from the machined shape d In Set Up Mode input the actual diameter for the tool called in the Repeat event b This will produce the final dimensioned cut 7 13 Two Versus Three Axis Programming The ProtoTRAK SM CNC three axis CNC models may be operated as either a two or three axis CNC Many jobs in tool rooms are simply easier to do with a two axis CNC Many jobs are more complex or require a lot of metal removal so the extra programming and set up of the three axis is worth the effort Th
97. ate a mirror event Consider the figure below X CENTER i00840 FIGURE 8 9 2 Shape A programmed with 4 MILL events and Conrads Using ROTATE these 4 events are rotated through a 45 degree angle about a point offset from absolute zero by X Center and Y Center dimensions A is rotated 3 times to produce shape B C and D Press the SUBROUTINE SUB soft key to call up the Repeat Mirror and Rotate options 8 9 1 Repeat Press the REPEAT soft key Where First Event is the event number of the first event to be repeated Last Event is the event number of the last event to be repeated if only one event is to be repeated the Last Event is the same as the First Event X Offset is the incremental X offset from event to be repeated Y Offset is the incremental Y offset from event to be repeated Repeats is the number of times events are to be repeated up to 99 Feed the percentage of the feeds programmed in the repeated events 100 is assumed Tool is the tool number you assign 8 9 2 Mirror Press the MIRROR soft key First Event is the event number of the first event to be mirrored 48 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual Last Event is the event number of the last event to be mirrored if only one event is to be mirrored the last event is the same as the first Cutting Order input 1 to cut from the lowest mirrored event
98. cessor The following are modifications to a Fanuc 6 post processor that are necessary for writing the ProtoTRAK post processor Beginning file format The ProtoTRAK has no special requirements it does not need any special characters End of file format the ProtoTRAK requires the to show the end of the file Characters after the will be ignored Beginning of an operation the ProtoTRAK requires that the tool number feedrate and tool offset appear before or on the same line as a move command In addition the ProtoTRAK VM but not the SM requires the spindle speed be set The absolute zero of the ProtoTRAK is set in a different mode and does not need to be set at the beginning of each operation The feedrate is modal once it is set it remains the same until changed Lines the line feed or carriage return line feed signals the end of the line ASCII code hex 0A or OD 0A A semicolon is optional Coordinates may be formatted in inch or metric The addresses used for specifying coordinates are X Y Z I J K The valid ranges are e Inch min 99 9999 to max 99 9999 Mm min 999 99 to max 99 999 Rapid moves rapid moves are generated by the ProtoTRAK automatically as part of the definition of an event For this reason GO moves are discarded unless they specify a location other than the beginning of the following event Linear moves G01 are formatted the same as rapid moves Arcs Arc centers are specified by the addre
99. creen saver already programmed in If the system is not used either by a key stroke or by counting for 20 continuous minutes the display will turn itself off The LED s on the keypad will flash every few seconds to indicate that the system is still on 15 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 4 2 4 3 4 4 4 5 Press any key or move any axis to bring the screen back to its previous display The key you press will be ignored except to turn the screen on Shutting down the ProtoTRAK SM CNC Important the system must be turned off properly First press the SYS hard key and then press the SHUT DOWN soft key see Figure 4 4 After a few seconds you will see the message it is now safe to turn off your computer Turn the ProtoTRAK SM CNC off by moving the toggle switch on the display side panel to the down position If the CNC is not shut down properly the system will make you wait while it runs a scan disk self diagnostic routine and scold you for not following the instructions Note When you turn the PROTOTRAK SM CNC off always wait a few seconds before turning it back on Emergency Stop Press the button to shut off power to the spindle motor and axis motors Rotate the switch to release Switching Between Two and Three axis Operation When purchased as a three axis CNC the ProtoTRAK SM CNC may be operated as a two axis CNC as
100. dard finish cut is along the walls of the part but you may have the ProtoTRAK machine a finish cut along the bottom as well When the highlight is on the Fin Cut prompt the blue appears next to the Help key Pressing help gives you the ability to choose a Finish cut in Z You can remove the bottom finish cut by placing the highlight on the Fin Cut prompt and pressing Help again When you select Yes to the bottom finish cut the following prompt will appear Z FIN CUT the finish cut at the bottom Islands Within the Pocket event choices you may also select a circular rectangular or irregular island An island is a shape that is left standing when the surrounding material is removed The ProtoTRAK gives you the ability to machine almost any shape as an island within a rectangular pocket Both the shape of the island and the dimension of the surrounding pocket are defined within the island event The tool path for machining the island event is that the tool will first plunge or ramp into the material next to the island offset by the programmed finish cut to the depth of the first pass The tool will machine the perimeter of the island offset by the island finish cut Then the tool will machine the material in the pocket in a spiral path moving away from the island in the programmed clockwise or counterclockwise direction It will continue this outward spiral motion until it encounters the programmed rectangular perimeter or pocket It will
101. e CIRCLE PCKT soft key if you wish to mill a circular pocket Prompts for the circle pocket X Center is the X dimension to the center of the circle Y Center is the Y dimension to the center of the circle Z Rapid is the Z dimension to transition from rapid to feed Z End is the Z dimension at the bottom of the pocket incremental is from the previous event Radius is the finish radius of the circle Direction is the clockwise input 1 or counterclockwise input 2 direction for milling Passes number of cycles to machine to the final depth spaced equally from Z Rapid to Z End hint keep Z Rapid small Entry mode choose between a zigzag ramp and a plunge The plunge will machine straight down Z to the appropriate Z depth The zigzag ramp will move in a zigzag pattern to depth See Section 9 6 5 for more information about the zigzag ramp Fin Cut is the width of the finish cut If 0 is input there will be no finish cut See Section 9 6 7 for a bottom finish cut Z Feedrate is the Z feedrate from Z rapid to Z end XYZ Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Fin Feedrate is the milling feedrate for the finish cut Tool is the tool number you assign 9 6 2 Rectangular Pocket Press RECTANGLE soft key if you wish to mill a rectangular pocket all corners are 90 right angles and the sides are parallel to the X and Y axes 54 Southwestern Industries Inc TRAK Knee Mill and Pro
102. e Operation Spindle On Off Forward Reverse Table Saddle Knee Clamps Raising Lowering the Knee Spindle Brake Draw Bar Changing Speeds High Low Neutral Changing Speeds Variabe Speed Operating the Quill Adjusting the Quill Stop Quill Feed 17 10 1 Power Feed Engagement Lever 17 10 2 Fine Feed Direction Shaft 17 10 3 Quill Feed Selector 109 109 110 110 110 110 111 111 112 116 118 119 119 119 119 121 122 123 123 124 125 126 127 132 135 135 136 137 137 137 137 137 138 139 140 140 140 140 140 141 141 141 141 142 142 17 10 4 Feed Trip Lever 17 10 5 Fine Hand Quill Feed 17 10 6 Fine Automatic Quill Feed ProtoTRAK SM Training Checklist TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 143 143 143 iV TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 1 0 Introduction Congratulations Whether you bought the ProtoTRAK SM CNC as a retrofit or as the CNC integrated into the TRAK Knee Mill you have an excellent toolroom machine The ProtoTRAK SM has an easy to use interface and dozens of features that maximize your productivity for any toolroom job Manual machining is always available and made easier with features like power feed 100 inch per minute rapids tool offsets and all the best features of sophisticated DRO s Two axis machining is available at the touch of a button
103. e ProtoTRAK SM CNC control in a network environment There are many resources available at most bookstores on this subject 14 12 1 What is a Network A network is nothing more than two or more computers connected by a cable so that they can exchange information Networks are often called LANs Local Area Network 14 12 2 Why would you want to use the networking capability of the ProtoTRAK SM CNC control 1 To allow an easy way to backup programs to other computers or a dedicated storage device s connected to the network 2 To transfer files between the ProtoTRAK SM CNC control and other SM ProtoTRAK or Fanuc type controls To import CAD CAM programs written on other computers connected to the network To access printers on the network To access e mail over the network To access an internet modem that is connected to the network el sO Ole ae Oe To run programs that are larger than the ProtoTRAK SM CNC control s storage capabilities from network storage devices connected to the network 8 To allow easy access for customer service support i e software updates and access to error logs via the internet 110 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual The two most common types of networking are peer to peer networking and networking using a server and clients Both types of networking can be used in a multitude of configurations so for the p
104. e ProtoTRAK SM CNC lets you choose how much CNC you want to use on the job at hand See Section 4 4 for switching between two and three axis operation Programming is very similar between the two EVENT 1 BOLT HOLE EVENT 1 BOLT HOLE DRILL OR BORE HOLES HOLES X CENTER X CENTER Y CENTER Y CENTER RADIUS Z RAPID ANGLE Z END TOOL RADIUS ANGLE PECKS FOR DRILL Z REEDRATE TOOL FIGURE 7 13 Programming a Bolt Hole On the left the prompts required in programming in three axis CNC On the right the prompts required for two axis In Figure 7 13 the prompts for programming a Bolt Hole in two axis and in three axis are shown side by side Note that the difference is that the three axis requires a few additional prompts 38 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 8 0 Two Axis Program Events This section describes the events and prompts you encounter when programming your ProtoTRAK SM as a two axis CNC Events are fully defined pieces of geometry By programming events you tell the ProtoTRAK SM CNC what geometry you want to end up with it figures the tool path for you from your answers to the prompts and the tool information you give it in the Set Up Mode 8 1 8 2 8 3 POSN DRILL This event type positions the table and quill at a specified position The positioning is always at rapid speed modified by feedrate override
105. e corner of the rectangular pocket that surrounds the island Y1 POCKET Y dimension for one corner of the rectangular pocket that surrounds the island X3 POCKET X dimension for the opposite corner of the rectangular pocket that surrounds the island Y3 POCKET Y dimension for the opposite corner of the rectangular pocket that surrounds the island CONRAD PCKT the value of the tangential radius in the corners of the rectangular pocket that surrounds the island FIN CUT PCKT finish cut along the perimeter of the pocket If 0 is input there will be no finish cut See the previous section for a bottom finish cut Z FEEDRATE is the Z feedrate from Z rapid to Z end XYZ FEEDRATE the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 FIN FEEDRATE the finish milling feedrate for both the island and pocket finish cuts 59 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 9 8 TOOL is the tool number you assign When the initial screen is complete you will define the perimeter of the island with a series of A G E Mills and A G E Arcs Programming with the Auto Geometry Engine is explained in Section 10 0 PROFILE Events This event allows you to mill around the outside or inside of a circular or rectangular frame or an irregular profile The irregular profile may be closed or open All profiles are limited to the XY plane When the irregul
106. e desired results are obtained Tool cutter compensation is always specified as the tool either right or left of the workpiece while looking in the direction of the tool motion 100175 FIGURE 5 6 1 Examples of tool right FIGURE 5 6 2 Examples of tool left Tool center means no compensation either right or left That is the centerline of the tool will be moved to the programmed points Connective Events Connective events occur between two milling events either Mill or Arc when the X Y and Z ending points of the first event are in the same location as the X Y and Z starting points of the next event In addition the tool offset and tool number of both events must be the same And both events must lie in the XY plane or the same vertical plane see Section 5 10 21 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 5 8 5 9 Conrad Conrad is a unique feature of the ProtoTRAK SM CNC that allows you to program a tangentially connecting radius between connective events or tangentially connecting radii for the corners of pockets and frames without the necessity of complex calculations For the figure below you program an Arc event from X1 Y1 to X2 Y2 with tool offset left and another Arc event from X2 Y2 to X3 Y3 also with tool offset left During the programming of the first Arc event the system will prompt for Conrad at w
107. ed Repeats These are handled a bit For example differently between the controls Not Acceptable The Nested Repeat must Event 13 Repeat Events 1 12 reference all event numbers from Event 14 Repeat Events 13 a previous Repeat event not just Acceptable the previous Repeat event Event 13 Repeat Events 1 12 number otherwise it will be Event 14 Repeat Events 1 13 ignored The ProtoTRAK SM CNC will convert the 3 or 4 Sided Pocket routines into an Irregular Pocket Event 3 or 4 Sided Pocket These Events will be recognized by the ProtoTRAK SM CNC but in a modified format 107 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 14 10 3 Running ProtoTRAK SM Files on ProtoTRAK and TRAK CNC Controls In order to have a program written on a ProtoTRAK SM run on a previous version ProtoTRAK or TRAK CNC you will need the MX2 and MX3 converters activated see section 14 9 above Save the program as either a MX2 or MX3 file depending on the control or program you want to run Since there are some feature differences between the CNC s the process will generally yield a useable mx2 or mx3 program but with the following exceptions Event or feature Hidden Areas in Irregular Pocket Tap Events Comment The ProtoTRAK or TRAK CNC does not recognize Hidden Areas in Irregular Pockets This routine does not exist in the Pro
108. eloaded with the data that you selected EDIT PIN R0424 11 l l 3 AXIS INCH RPM X BEGIN Z CENTER FIN RPM Y BEGIN X1 Z FEED Z BEGIN Y1 XYZ FEED X END X3 FIN FEED Y END Y3 Z RAPID Z END PASSES CONRAD X CENTER FIN CUT F F2 F3 Fa F5 FG Fi FS v a 4 gt RETURN FIGURE 11 2 2 Pressing Help while viewing the spreadsheet lets you change the program parameters 78 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual After you press the HELP hard key the screen will display all the different parameters that can be displayed on the spreadsheet To either select or deselect any parameter simply highlight that parameter and press SET When you are finished press the Return softkey and return to the spreadsheet 11 2 2 Sorting Data Data may be sorted by any of the data types displayed in the column head Red letters show which column is used for sorting the data To change the sort press the SORT softkey then select the type of data you want to use for sorting from the softkeys The table will be changed to sort the data in ascending order the smallest value first the largest last 11 2 3 Making Global Changes to Data Sometimes it is useful to be able to change data in a program without having to go through each event one at a time For example if you were to want to change the tool number for every milling event it may be a chore to go through
109. en pin 3 plus and pin 4 minus o Input to the ProtoTRAK SM CNC is 3 second actuation of a solid state relay between pin 1 plus and pin 2 minus o Note Pin 1 is on top 2 on right 3 on left 4 on bottom 3 4 7 Limit Switches There are limit switches for the ram saddle and table travel Ballscrews Precision ground ballscrews are installed in the table and saddle for smooth positive control without backlash Servo Motors The servo motors on table saddle and ram are 280 in oz torque Integrated into each motor is an encoder with 0 000018 underlying resolution Z Axis Glass Scale For two axis CNC models a glass scale is installed on the quill 13 Southwestern Industries Inc TRAK Knee Mill amp Proto TRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 3 8 Z Axis Ballscrew and Motor Assembly For three axis CNC operation a ballscrew and motor assembly is attached to the front of the machine head using the four tramming bolts The ballscrew is attached to the quill through the threaded hole for the quill stop knob Quill motion is measured using an encoder on the ballscrew 14 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 4 0 Basic Operation One of the things that makes the ProtoTRAK SM CNC so easy to use is that most of the operations are organized in Modes Modes are logical groups of activities that natur
110. ents will be ignored Thread Mill events will be ignored We recommend that you replace these events with the Helix Events and Mill Events to ramp in and ramp out of the helix Tool Table I nfo The part programs for ProtoTRAK or TRAK CNC do not contain tool table information This information is kept separately Tool table information will have to be set in the ProtoT RAK or TRAK CNC as usual Irregular Profile The ProtoTRAK or TRAK CNC does not contain an Irregular Profile Event 108 The Irregular Profile Event will be converted to Mill and Arc Events and the programming of the finish cut and steps will be lost We recommend that after conversion you add repeat events for the steps and finish cut using the technique of overstating the size of the cutter you will use to cut the profile Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 14 11 Running G Code Files The ProtoTRAK SM allows you to run G Code files directly without having them converted to the ProtoTRAK SM programming format You may want to do this if you have a very large CAM file made up of small XYZ position moves or if there is complex surface contouring In these cases the ProtoTRAK SM can handle the files more efficiently by running the G Code directly While running the G Code file directly does not give you the benefit of the easy programming format of the
111. er the Set Up Mode by pressing the SET UP soft key at the Select Mode screen FIGURE 12 0 The Set Up mode 12 1 The Tool Table From the screen above press the TOOL TABLE softkey TOOL REF 0 2500 0 0 0000 0 3750 3 0 0000 0 1875 f 0 0000 0 2400 0 0000 0 0000 0 0 0000 0 0000 5 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 3 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 FIGURE 12 1 The Tool Table 83 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 12 1 1 The Tool Table Screen When you first enter the tool table by pressing the TOOL TABLE soft key you will see the screen shown in Figure 12 1 Tool the number of the tool from 1 to 99 Tool numbers shown in red are active for the program in current memory Diameter the diameter of the tool Z Offset the difference between the Z position of the tool and the Z position of the reference The Z offset is always relative to a reference point Before the reference point is set the highlight will not go into the Z Offset column because setting a Z offset before the Z reference is set has no meaning Z modifier a value you enter to make adjustments for the tool depth See 12 1 8 below Ref the reference position for the Z offset Before the reference position is set and the Ref row reads NOT SET the highlight will not go i
112. erating amp Care Manual 8 7 8 6 3 Irregular Island Press the IRREG ISLAND key if you wish to mill an island other than a rectangle or circle The Irregular Island gives you the powerful Auto Geometry Engine to define a shape made up of straight lines and arcs The first screen in an Irregular Island event will define the beginning point and some of its general parameters The last event of the irregular pocket must end at the same point as defined in the first event Prompts for the Irregular Island event X BEGIN X dimension to the beginning of the island Y BEGIN Y dimension to the beginning of the island FIN CUT ISL Finish cut for the Island If 0 is input there will be no finish cut X1 POCKET X dimension for one corner of the rectangular pocket that surrounds the island Y1 POCKET Y dimension for one corner of the rectangular pocket that surrounds the island X3 POCKET X dimension for the opposite corner of the rectangular pocket that surrounds the island Y3 POCKET Y dimension for the opposite corner of the rectangular pocket that surrounds the island CONRAD PCKT the value of the tangential radius in the corners of the rectangular pocket that surrounds the island FIN CUT PCKT finish cut along the perimeter of the pocket If 0 is input there will be no finish cut FEEDRATE the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 FIN FEEDRATE the finish milling feedrate for both the island and
113. erent types TEACH POSWN DRILL See Section 8 1 for a description of Position Drill event prompts TEACH MILL a straight line that specifies the beginning and the end When TEACH MILL events are defined using the CONT MILL softkey the prompts for information that cannot change will be suppressed See Section 8 3 for a description of Mill event prompts When a Teach event is unfinished the words NOT OK will appear next to the event type Once the prompts are completed the words NOT OK and Teach will disappear The event will become a normal POSN DRILL or MILL event 50 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 9 0 Three Axis CNC Program Events This section describes the program events and prompts that are available in three axis programming If your ProtoTRAK SM CNC model is configured for two axis programming only you should skip this section If you are interested in both two and three axis programming you will encounter a lot of redundancy between this and the previous section Two Axis Program Events as many of the events and prompts are similar While the redundancy itself is irritating it does have the benefit of describing all the events completely without forcing you to look in different places Events are fully defined pieces of geometry By programming events you tell the ProtoTRAK SM CNC what geometry you want to end up with it figur
114. es and no appear when the Dwell Request Auxiliary Function Request and the Event Comments are highlighted Choosing Yes will give you prompts for using these options while you are programming You may return to the Program Header Screen at any time to choose or cancel these prompts PART GEO sets up the programming as Part Geometry TOOL PATH sets up the programming as Tool Path 7 4 Auxiliary AUX Functions Three axis CNC programming only The ProtoTRAK SM CNC can control four different auxiliary functions You can select whether to activate or deactivate these functions at the beginning or end of each event If Auxiliary Functions are selected on the program header the system will prompt for AUX BEG and AUX END in each event When running programs with Auxiliary functions the ACCESSORY hard key on the front panel must be in the correct position If you want the program to automatically turn the Auxiliary functions on and off press the ACCESSORY key until the light is on in the AUTO position 32 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual AUX BEG options Input Function Comments 0 None No Auxiliary functions will begin when this event begins to run Coolant Air The coolant pump or air solenoid will be turned on when this event begins to run Pulse indexer Activates a 0 3 second electronic pulse at the beginning of the event See note
115. es the tool path for you from your answers to the prompts and the tool information you give it in the Set Up Mode 9 1 POSN Position Events This event type positions the table and quill at a specified position The positioning is always at rapid speed modified by feedrate override and in the most direct path possible from the previous location The most common use of the position event is to move the tool around an obstacle such as a clamp For this reason Z and X Y motion will not occur simultaneously First the Z head will move to the higher of the Z rapid position of the current and next event then the X table and Y saddle will move at to the programmed position To program a Position event press the POSN soft key Prompts for the Position event X END is the X dimension to the position Y END is the Y dimension to the position Z Rapid is the Z dimension to the position Tool is the tool number you assign SET will use the tool number of the previous event 9 2 DRILL Events This event positions the table to the specified X and Y position moves the HEAD at rapid to the Z RAPID location feeds the quill to the Z END location and rapids back to Z RAPID for drill and feeds back for bore Press the DRILL soft key Prompts for the drill event Drill 1 Bore 2 selects whether the hole is to be drilled or bored X is the X dimension to the hole Y is the Y dimension to the hole Z Rapid is the Z dimension to transition
116. fice cubicle When the person using a client needs to make a change to a main database he accesses the server through the network The server uses software specifically designed to manage this type of network set up The most commonly used software is Microsoft Windows NT 2000 This software carries out the tasks of coordinating the access to shared network resources among the network client computers Most clients use a desktop version of Microsoft Windows 95 98 ME XP 14 12 7 Network Description of the ProtoTRAK The following table summarizes important settings for the ProtoTRAK V series and ProtoTRAK S series CNCs It is intended for use by a professional Network Administrator Note The ProtoTRAK has many similarities to a desktop computer but it is somewhat different because the use of the computer s resources is optimized for running part programs and a machine in real time In order to avoid causing a slow down or even instability in the operating system of the control keep the following in mind while setting up the network e Do not use a resource intensive networking program such as SMS e Avoid loading in programs that direct background tasks e g anti virus programs ProtoTRAK system SL or SM VL or VM Windows 95 OSR 2 Processor Pentium 2 233 Pentium 2 233 Memory RAM 32 32 Disk Compact flash optional Hard drive 2 gig or bigger second compact flash leer Floppy drive Yes Yes Network 10 100 base T Ethernet 10
117. first example Note the Tool at B does not drop below the AB line and therefore never touches point B As a result a fillet is formed at point B equal to the tool radius This second example of continuous machining from one cut AB to another BC with full cutter compensation between requires the two cuts to be made with events which are connective see Section 5 7 or 5 8 for a more complete discussion of this requirement 24 Southwestern Industries Inc TRAK Knee Mill and Proto TRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 6 0 DRO MODE The ProtoT RAK SM CNC operates in DRO Mode as a sophisticated 3 axis digital readout with jog and power feed capability 6 1 6 2 Enter DRO Mode Press MODE select DRO soft key The screen will show DRO PIN PIN 0812 2 TOOL 1 3 AXIS INCH X 0 0000 s Vi 0 0000 ves Z 0 0000 ves a 7 Feed Rate 100 0 10 100 150 Override 100 FIGURE 6 1 The DRO screen Note the RETURN soft key is lit when in Jog or Power Feed operation DRO Functions Clear Entry Press RESTORE then re enter all keys Inch to MM or MM to Inch Press N MM and note LCD screen status line Reset One Axis Press X or Y or Z INC SET This zeros the incremental position in the selected axis Preset Press X or Y or Z numeric data INC SET to preset selected axis Reset Absolute Reference Press X or Y or Z ABS SET to set selected axis absolute to zero a
118. for the prototyping and moderately complex low volume work that is typically done on knee mills Three axis CNC machining is also available for retrofit and with the TRAK Knee Mills Programs may be entered at the control or imported from CAD CAM files The operation of the ProtoTRAK SM CNC has been painstakingly refined to bring you the best in technology while retaining the ease of use that has made ProtoTRAK the top brand in controls for low volume production 1 1 Models The ProtoTRAK SM CNC is featured as a two or three axis CNC in the following products Retrofits Model Description PTSM2 Two axis CNC retrofit to your knee mill PTSM3 Three axis CNC retrofit to your knee mill Knee Mills TRAK K2S Two axis CNC 33 x 12 3HP TRAK K3S Two axis CNC 32 x 16 3 HP TRAK K4S Two axis CNC 32 x 16 7 5 HP TRAK K2S 2 Three axis CNC 33 x 12 3 HP TRAK K3S 3 Three axis CNC 32 x 16 3 HP TRAK K4S 3 Three axis CNC 32 x 16 1 2 5 HP 1 2 Manual Organization This manual covers the operation of all retrofit and TRAK K Mill products that use the ProtoTRAK SM CNC Some Sections do not apply to all users For example if you own a ProtoTRAK SM 2 axis retrofit you should skip e Section 9 Three axis program events e Section 16 and 17 description and operation of TRAK K Mills Sections that may not apply to all users contain a note to inform you of this fact 1 Southwestern Industries Inc T
119. from a storage location press the DELETE softkey from the Program In Out Mode screen Use the navigation procedure described in Section 14 2 above and highlight the program file or folder you wish to delete Press the DELETE FILE or DELETE FOLDER softkey A warning message will appear for confirmation Additional Softkeys in DELETE DELELE FILE Press this to delete a file DELETE FOLDER Press this to delete a folder 101 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 14 7 Softkeys that appear with the confirmation message YES Press this if you want to delete NO Press this if you do not want to delete The delete operation will be aborted and the previous softkey selections will return When the delete operation is finished the file or folder name will disappear from the listing area Renaming To rename either a file or a folder press the RENAME softkey from the Program In Out Mode screen To rename a file or folder 1 Use the navigation procedure described in Section 14 2 above and highlight the program file or folder you wish to rename 2 TAB to the New Name area and enter a new name Use the same procedure as for naming a program see Section 7 3 1 3 TAB to the New Extension and enter a new extension 4 Press either RENAME FILE or RENAME FOLDER PROGO PIN 0807 F 3 AXIS INCH RENAME Lookin sa oe E SWI 2615 PT4
120. from rapid to feed Z End is the bottom of the hole Pecks is the number of tool withdrawal cycles each cycle drills and then retracts to the Z Rapid position The factory setting is for each peck to be successively smaller taking the largest cuts at the beginning and the smallest at the end When the highlight is on this prompt you may change this setting by pressing the HELP key This will take you to a screen where you may choose to have the same amount of material taken per peck 51 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 9 3 9 4 Z Feedrate is the drilling feedrate Tool is the tool number you assign BOLT HOLE Events This event allows you to program a bolt hole pattern without needing to compute and program the position of each hole Prompts for the Bolt Hole event Drill 1 Bore 2 selects whether the hole is to be drilled or bored Holes is the number of holes in the bolt hole pattern X Center is the X dimension to the center of the hole pattern Y Center is the Y dimension to the center of the hole pattern Z Rapid is the Z dimension to transition from rapid to feed Z End is the bottom of the hole Radius is the radius of the hole pattern from the center to the center of the holes Angle is the angle from the positive X axes that is 3 o clock to any hole positive angle is measured counterclockwise from 0 000 to 359 99
121. g to end in in min from 1 to 100 or mm min from 5 to 2540 Tool is the tool you assign Subroutine Events The Subroutine Events are used for manipulating previously programmed geometry within the XY plane The Subroutine Event is divided into three options Repeat Mirror and Rotate Repeat and Rotate may be connective As long as the rules of connectivity are satisfied see Section 5 7 the ProtoTRAK SM CNC will continue milling between preceding and subsequent events REPEAT allows you to repeat an event or a group of events up to 99 times with an offset in X and or Y and or Z This can be useful for drilling a series of evenly spaced holes duplicating some machined shapes or even repeating an entire program with an offset for a second fixture Repeat events may be nested That is you can repeat a repeat event of a repeat event of some programmed event s One new tool number may be assigned for each Repeat Event MIRROR is used for parts that have symmetrical patterns or mirror image patterns In addition to specifying the events to be repeated you must also indicate the axis or axes X or Y or XY are allowed that the reflection is mirrored across In addition you must specify the offset from absolute zero to the line of reflection You may not mirror another mirror event or mirror a rotate event Consider the figure below 62 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Progra
122. gerous flying projectiles Never operate a milling machine after consuming alcoholic beverages or taking strong medication or while using non prescription drugs Protect your hands Stop the machine spindle and ensure that the CNC control is in the stop mode e Before changing tools e Before changing parts e Before you clear away the chips oil or coolant Always use a chip scraper or brush e Before you make an adjustment to the part fixture coolant nozzle or take measurements e Before you open safeguards protective shields etc Never reach for the part tool or fixture around a safeguard Protect your eyes and the machine as well Don t use a compressed air hose to remove the chips or clean the machine oil coolant etc Stop and disconnect the machine before you change belts pulley gears Keep work area well lighted Ask for additional light if needed 6 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 14 15 16 17 18 19 20 21 22 23 24 25 26 Do not lean on the machine while it is running Prevent slippage Keep the work area dry and clean Remove the chips oil coolant and obstacles of any kind around the machine Avoid getting pinched in places where the table saddle or spindle head create pinch points while in motion Securely clamp and properly locate the workpiece in the vise
123. ges The ProtoTRAK SM CNC performs a number of automatic checks or self diagnostics If problems are found a message will appear Fault __ ______ The information area will display an explanation and suggested solution 96 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 14 0 Program In Out Mode From the Select Mode screen press the PROG IN OUT softkey The first screen you see will ask LIST SUPPORTED PROGRAMS ONLY With a highlighted YES or NO PROGWO PINOBOT ET CS AXIS INCH List Supported Programs Only YES Fi F2 F3 F4 F F F7 FS YES No OPEN SAVE COPY oetere RENAE net FIGURE 14 0 Supported programs are part programs that can run on the ProtoTRAK SM CNC You do not have to answer this question every time you are at this screen Simply press the softkey for the operation you want Supported programs are the programs that will run on your ProtoTRAK SM CNC It is possible to view other types of files through the Program In Out Mode for example Microsoft Word files This type of file is not supported on the ProtoTRAK SM CNC in the sense that you cannot open it and work on it We recommend a Yes response to this prompt If No is selected it is possible to view and inadvertently damage files that are critical to running the ProtoTRAK SM CNC as well as on other networked computers Filenames and File Extensions
124. grammed with a CONRAD if it is connective with the next event Prompts for the Arc event X Begin is the X dimension to the beginning of the arc cut Y Begin is the Y dimension to the beginning of the arc cut X End is the X dimension to the end of the arc cut incremental is from X Begin Y End is the Y dimension to the end of the arc cut incremental is from Y Begin X Center is the X dimension to the center of the arc incremental is from X End Y Center is the Y dimension to the center of the arc incremental is from Y End Conrad is the dimension of a tangential radius to the next event Direction is the clockwise input 1 or counterclockwise input 2 direction of the arc Tool Offset is the selection of the tool offset to right input 1 offset to left input 2 or tool center no offset input 0 relative to the programmed edge and direction of tool cutter movement XY Feedrate is the milling feedrate from Begin to End in in min from 1 to 100 or mm min from 5 to 2540 Tool is the tool number you assign Continue input 1 for Yes if you want to mill continuously from this line to the next event input 2 for No if you want the ProtoTRAK SM to stop at the end of the event POCKET Event This event selection gives you a choice between circle pocket rectangular pocket and irregular pocket Pockets include machining the circumference as well as all the material inside the circumference of the programmed shape If a finished
125. gular and circular pockets the tool will start in the center of the pocket For irregular pockets since there is no center defined the tool will start in the lower left corner of the pocket The direction of the ramp will be the same as the initial direction in either X or Y depending on how the pocket is to be cut The tool will zigzag back and forth along the X or Y over a length of one tool radius while at the same time moving in the Z direction When it travels one tool radius along this direction it will have traveled a distance of ten percent of the tool diameter along the Z This works out to roughly ramping into the part at an angle of 11 degrees In order to use a zigzag ramp the X or Y move must be larger than the diameter of the tool plus the radius of the tool minus the finish cut of the pocket The formula is the pocket x or y move gt tool diameter tool radius fin cut If the tool is too large for the zigzag ramp the ProtoTRAK SM CNC will give an error message during program run and will then default to plunge This will occur for each pass of the pocket depth 9 6 6 Conrad in Pocket Events A conrad may be added to the last event of an Irregular Pocket The conrad will be inserted between the end of the last event and the beginning of the next event 56 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 9 7 9 6 7 Bottom Finish Cut The stan
126. having to change programmed Z end dimensions or change the tool offsets For example say an end mill was under cutting the depth of a part by 003 An easy way to correct this is to enter a Z modifier 1 Highlight the number in the Z MODIFIER column in the row for the correct tool 2 Enter the amount of the adjustment you wish to make To cut deeper enter a negative number To cut shallower enter a positive number In the example above to correct this undercut we would enter 003 3 Press SET The ProtoTRAK SM CNC will apply this modifier each time this tool is used 12 1 9 Resetting the Reference Point Once the reference reads SET you are not allowed to highlight and reset it If you need to reset the reference there are two ways to change the reference to NOT SET You can erase the table and lose all the tool information or load in a program 12 1 10 Saving Tool Information Tool information is saved with the program If you have made changes to the program or to the tool table that you wish to keep you must save or store the program in the Program In Out Mode 12 1 11 Opening a Program When you open a program the tool information that is saved with the program will be loaded into the tool table The numbers for the tools that are used in the program are in red The diameters Z Offsets and Z modifiers that were saved with the program will overwrite any information that was in the tool table before the program was
127. he Auto mode the coolant pump or mister will be 9 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual controlled as programmed by the Auxiliary functions To get to the Auto operation press and hold the Accessory key If neither light is on the coolant pump or mister will not operate INC SET loads incremental dimensions and general data ABS SET loads absolute dimensions and general data INC ABS switches all or one axis from incremental to absolute or absolute to incremental IN MM causes Inch to Metric or Metric to Inch conversion of displayed data LOOK part graphics in Program mode X Y Z selects axis for subsequent commands RESTORE clears an entry aborts a keying procedure 0 9 inputs numeric data with floating point format Data is automatically unless key is pressed All input data is automatically rounded to the system s resolution MODE to change from one mode of operation to another SYS To shut down the ProtoTRAK SM CNC and if the 3 axis CNC is operable to change from 2 axis to 3 axis or 3 axis to 2 axis operation Access to Windows functions for network configuration is also available via this key A reinstates a window v eliminates a window HELP displays help information math help or additional functions Active for additional functions when the help symbol a blue question mark is displayed on the sc
128. he set height of the character will change the width in order to keep the overall size of the character proportional TEXT The text to be milled When you get to this prompt the Alpha keys will automatically pop up to allow you to enter the text Once you have finished entering text you must press End F8 and then any of the SET keys to successfully enter your text into the event The alpha keys will appear automatically if the text field is blank If you have already entered text but wish to make a change you will see a blue question mark appear on the lower left corner of the screen when you scroll to this field press the Help button and the alpha keys will appear Z FEEDRATE Is the feedrate from Z rapid to Z end XYZ FEEDRATE The feedrate of XYZ along the path of the text Tool is the tool number you assign PROG PIN ENGRAVE i F 3AxIS INCH EVENT 0 EVENT 1 ENGRAVE PROGRAM NAME ENGRAVE X BEGIN 0 0000 abs SCALE abs DWELL REQL abs AUXILIARY FI abs Text Length 1324162 F4 F5 F F7 FB FL F2 F3 BACK CLEAR SPACE v A lt gt ENTER END i01058 FIGURE 9 14 The above figure shows the text and special characters available for the Engrave event Notice the field that is labeled Text Length This field will display the total length of your programmed text and will update will update as you enter each character 67 Southwestern Industries Inc TRAK Knee Mill and Proto TRAK SM CNC Retrofit S
129. hich time you input the numerical value of the tangentially connecting radius r K3 The system will calculate the tangent points T1 and T2 and direct the tool cutter to move continuously from X1 Y1 through T1 r k3 T2 to X3 Y3 i00180 FIGURE 5 8 1 A Conrad is added between the two intersecting lines Note Conrad must always be the same as or larger than the tool radius for inside corners If Conrad is less than the tool radius and an inside corner is machined the ProtoTRAK SM CNC will ignore the Conrad For the figure below you program an Arc event from X1 Z1 to X2 Z2 and a Mill to X3 Z3 During the programming of the Arc event the system will prompt for Conrad at which time you input the numerical value of the tangentially connecting radius r k The system will calculate the tangent points T1 and T2 and direct the tool cutter to move continuously from X1 Z1 through T1 r k T2 and on to X3 Z3 x2 T2 X3 Z3 Z XZ VERTICAL PLANE X1 Z1 me X FIGURE 5 8 2 A Conrad is added between an arc and a line Memory amp Storage Computers can hold information in two ways Information can be in current memory or in storage Current memory also known as RAM is where the ProtoTRAK SM CNC holds the operating system and any part program that is ready to run While a program is being written it is in current memory Storage of information is on the ProtoTRAK SM 22 Southwestern Industries Inc TRAK Knee Mill
130. highlight moves to the Z Modifier column Input a Z modifier if you wish see below or simply press SET again for the highlight to move to the DIAMETER column of the next tool 10 Repeat steps 5 to 8 for each of the tools you want to set up Remember to touch the same surface you used to set the reference tool Once the reference position is set you will not be able to move the highlight back to the word SET Note You must set absolute zero reference in the DRO Mode before machining the part You may use any tool that you have set up with the above procedure to set your reference and the ProtoTRAK will automatically compensate for the difference in length for the rest of the tools 12 1 5 Starting Over Erasing Tool Information There will be times when you don t completely trust the information that is in the tool table For example perhaps you have loaded in a program that you wrote a month ago and you recall that one of the tools you used was held in a chuck In that case you probably want to erase the table and start over In order to do this simply press the ERASE TABLE softkey and answer yes to the prompt All the data in the tool table will be erased including the reference The numbers of the tools used in any program in current memory will still be red 12 1 6 Adding a Tool When the reference is SET and the original touch off surface is still available you can add a tool very easily First make the tool number active by
131. ic strategy is to first fill in the initial program information in the Program Header screen and then program the features of the part by selecting the soft key event types geometry and then follow all instructions in the Data Input Line When an event is selected all the prompts that need to be input will be shown on the right side of the screen The first prompt will be highlighted and also shown in the Data Input Line Input the dimension or data requested and press INC SET or ABS SET For X or Y dimension data it is very important to properly select INC SET or ABS SET For all other data either SET will do As data is being entered it will show in the Data Input Line When SET the data will be transferred to the list of prompts in the right side of the screen and the next prompt will be shown in the Data I nput Line When all data for an event has been entered the entire event will be shifted to the left side of the screen and the conversation line will ask you to select the next event Enter Program Mode Press MODE select PROGRAM soft key The ProtoTRAK SM CNC will allow only one program in current memory To write a new program you must first erase the one in current memory you may want to first store the program for use in the future If there is already a program in current memory entering the Program mode will allow you to edit or add to that program PROG PINO TOOL 4 SAXIS INCH Program Name Scale 1 000 Dwe
132. ich looks like a telephone cable and is readily available at most computer supply stores In a peer to peer network all the computers that are connected together are thought of as peers or equals The ProtoTRAK SM CNC control can be considered a peer to other CNC s or desktop computers Peer to peer networking features are built right into the Windows 95 98 ME XP software If you are using any of these Microsoft operating systems you do not have to purchase any additional software to set up this type of network The ProtoTRAK SM CNC control uses the Windows 95 OSR2 operating system PROTOTAAN VM oe X DESKTOP PC FIGURE 14 12 4 Peer to Peer desktop PC to ProtoTRAK 111 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 14 12 5 Basic Network Set Up This section will give you instructions for the most basic set up of one ProtoTRAK with one desktop computer The desktop computer must have an Ethernet card installed Use a crossover CAT5 cable to connect the machines Before you begin connect a keyboard and mouse to your ProtoTRAK and turn the ProtoTRAK on with them connected so that it will recognize them If your set up is more complicated than that pictured in Figure 14 12 4 you should skip this section and see Section 14 12 6 1 For the ProtoTRAK VL and VM CNCs press the Windows key and then press Windows 98 For the ProtoTRAK SM and SL pres
133. ies of events that are programmed to machine continuously The first event of the series will be called an IRR PROFILE and it will define the beginning point of the profile and other information that applies to the entire profile X Begin is the X dimension of the beginning of the profile Y Begin is the Y dimension of the beginning of the profile Tool Offset is the selection of the tool offset to right input 1 offset to left input 2 or tool center no offset input 0 relative to the programmed edge and direction of tool cutter movement Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Fin Cut is the width of the finish cut If 0 is input there will be no finish cut 45 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 8 8 Fin Feedrate is the finish cut milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Tool is the tool number you assign When the initial Irregular Profile screen is complete the rest of the profile is programmed using A G E Mill and A G E Arc events Programming with the Auto Geometry Engine is explained in Section 10 0 Engrave Event The Engrave Event allows you to machine numbers letters and special characters as part of a part program See figure 8 8 below for the letters and special characters that are available in the Engrave Event When programming with the Engrave Event
134. ilenames letters and numbers of up to twenty five 25 characters Be sure to use only numeric filenames when storing a file on a ProtoTRAK SM CNC that will be retrieved by previous ProtoTRAK and TRAK CNC s Before conversion you can easily rename the file in the ProtoTRAK SM CNC current memory 14 10 1 File Formats The ProtoTRAK SM CNC can store and retrieve the follow ing ProtoTRAK and TRAK CNC dot file formats Previous ProtoTRAK and TRAK CNC dot file formats ProtoTRAK M2 mx2 pronounced dot mx2 ProtoTRAK MX2 mx2 ProtoTRAK MX2E mx2 TRAK AGE2 mx2 ProtoTRAK EDGE mx2 ProtoTRAK M3 mx3 ProtoTRAK MX3 mx3 ProtoTRAK MX3E mx3 TRAK AGE3 mx3 TRAK QMV mx3 14 10 2 Opening MX2 and MX3 files on a ProtoTRAK SM CNC Programs written on previous generation ProtoTRAK and TRAK CNCs may be opened and run on the ProtoTRAK SM CNC You will need to have the MX2 or MX3 converters activated see section 14 9 above The ProtoTRAK SM CNC will automatically convert the file MX2 or MX3 to a PT4 file The original file will remain on the storage device unchanged and the converted file will be in current memory You will have to save the converted file using the procedure in Section 14 4 above in order to place in into storage Since there are some feature differences between the ProtoTRAK SM and previous generation controls you will have to pay attention to the following Event or feature Comment Result Nest
135. in from 5 to 2540 41 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual Fin Feedrate is the finish cut milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Tool is the tool number you assign When the initial screen is complete you will define the perimeter of the pocket with a series of A G E Mills and A G E Arcs Programming with the Auto Geometry Engine is explained in Section 10 0 No islands may exist in an irregular pocket 8 5 4 Tool Path in Pocket Events In Program Run the ProtoTRAK SM will first direct the cutter along a path to rough out all the material inside of the perimeter and then will do a rough cut along the inside of the perimeter which leaves the amount of material programmed in the FIN CUT prompt This will be followed by a finish pass if FIN CUT was not zero along the inside of the perimeter at the Finish Feedrate Whether the cuts to clear the interior material of the irregular pocket are along the X or Y axis depends on if there are hidden areas of the pocket The ProtoTRAK SM CNC always looks to cut along the X axis first If there are areas that are hidden to the X axis it will machine along the Y axis If there are hidden areas that cannot be machined continuously in the X or Y axis the pocket will be machined in two or more steps When a step is completed the ProtoTRAK SM will prompt CHECK Z at which time you
136. in order to reduce the amount of set up needed requires that care be taken to avoid mistakes Milling work usually requires a lot of tools many of which are not preset into fixed tool holders That means tool information that is not very recent is probably no good Think of the information in the tool table this way if you clearly remember setting the tools and entering the diameters very recently then use the tool table in DRO and CNC run If you can t remember setting the tools clearly erase the table and start over it only takes a moment This may cause some confusion because the normal sequence for running a two axis program is to load in a tool touch it off and set zero then press GO The ProtoTRAK SM CNC will apply the tool offset after the GO press making the Z dimension meaningless You have two choices 1 Use the tool table setting the reference and absolute dimension for one of them per the instructions above This will save you from having to touch off tools every time they are changed in program Run 2 Don t use the tool table Erase the entire tool data so that the ProtoTRAK SM CNC will not try to apply offsets 12 1 4 Initial Tool Set Up This procedure is used for setting up tools when the tool table is clear 1 When you enter this screen for the first time the words NOT SET appear directly under the Z OFFSET column in the REF row The Data Input Line reads TOUCHOFF REFERENCE POINT This is prompting you to e
137. increase by one At any time you may exit the Teach and return to the DRO screen The events you have defined with their X and Y dimensions are finished in the Program Mode See Section 8 10 for finishing two axis Teach events or section 9 14 for finishing three axis Teach events Return to Absolute Zero At any time during manual DRO operation you may automatically move the table to your absolute zero location in X and Y by pressing the RETURN ABS O soft key When you do the message window will read Ready to Begin Press Go when Ready Make sure your tool is clear and press the GO key The table will move at rapid speed to your X and Y absolute zero position You will be at zero and in manual DRO operation Tool The ProtoTRAK SM CNC allows you to use the offsets for tools in your Tool Table see Section 12 1 in the DRO Mode To change tools press the TOOL soft key and enter the tool number when prompted by the Data Input Line Even when you set up a tool in the Set Up Mode if you do not wish to use the tools in the Tool Table simply ignore the Tool feature 28 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 7 0 7 1 7 2 Program Mode Getting Started amp Some General I nformation Programming Overview The ProtoTRAK SM CNC makes programming easy by allowing you to program the actual part geometry as defined by the print The bas
138. ine your part Section 14 Program In Out Mode Storing and managing your programs Section 15 Sample Programs Contains two sample programs to help you get started Section 16 provides a description of each model of TRAK K Mill Section 17 describes the operation of the TRAK K Mill 2 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 2 0 Safety The safe operation of your knee mill depends on its proper use and the precautions taken by each operator e Read and study this manual Be certain every operator understands the operation and safety requirements of this machine before its use e Always wear safety glasses and safety shoes e Always stop the spindle and check to ensure the CNC control is in the stop mode before changing or adjusting the tool or workpiece e Never wear gloves rings watches long sleeves neckties jewelry or other loose items when operating or around the machine e Use adequate point of operation safeguarding It is the responsibility of the employer to provide and ensure point of operation safeguarding per OSHA 1910 212 Milling Machine 2 1 Safety Publications Refer to and study the following publications for assistance in enhancing the safe use of this machine Safety Requirements For The Construction Care And Use of Drilling Milling and Boring Machines ANSI B11 8 1983 Available from The American National Stand
139. is your job to calculate and program the tool path Absolute amp Incremental Reference The ProtoTRAK SM CNC may be programmed and operated in either or in a combination of absolute or incremental dimensions An absolute reference from which all absolute dimensions are measured in DRO and program operation can be set at any point on or even off the workpiece To help understand the difference between absolute and incremental position consider the following example ABSOLUTE DIMENSIONS ABSOLUTE REFERENCE i00169 INCREMENTAL DIMENSIONS FIGURE 5 3 Each point has both an absolute and an incremental reference in the X axis The 5 4 5 5 ProtoTRAK SM CNC allows you to program using either Referenced amp Non Referenced Data Data is always loaded into the ProtoTRAK SM CNC by using the INC SET or ABS SET key X Y Z positions are referenced data In entering any X Y or Z position data you must note whether it is an incremental or absolute dimension and enter it accordingly All other information non referenced data such as tool diameter feedrate etc is not a position and may therefore be loaded with either the INC SET or ABS SET key This manual uses the term SET when either INC SET or ABS SET may be used interchangeably Incremental Reference Position in Programming When X Y Z RAPID and Z data for the beginning position of any event are input as incremental data this increment must be measured from some
140. ke changes Once you do this the Resolve key will appear Resolve press this to have the Math Help use the new data to give new solutions Windows Up or Down Some of the selections in the ProtoTRAK SM CNC will cause a window to appear with a message To eliminate the window in order to see what is behind it press the hard key To restore the window press the hard key 18 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 5 0 5 1 5 2 Definitions Terms amp Concepts ProtoTRAK SM CNC Axis Conventions X Axis positive X axis motion is defined as the table moving to the left when facing the mill Consequently measurement to the right is positive on the workpiece Y Axis positive Y axis motion is defined as the table moving toward you Measurement toward the machine away from you is positive on the workpiece Z Axis positive Z axis motion is defined as moving the head up Measurement up is also positive on the workpiece Z Y Xx X FIGURE 5 1 ProtoTRAK SM CNC conventions The Z RAPID dimension is the position at which Z will stop rapid traversing and switch to its programmed Z feedrate Z motion will continue until Z End depth has been reached Part Geometry amp Tool Path Programming The ProtoTRAK SM CNC gives you ultimate flexibility in programming Programs that are entered through the ProtoTRAK SM CNC system can be ente
141. l for drilling a series of evenly spaced holes duplicating some machined shapes or even repeating an entire program with an offset for a second fixture Repeat events may be nested That is you can repeat a repeat event of a repeat event of some programmed event s One new tool number may be assigned for each Repeat Event MIRROR is used for parts that have symmetrical patterns or mirror image patterns In addition to specifying the events to be repeated you must also indicate the axis or axes X or Y or XY are allowed that the reflection is mirrored across In addition you must specify the offset from absolute zero to the line of reflection You may not mirror another mirror event or mirror a rotate event Consider the figure incase FIGURE 8 9 1 Holes 14 are mirrored across the Y axis to 5 8 respectively about a line X OFFSET from X absolute 0 47 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual ROTATE is used for polar rotation of parts that have a rotational symmetry around some point in the XY plane In addition to specifying the events to be repeated you must also indicate the absolute X and Y position of the center of rotation the angle of rotation measured counterclockwise as positive and clockwise as negative and the number of times the specified events are to be rotated and repeated You may not rotate another rotate event or rot
142. l in space It may be programmed with a CONRAD if it is connective with the next event Prompts for the Mill event X Begin is the X dimension to the beginning of the mill cut Y Begin is the Y dimension to the beginning of the mill cut X End is the X dimension to the end of the mill cut incremental is X Begin Y End is the Y dimension to the end of the mill cut incremental is Y Begin Conrad is the dimension of a tangential radius to the next event that must lie in the same plane for part geometry programming 39 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual Tool Offset is the selection of the tool offset to right input 1 offset to left input 2 or tool center no offset input 0 relative to the programmed edge and direction of tool cutter movement and as projected in the XY plane Feedrate is the milling feedrate from Begin to End in in min from 1 to 100 or mm min from 5 to 2540 Tool is the tool number you assign Continue input 1 for Yes if you want to mill continuously from this line to the next event input 2 for No if you want the ProtoTRAK SM to stop at the end of the event 8 4 ARC Events 8 5 This event allows you to mill with circular contouring any arc fraction of a circle In ARC events when X Center and Y Center are programmed incrementally they are referenced from X End and Y End respectively An ARC event may be pro
143. ll Request NO Auxiliary Function Request NO Event Comments NO Multiple Fixtures NO Dimension Definition PART GEOMETRY 2 Program Name Fi F2 F3 F4 F5 F FF FS DATA DATA GOTO GOTO GOTO FWD BACK BEGIN END FIGURE 7 2 The Program Mode header screen 29 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 7 3 Program Header Screen The first screen you see when you enter the Program Mode is the Program Header Screen The Program Header Screen gives you options that apply to the entire program The softkey selections allow you to enter the program at any point The program name and general programming options you choose in the Program Header Screen will be summarized in the program as Event 0 7 3 1 Program Name Programs written on the ProtoTRAK SM CNC are usually named for the part that is to be machined When programs or files are named using the ProtoTRAK SM CNC the name can be up to 20 characters long Programs imported into the ProtoTRAK SM CNC may be longer While 20 characters are allowed the entire program name may not be shown in the status line or the program header screen PROGE SSS SS eS Program Name Scale Dwell Rewzcct Auxiliary Event Co Dimensio AXIS INCH FIGURE 7 3 Pressing the Help hard key when the Program Name is highlighted calls up alpha keys Program names can include
144. ll appear when the prompt is on X or Y dimensioned data Press the Guess key before you press INC SET or ABS SET to enter the data as a guess See Section 10 7 70 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 10 3 10 4 10 5 A G E Arc Prompts Press the A G E ARC key Prompts in A G E Arc programming Tangent this refers to the tangency of the mill to the previous event See Section 10 11 for a discussion of tangency DIRECTION is the clockwise input 1 or counterclockwise input 2 direction of the arc X END is the X dimension to the end of the arc cut incremental is from X Begin Y END is the Y dimension to the end of the arc cut incremental is from Y Begin X CENTER is the X dimension to the center of the arc incremental is from X End Y CENTER is the Y dimension to the center of the arc incremental is from Y End CONRAD is the dimension of a tangential radius to the next event RADIUS is the radius of the arc CHORD LENGTH is the straight line distance from the begin point to the end point CHORD ANGLE is the angle spanned by the arc In addition to the normal Softkeys this additional one will appear in A G E Arc programming GUESS this softkey will appear when the prompt is on X or Y dimensioned data Press the Guess key before you press INC SET or ABS SET to enter the data as a guess See Section 10 7 Skipping Over Prompts In
145. ments Software 33 software and firmware version 141 load EEPROM file Displays current software versions and system settings To load in set up values from a disk in the floppy drive 142 save EEPROM file To set up values to a file on a floppy drive 316 software update master Use with floppy disk 317 software update slave 318 converter activation 37 RS232 Baud rate To set for RS232 communication 232 RS232 com port Change default Machine set up 123 sensor calibration 132 handwheel test 100 open loop test DANGER The machine will move 129 arc accuracy setting To enter the preference Default is 001 304 toggle X glass scale or TRAK sensor on or off 304 toggle Y glass scale or TRAK sensor on or off Run the machine from the motor encoders in case of table scale or sensor failure Run the machine from the motor encoders in case of saddle scale or sensor failure Servo calibration 128 backlash calibration constant 127 auto backlash configuration 11 backlash hysteresis test Service code number 12 feed forward constant None CAUTION The servo parameters may change Shortcut to entering the service code when you know it 91 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 92 Southwestern Industries Inc TRAK Knee Mill am
146. mming Operating amp Care Manual XOFF SET t 100838 FIGURE 9 10 1 Holes 1 4 are mirrored across the Y axis to 5 8 respectively about a line X OFFSET from X absolute 0 ROTATE is used for polar rotation of parts that have a rotational symmetry around some point in the XY plane In addition to specifying the events to be repeated you must also indicate the absolute X and Y position of the center of rotation the angle of rotation measured counterclockwise as positive and clockwise as negative and the number of times the specified events are to be rotated and repeated You may not rotate another rotate event or rotate a mirror event Consider the figure below X CENTER i00840 FIGURE 9 10 2 Shape A programmed with 4 MILL events and Conrads Using ROTATE these 4 events are rotated through a 45 degree angle about a point offset from absolute zero by X Center and Y Center dimensions A is rotated 3 times to produce shape B C and D Press the SUBROUTI NE SUB soft key to call up the Repeat Mirror and Rotate options 63 Southwestern Industries Inc TRAK Knee Mill and Proto TRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 9 10 1 Repeat Press the REPEAT soft key Where First Event is the event number of the first event to be repeated Last Event is the event number of the last event to be repeated if only one event is to be repeated the Last Event is the same as the First Event X Off
147. mputer or control or you may give it a different name After entering the file name move the cursor to the Open As box and select the format of the file that you wish to receive as it exists in the remote computer or control For example if you were transferring a Haas file from a Haas CNC you would select the file type HS1 After you have set up the ProtoTRAK SM CNC to receive the file press the Open soft key A message window will appear to notify you that the ProtoTRAK SM CNC is ready to receive the file If the remote computer or control is a TRAK or ProtoTRAK CNC or is a computer that is running ProtoTRAK or TRAK A G E offline software you can send the file by simply using the Save softkey via the RS232 in the Program In Out Mode If the remote computer or control is not a TRAK or ProtoTRAK CNC consult your manual for sending files via the communications port Modern Windows operating systems have programs such as Windows hyper terminal and CAD CAM systems have the capability of communicating via the RS232 port Modern Windows operating systems have programs such as Windows hyper terminal and CAD CAM systems have the capability of communicating via the RS232 port The commands for an MS DOS system are mode COM1 4800 e 7 1 to set up the port where COM1 is the serial port on the remote computer and copy filename COMI to send a copy of the file to the COM1 port As the program is received it will be converted
148. n Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 14 5 PROG 0 PIN 0807 E AXIS l INCH SAVE Look In r B 0807 2 PT4 sw 2615 PT4 File Name 0807 Save As SWI PT4 r Fi F2 F3 F4 FS F F7 Fe pata DATA OPEN CREATE SAVE TAB FWD BACK FOLDER FOLDER FILE RETURN FIGURE 14 4 The Save screen File Name displays the name of the file that is in current memory Save As lists the formats for which the file may be saved The default is PT4 Three additional softkeys appear CREATE FOLDER Use this to create a new folder for the program file This new folder will be added to the list shown in the listing area at the same level of organization as the files and folders shown Once the CREATE FOLDER softkey is pressed a Data Input Line will appear for entering the name of the folder The name Folder will be written in the box To accept this name press SET You may input a name you select by writing over this name Use the same procedure for naming a program see Section 7 3 1 SAVE FILE Saves the program file to the location shown in the Look In area RETURN Returns to the Program In Out Mode screen Once the save operation is finished you will see the file name added to the files in the listing area Copying Programs To copy a program file from one storage location to another press the COPY softkey from the Program In Out Mode screen
149. n the cursor to the prompt and re input the data 10 10 Arcs and Conrads If the print is missing a lot of data it may be desirable to program arcs as separate events where possible This gives the system more information to work with 10 11 Tangency Tangency can occur between a mill and arc or an arc and arc Specifically it means that the two events share one and only one point You would answer yes to the TANGENCY prompt if the event you are programming is tangent to the previous event The 74 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual information that events are tangent helps the Auto Geometry Engine calculate other dimensions You can often tell by looking at the print if events are tangent tangent intersections tend to blend smoothly without a sharp corner a smooth probably tangent sharp not tangent For the A G E the tangent mill or arc are assumed to continue in the same direction and not double back on the previous event oe like this not this 75 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 76 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 11 0 Edit Mode Within Program Mode you can recall and re input specific data prompt by prompt The Edit Mode contains powerf
150. n tool path If you wish to program the part by defining tool path yourself you may choose the TOOL PATH softkey Otherwise Part Geometry programming is assumed Tool Path operates under the same rules as Haas standard RS274 A program must be entirely written in Part Geometry or Tool Path programming you cannot combine the two methods in one program 7 3 3 Program Header Softkeys The following softkeys are encountered in the Program Header Screen The first five listed below are always there The last four appear when relevant to the general programming option DATA FWD moves the highlight forward through the programming options without setting an input into the program DATA BACK moves the highlight backward through the programming options without setting an input into the program GO TO BEGIN puts the Program Header on the left side of the screen and the first event on the right side GO TO END puts the last programmed event on the left side of the screen and the next event to be programmed on the right side GO TO enter the event number you wish to go to and then press SET Puts the requested event number on the right side of the screen and the previous event number on the left Note for a new program that has no Events all the GO TO selections will take you to the beginning with the program header information summarized on the left as Event 0 and the Select an Event options for Event 1 on the right YES and NO Y
151. ncrements The changes in speed may be seen in the Feed rate box and on the green feed rate indicator The amount of override is displayed in the Override box To jog at a certain rate simply enter that number as inches or mm per minute and then press the X Y or Z key You may also use the override key to adjust this number Press RSTR to return to 100 ipm or 2540mm Press RETURN soft key to return to manual DRO operation Z axis jog available for the three axis CNC only 6 4 Power Feed The servomotors can be used as a power feed for the table saddle or quill or all three simultaneously a b Press the POWER FEED soft key A message box will appear that shows the power feed dimensions All power feed moves are entered as incremental moves from the current position to the next position Enter a position by pressing the axis key the distance to go and the key if needed Input the entry by pressing INC SET For example if you wanted to make a power feed move of 2 00 of the table in the negative direction you would enter X 2 INC SET 26 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 6 5 6 6 d Initiate the power feed move by pressing GO e The feedrate is automatically set to 10 ipm or 254 mm per min Press FEED 4s or FEED to adjust the feedrate from 1 ipm to 100 ipm or 254 to 2540 f Press STOP to halt
152. ng amp Care Manual 125 Southwestern Industries Inc 14 14 6 Accepted M Codes Function A pause is generated The axes will not move but the motors will be engaged The spindle motor will not turn off Executed automatically at the end of all programs Turns off the servo motors and all auxiliary functions The auxiliary function box must be present for this function to work Stops the spindle at the end of the current event The auxiliary function box must be present for this function to work Tool change The M06 is ignored as the tool change on the ProtoTRAK is accomplished by changing the tool number Flood coolant on This will turn on the auxiliary box A C outlet before the event Mist coolant on This will turn on the air supply from the auxiliary box before the event M12 amp M20 Coolant off This will turn off the auxiliary box A C outlet and air supply after the event Send a pause to the indexer and wait for an in position response Notes All other M codes will be ignored 1 Place M Codes on same line as movement G Code 2 One M Code per block 126 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 15 0 Sample Programs 15 1 Sample Program No 1 2 Axis Profile with This program is designed to provide practice with the ProtoTRAK Limited Print Data
153. ng without the tool set up is one of the benefits of using a two axis CNC 12 1 3 The Logic of the Tool Table The tool table is organized to do the following e Make it easy to set up tools e Make it easy to replace a tool or add a tool e Retain tool information in memory to reduce set up You assign tool numbers as you write a program These tool numbers may be from 1 to 99 Before machining the diameters and Z offset of each of the tools in the program 84 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual must be defined so that the ProtoTRAK SM CNC can calculate the tool path Tools that are used in the program that is in current memory are called active tools and their numbers are in red in the tool table When you save a program all the tool information for active tools is saved with it When the program is opened the tool information is put into the tool table This information will replace any information that already is in the tool table for the same tool numbers In addition to information about the tools used in a program you may load in information for tools to be used in 2 axis CNC or in the DRO mode for machining manually When you tell the ProtoTRAK SM CNC which tool you are using it will adjust the Z DRO dimensions accordingly so you don t have to touch off and reset after a tool change The idea of retaining tool information in memory
154. ng ProtoTRAK SM Files on ProtoTRAK amp TRAK CNC 108 TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 14 11 14 12 14 13 14 14 15 0 15 1 15 2 16 0 16 1 16 2 16 3 16 4 16 5 16 6 16 7 17 0 17 1 17 2 17 3 17 4 17 5 17 6 17 7 17 8 17 9 17 10 Running G Code Files 14 11 1 G Codes Recognized by the ProtoTRAK SM CNC 14 11 2 M Codes Supported by the ProtoTRAK SM CNC 14 11 3 Valid Characters for Word Address Sequences Networking 14 12 1 What is a Network 14 12 2 Why would you want to use the networking capability of the ProtoTRAK SM CNC control 14 12 3 A Word of Advice Before Setting Up Your Network 14 12 4 Peer to Peer Network 14 12 5 Basic Network Set Up 14 12 6 Server amp Client Network Overflow 14 12 7 Network Description of the ProtoTRAK RS232 Interface 14 13 1 Connections 14 13 2 Receiving a File 14 13 3 Sending a File CAD CAM amp Post Processors 14 14 1 Writing a Post Processor 14 14 2 Convertible G Codes 14 14 3 Supported Addresses 14 14 4 Format Terms amp Definitions 14 14 5 G Codes that Generate Errors 14 14 6 Accepted M Codes Sample Programs Sample Program No 1 Sample Program No 2 Description of TRAK K Mills TRAK K Mill Models Machine Overview Machine Dimensions Machine Specifications Maximum Machining Capacities Machine Options Lubrication 16 7 1 Manual Lubrication 16 7 2 Head Lubrication Machin
155. ning it is necessary to activate the spindle brake See 17 4 above If the tool holder does not release from the spindle lightly tap on the top of the bar to dislodge the tool 17 6 Changing Speeds High Low Neutral Level The spindle speed may be varied within a low range 70 500 RPM or high range 600 to 4200 RPM The range selection is made through the High Low Neutral Lever Figure 17 6 140 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual CAUTI ON Never attempt to change the range selection through the High Low Neutral lever when the spindle is rotating Be certain the spindle ON OFF switch is in the Off position Rotate the spindle by hand to help engage the lever into the high or low position Note Shifting from the high to low range or low to high range changes the direction of rotation for the On Off switch See Section 17 1 17 7 Changing Speeds Variable Speed Within each speed range the spindle speed may be varied by rotating the variable speed crank CAUTI ON Do not rotate the variable speed crank when the spindle is stationary 17 8 Operating the Quill The quill may be moved up and down through its range with the quill feed handle The quill may be locked into position by rotating the quill lock clockwise Pull the handle out slightly to rotate it freely to a new position 17 9 Adjusting the Quill Stop The quill s
156. nt to be rotated if only one event is to be rotated the last event is the same as the first X Center is the X absolute position of the center of rotation Y Center is the Y absolute position of the center of rotation Angle is the angle of rotation of the repeated events positive is counterclockwise negative is clockwise Repeats is the number of times events are to be rotated up to 99 64 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 9 11 9 12 COPY Events Copy Events are programmed exactly like Subroutine Events The only difference is that in Copy the events are rewritten into subsequent events If for example in Event 11 you Copy Repeated Events 6 7 8 9 10 with 2 repeats Events 6 10 would be copied with the input offsets into Events 11 15 and recopied into 16 20 Copy Events may be Repeat Mirror or Rotate Copy is very useful With copy you can Edit the events that are being repeated mirrored or rotated without changing the original events Connect so that the quill will not move up to the Z Rapid position and back down unnecessarily However to be connective you must be certain that the X Y Z begin of the first event once offset or rotated coincides with the X Y Z end of the last event Program an event parallel to X or Y where the geometry is the easiest to describe rotate it to the desired position and
157. nto the Z Offset column Once it set the highlight will not go into the Ref row that is you will not be able to highlight and reset your reference once it says SET The soft keys in the tool table DATA DOWN DATA UP DATA LEFT DATA RIGHT move the highlight around the table ERASE TABLE clears all tool information so you can start over See 12 1 4 below JOG puts the ProtoTRAK SM CNC into the DRO jog operation see Section 6 3 RETURN reverts to the SET UP mode screen The electronic handwheels are active including the fine coarse selection while you are in the tool table 12 1 2 Simple Tool Set Up for Two Axis CNC Machining When machining in two axis CNC you have a choice for how much tool set up you want to do Ata minimum you must tell the ProtoTRAK SM the tool diameter for all the active tools in the program active tools have red numbers when you want tool compensation applied or when you are machining a pocket If you want Z tool offsets applied to the DRO measurement you can do the set up steps in the following sections For most two axis work however this is not worth the effort During program run you can easily set or zero out your Z dimensions when you change tools If you want to do the minimum simply enter the diameters for the active tools in the Tool Table Please also read Sections 12 1 5 12 1 10 and 12 1 11 for general information about the tool table The other 12 1 sections may be safely ignored Doi
158. o 7 11 3 Erase Program Use the ERASE PROG soft key to erase the program from the current memory Erasing the program from current memory will not affect any programs that are stored If you have made changes to the program and wish to save this modified program you will need to store it See Section 14 4 11 4 Clipboard The Clipboard feature is a way to copy events in one program in order to put them into a different program It is a two part process that takes place in two different Modes First in the Edit Mode the desired events are copied or placed on the Clipboard from the source program Then the events are inserted into the destination program in the Program Mode When you press the Clipboard key from the Edit Mode you start the process that copies the events that you want to put into a different program than the one in current memory Before you do that you should write a program or open the program file that has the events you want to copy This is called the source program Inspect the events you want to copy Make sure that the dimensioned data uses Absolute references in the first event to be copied and in all events where it will be important Incremental references may be used but keep in mind where the Incremental reference will be made from See the section on Incremental Reference Position in this manual 81 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming
159. of the earth you could go clockwise or counterclockwise around the equator or you could go up over the north pole or down under the south pole The ProtoTRAK SM CNC will automatically assume that all 180 arcs that have the same beginning ending and center dimensions for Z lie in the XY plane If you want a 180 arc in a vertical plane you must program two 90 arcs or some equivalent Prompts for the Arc event X Begin is the X dimension to the beginning of the arc cut Y Begin is the Y dimension to the beginning of the arc cut Z Rapid is the Z dimension to transition from rapid to feed Z Begin is the Z dimension to the beginning of the arc cut X End is the X dimension to the end of the arc cut incremental is from X Begin Y End is the Y dimension to the end of the arc cut incremental is from Y Begin Z End is the Z dimension to the end of the arc cut incremental is from Z Begin X Center is the X dimension to the center of the arc incremental is from X End Y Center is the Y dimension to the center of the arc incremental is from Y End Z Center is the Z dimension to the center of the arc incremental is from Z End Conrad is the dimension of a tangential radius to the next event which must lie in the same plane Direction is the clockwise input 1 or counterclockwise input 2 direction of the arc as viewed looking down for an arc in the XY plane looking from the front for a vertical plane or looking from the right fo
160. oint of the last event must be the same as the X and Y beginning point so that the pocket is closed Otherwise the ProtoTRAK SM CNC cannot program the tool path to clear the pocket The Irregular Profile has no such restriction since profiles may be open or closed Once the A G E is ended the Irregular Pocket or Irregular Profile event is complete and you may then choose from all the programming canned cycles from the Select an Event screen To reopen the A G E Profile or Pocket simply use the BACK hard key or the PAGE FWD or PAGE BACK softkeys to position on of the A G E events on the right side of the screen You may edit or insert other events Guessing Data Whenever you are missing X or Y Ends or Centers you should generally enter a guess Guessed data is treated differently by the ProtoTRAK SM CNC than regular data Often the information you put into the system will allow it to calculate a mathematically correct line or arc that would satisfy the conditions of the hard data you entered This line or arc may yield more than one solution to particular point you are looking for That is where the Guess comes in the A G E uses the guess to choose from the mathematically possible solutions In most cases your guesses do not have to be very precise The smaller the lines or arcs the more precise the guess should be PROG PIN PIN 0812 2 TOOL 1 3 AXIS INCH EVENT1 IRR PROFILE EVENT2 AGE MILL Be X BEGIN 0 0000 abs TANGENT Y B
161. ometry programming Tool Offset is the selection of the tool offset to right input 1 offset to left input 2 or tool center no offset input 0 relative to the programmed edge and direction of tool cutter movement and as projected in the XY plane 52 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual Z Feedrate is the Z feedrate from Z Rapid to Z begin XYZ Feedrate is the milling feedrate from Begin to End in in min from 1 to 100 or mm min from 5 to 2540 Tool is the tool number you assign 9 5 ARC Events This event allows you to mill with circular contouring any arc fraction of a circle that lies in the XY plane or a vertical plane see Section 5 10 Vertical plane arcs are also limited to those that are entirely concave or convex in other words if you think of the arc lying on the surface of the earth then it can t cross the equator In ARC events when X Center Y Center and Z Center are programmed incrementally they are referenced from X End Y End and Z End respectively An ARC event may be programmed with a CONRAD if it is connective with the next event this next event must lie in the same plane as the Arc event Note When an arc is a 180 arc there are several paths that all have the same beginning ending and center locations To illustrate Imagine that if you were on the earth s equator and you wanted to get to the other side
162. on the table or in the fixture Use stop blocks to prevent objects from flying loose Use proper holding clamping attachments and position them clear of the tool path Use correct cutting parameters speed feed depth and width of cut in order to prevent tool breakage Use proper cutting tools for the job Pay attention to the rotation of the spindle Left hand tool for counterclockwise rotation of spindle and right hand tool for clockwise rotation of spindle Prevent damage to the workpiece or the cutting tool Never start the machine including the rotation of the spindle if the tool is in contact with the part Check the direction or of movement of the table when using the jog or power feed Don t use dull or damaged cutting tools They break easily and become airborne Inspect the sharpness of the edges and the integrity of cutting tools and their holders Use proper length for the tool Large overhang on cutting tools when not required result in accidents and damaged parts Prevent fires When machining certain materials magnesium etc the chips and dust are highly flammable Obtain special instruction from your supervisor before machining these materials Prevent fires Keep flammable materials and fluids away from the machine and hot flying chips When working in manual mode not CNC make sure the computer control is switched to DRO or OFF 7 Southwestern Industries Inc TRAK Knee Mill amp Proto
163. or Two Axis CNC Machining 84 12 1 3 The Logic of the Tool Table 84 12 1 4 Initial Tool Set Up 85 12 1 5 Starting Over Erasing Tool Info 86 12 1 6 Adding a Tool 86 12 1 7 Replacing a Tool 86 12 1 8 Z Modifiers 87 12 1 9 Resetting the Reference Point 87 12 1 10 Saving Tool Information 87 12 1 11 Opening a Program 87 12 1 12 Making Tool Set Ups Easy 88 12 1 13 Tool Table amp 2 Axis CNC Operation 88 Tool Path 88 12 2 1 Soft Keys in Tool Path 89 Reference Positions REF POSN 89 12 3 1 Z Retract 90 12 3 2 Home Positions 90 12 3 3 Limit Positions 90 Fixture Offsets 90 Service Codes 91 Run Mode Run Mode Screen 93 Two Versus Three Axis Running 93 Starting to Run 94 Program Run 94 Program Run Messages 95 Stop 95 Feedrate Override 95 Trial Run 95 Data Errors 96 Fault Messages 96 Program In Out Mode Softkey Selections in the Program In Out Mode 98 Basic Navigation of Program In Out Mode Screens 98 14 2 1 Basic Parts of the Program In Out Mode Screens 98 14 2 2 Softkeys in the Program In Out Mode Screens 99 Opening a File 99 Saving Programs 99 Copying Programs 100 Deleting Programs 101 Renaming 102 Backing Up 103 Converters 104 14 9 1 Activating Converters 104 14 9 2 Converting from a Different Format Into a ProtoTRAK SM CNC 105 14 9 3 Converting from the ProtoTRAK CNC to a Different Format 106 ProtoTRAK and TRAK CNC Compatibility 106 14 10 1 File Formats 107 14 10 2 Opening MX2 amp MX3 Files 107 14 10 3 Runni
164. our manual for sending files via the communications port The MS DOS commands for receiving the file are mode COM1 4800 e 7 1 and then copy filename COM1 The receiving computer or control will attach the filename to the program it receives via the RS232 port When the receiving computer or control is ready press the Save key a second time to send the file Once the file is sent the Program In Out Mode Save screen will remain and the Look In drive will change to the one used previous to the RS232 operation 14 14 CAD CAM and Post Processors In addition to running G code files the ProtoTRAK will also accept CAM files and convert them into the ProtoTRAK events This is a great advantage as it allows you to have your CAD CAM programmer send files to the machine that the machinist can then work with in the familiar ProtoTRAK interface The machinist can modify the program as necessary without having to go back to the CAD CAM programmer In order to be able to convert the program from a CAM system to a ProtoTRAK program the CAM program must be two or 2 axis A 2 axis program is defined as a program where the Z axis is stationary while X and Y is moving If you want to run a full three axis program you should run a G Code or GCD program see section 13 11 The above 2 axis restriction does not mean that the ProtoTRAK is not capable of running three axis simultaneous programs written in ProtoTRAK events as some ill
165. p ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 13 0 RUN MODE 13 1 Run Mode Screen Press MODE and select the RUN soft key The display will show RUN PIN RO424 11 TOOL 1 3AXIS INCH Event 1 RUN Repeat 0 X 0 0000 ss Y 0 0000 s Z 2 0000 x2 Feed Rate 100 0 SO S Override 100 F F B H F F FT Fg START TRIAL STARI EVENT RUN i01060 FIGURE 13 1 The Run Mode The ProtoTRAK SM CNC awaits your instructions for how to begin machining Part Number R0424 11 Items on the Run Screen Event counter this will be the current event number and event type Repeat if a repeat event is in the event counter this will show which repeat number for example if you program a drill with 5 repeats this will show which repeat of the event that is being machined Feed Rate programmed feedrate of the current move as adjusted by the feed override Green bar graphical representation of the feed override Override of feed override 13 2 Two Versus Three Axis Running The three axis run will control all three axes the two axis will control the X and Y table and saddle only with you manually positioning the Z head Most differences that occur as a consequence of either two or three axis operation are obvious Two issues are worth noting 1 The way the tool table works between two and three axis operation See Section 12 1 2 Positioning of the quill is automatic in the 3 axis CNC but in two axi
166. p ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual Your guess entries are loaded into the program when you exit the LOOK screen by pressing BACK or by pressing LOOK again The ProtoTRAK will use the last ENTER key press and load that into the program When you use the graphics to guess dimensions on arcs you may load in guesses for both the X Y End and the X Y Center before leaving the LOOK screen When you have not first pressed the Guess key pressing LOOK gives you the same screen as in regular programming Whether you enter the guesses as key presses or by using the graphics the drawing of the LOOK screen distinguishes between events that are fully defined and those that rely on guessed data OK events are represented by solid lines NOT OK events are represented by dashed lines PROG PIN 080701 SAXIS INCH Fi ADJUST _ VIEW XZ 3D F2 F3 F4 FIT LIST START DRAW STEP EVT FIGURE 10 8 2 when the events are calculated based on Guessed data they are represented by a dotted line gt 10 9 Calculated Data Prompts that are skipped or for which guesses are entered may be replaced by data calculated by the ProtoTRAK SM CNC Calculated data is shown in red in order to distinguish it from the data that you entered You cannot edit calculated data but you may edit your original input By putting the event with the calculated data on the right side of the screen you may positio
167. p with prompt press go to procd M01 optional stop M02 end of program no rewind M03 spindle CW M04 spindle CCW M05 spindle stop M06 tool change M07 mist coolant ON M08 flood coolant ON M09 coolant OFF M30 end program rewind stop M79 Send SWI O ascii 79 commands value in P word M98 Subroutine Call to block PWORD repeat L WORD 109 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 14 11 3 Valid Characters for Word Address Sequences G Prepare to execute a G COMMAND ParseGcode M Prepare to execute a M COMMAND ParseMcode N Introduces a block number ParseEventNum T Specifies the tool number to use ParseToolINum F Specifies a feedrate ParseFcode S Specifies a spindle rom ParseScode D Specifies the diameter for the current tool ParseDval E Optional parameter ParseEval X Specifies the X dimension ParseXval Y Specifies the Y dimension ParseYval Z Specifies the Z dimension ParseZval l Specifies the incremental X dimension Parsel val J Specifies the incremental Y dimension Parse val K Specifies the incremental Z dimension ParseKval L An Optional Parameter ParseLval P An Optional Parameter ParsePval Introduces a comment ParseComment 14 12 Networking This portion of the ProtoTRAK SM CNC manual is written to give you a brief overview of networking and point out the benefits that can be received when setting up th
168. pany name and complete address Name of trainer Machine Name Machine Model Machine Serial No In order for SWI to process a trainee for certification all aspects of the training on the product must be successfully completed to the satisfaction of the trainer and the trainee Please fill out and sign this document when the training is completed and send it to Ruby Yonan at Southwestern Industries Upon receipt the certification document will be created and sent to the trainee Complete the following information Place a checkmark next to each of the completed training areas Definitions terms and concepts for Axes Planes and Referenced Data The DRO Mode and using the machine tool manually Programming using all canned cycles Editing capabilities Using all of the program storage and retrieval choices Converting data from other program sources Setting up tools and using the tool table Programming setting up and running a complete part 9 Understanding networking capabilities 10 Using Math Help Using AGE capability in programming profiles 12 Using Windows functions for non programming functions 13 A review of related SWI products and compatibility to the SM control Trainee Signature Date Trainer Signature Date ining ProtoTRAK SM Tra F10371 2 05 30 02 Southwestern Industries Inc Trav A Dial amp TRAK Warranty Policy Warranty Trav
169. r a vertical YZ plane Tool Offset is the selection of the tool offset to right input 1 offset to left input 2 or tool center no offset input 0 relative to the programmed edge and direction of tool cutter movement and as projected in the XY plane Z Feedrate is the Z feedrate from Z Rapid to Z Begin 53 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 9 6 XYZ Feedrate is the milling feedrate from Begin to End in in min from 1 to 100 or mm min from 5 to 2540 Tool is the tool number you assign POCKET Event This event selection gives you a choice between circle pocket rectangular pocket and irregular pocket within the XY plane Pockets include machining the circumference as well as all the material inside the circumference of the programmed shape If a finished cut is programmed it will be made at the completion of the final pass The cutter will arc in and arc out of the finish cut and position itself the finish cut dimension away from the part before moving the tool out of the part The factory setting for tool stepover while machining a pocket is 70 This may be changed When you first enter the pocket event the blue will appear next to the help key Pressing Help will give you the choice of entering a new tool stepover percentage The value you enter here will remain the same until you change it again 9 6 1 Circular Pocket Press th
170. red as either Part Geometry or Tool Path Part Geometry programming is the popular programming style of the ProtoTRAK family of products This is done by defining the final geometry of the part and the ProtoTRAK SM CNC has the job of figuring out the tool path from the part dimensions and the tool set up information This is a great benefit compared to regular CNC because it doesn t force the programmer to do the difficult job of defining tool path A consequence of part geometry programming is that the following are not allowed e connection of an incline plane and another event e connection of two events that lie in different vertical planes Using Geometry Programming it is impossible for the ProtoTRAK SM CNC to calculate a tool path for these cases without creating a problem in cutting the geometry desired in the first event the tool ends up out of position for the next event Resolving the difference in tool position where the first event ends and the next event begins means either the CNC calculates and makes an unprogrammed move or it retracts the tool out and then back into the part 19 Southwestern Industries Inc TRAK Knee Mill and Proto TRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 5 3 These cases are not encountered often but when they are you have the option of using Tool Path programming In Tool Path programming you define the events the same way but all inputs are treated as tool center It
171. reen next to the HELP key 3 1 2 Soft Keys Beneath the display are 8 keys that are labeled with arrows These keys are called software programmable or soft keys A description of the function or use of each of these keys will be shown at the bottom of the display directly above each key If at any time there is no description above a key that key will not operate Sometimes the description or function of the key is visible but grayed out This indicates that the particular function is not available because of some other condition For example if the Z retract is not set the RUN mode key will be grayed out because setting the Z retract is a necessary step for running a program 3 1 3 Emergency Stop Switch The emergency stop E stop switch kills all power to the spindle and ProtoTRAK s servomotors The computer and pendant remain powered 10 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 3 1 4 The Liquid Crystal Display LCD The display of the ProtoTRAK SM CNC is a 10 4 active matrix color LCD The very top is the Status Line that shows the overall status of the ProtoTRAK SM CNC This includes the current Mode the current program part number the current tool number 2 or 3 axis mode and whether the X Y and Z dimensions are in inch or millimeter mm Just above the soft keys is a data input line that appears when an input is required 3 2 Pend
172. rmat dd use 2 digit only 2 leading 0 suppression 3 range 1 to 99 124 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual F miscellaneous or M codes function number denoted lt prep func gt 1 format dd 2 leading 0 suppression 3 range 1 to 99 G feedrate values denoted lt frate gt 1 format metric ddddd inch ddd dd leading 0 suppression decimal point not required fractional portion is optional range metric 1 to 6350 inch 0 1 to 250 Gi Ooh H RPM command VM 1 format dddd 1000 1000 RPM 14 14 5 G Codes that Generate Errors G Code Function G27 Reference point return check G28 Return to reference point G29 Return from reference point G30 Return to 2 reference point G31 Skip function G33 Thread cutting G37 Tool length automatic measurement G38 Cutter radius compensation vector change G39 Cutter radius compensation corner rounding G45 Tool offset increase G46 Tool offset decrease G47 Tool offset double increase G48 Tool offset double decrease G62 Automatic corner override mode G63 Tapping mode G65 User macro simple call G66 User macro modal call G67 User macro modal call cancel G74 Counter tapping cycle G76 Fine boring G86 Boring cycle G87 Back boring cycle G88 Boring cycle G92 Programming of absolute zero point G95 Feed per revolution TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operati
173. rt As a general rule always set your Z retract so that your longest tool is above the set up When you first enter the Reference Positions screen the Z Retract will show NOT SET and the message window will instruct you to move the ram to the desired retract position and then press SET You may have to go into the DRO Mode to move the ram to where you want it and then return to the Reference Positions screen to set this position 12 3 2 Home Positions X and Y home positions are where the table and saddle go when there is a tool change or at the end of the program These dimensions must always be from absolute zero Note Z home is the same as Z Retract 12 3 3 Limit Positions X and Y limit positions one for plus direction one for minus will stop the program if they are exceeded during run Note that pressing the LIMIT ON OFF soft key will turn the prompted limit off or back on to its input value If the limits are turned on your program and home positions must fit within the limits you define If you turn on the limits and leave them at the default of 0 Absolute the program will not run Fixture Offsets Fixture offsets are entered in the Set Up Mode From the screen in Figure 11 0 press the Fix Offset key The following screen will result SET UP 3AXIS INCH FIXTURE XOFFSET YOFFSET ZOFFSET 1 BASE BASE BASE 2 8 1230 0 1160 0 0000 3 0 0000 0 0000 4 0 0000 0 0000 0 0000 5 0 0000 0 0000 0 0000 6 0 0000 0 0000 0
174. s the ProtoTRAK SM CNC will prompt Check Z before a rapid move and Set Z for you to position the cutter to machine the part 93 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 13 3 Starting to Run Before running a part you must establish the position relationship between the part and quill That is you need to identify where the part is on the table relative to the tool or quill centerline This is done by using an edge finder or dial indicator to move the table so that the part program absolute zero is under the quill centerline ABS SET this position as absolute zero in the DRO mode In addition load the tool for Event 1 and position it at Z absolute zero If this is impossible position the tool some known distance above absolute zero and ABS SET this dimension The program may be started in the two ways identified as soft keys in the screen in Section 13 1 Pressing the START soft key begins the program at Event 1 and assumes that the absolute zero that was last set in the DRO mode corresponds to the part program zero That is if you were in the DRO mode and you moved the table to X 0 ABS and Y 0 ABS the part program zero would be directly under the quill centerline Pressing the START EVNT soft key allows you to start in the middle of a program When you press the START EVNT soft key the conversation line will prompt Input Event
175. s the SYS key then press CONFIG NETWORK This will take you to the Windows desktop 2 From there click on START then go to SETTINGS CONTROL PANEL 3 Double click the NETWORK icon and go to the Configuration tab You should get a window that looks something like the one below Configuration Identification Access Control The following network components are installed E Client for Microsoft Networks E Microsoft Family Logon Dial Up Adapter Realtek RTL8139 PCI Fast Ethernet TCP IP Dial Up Adapter X TCP IP gt Realtek RTL8139 PCI Fast Ethermet xl rapes Primary Network Logan Client for Microsoft Networks v File and Print Sharing f Description Figure 14 12 5 1 There are 4 components that are needed Client for Microsoft Networks Realtek PCI Fast Ethernet Adapter TCP IP File and Printer sharing 4 Double click on Realtek PCI Fast Ethernet it should be the one with the green icon next to it 5 Under the Bindings tab make sure that you have the option checked off which should read TCP IP as shown in Figure 14 12 5 2 112 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual Realtek RTL8139 PCI Fast Ethernet Properties ndnvvwenenesvanstsnanetneanentunensnpennenanssnsnsanensegsnedsnpensneanentensuteasuasienssnansntsnenssnnvansunsnanesnnessnsenensnneerenenen A E Figure 14 12 5 2 6 Exit
176. s the rapid plane to 0 1 Sets the drill depth to 0 75 The radius of the bolt hole circle Angle of first hole from zero 0 degrees Sets drill function for 6 pecks Sets Z plunge rate to 10 ipm Selects Tool 3 0 5 drill This is the end of the program 134 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 16 0 Description of TRAK K Mills This section provides a description of TRAK K Mills If you purchased your ProtoTRAK SM CNC as a retrofit please refer to the user manual that came with your machine 16 1 TRAK K Mill Models The TRAK K Mill comes in the following models TRAK K2S TRAK K2 Knee Mill 33 x12 3HP w PTSM2 CNC TRAK K3S TRAK K3 Knee Mill 32 x16 3HP w PTSM2 CNC TRAK K4S TRAK K4 Knee Mill 32 x16 1 2 5HP w PTSM2 CNC TRAK K2S 3 TRAK K2 Knee Mill 33 x12 3HP w PTSM3 CNC TRAK K3S 3 TRAK K3 Knee Mill 32 x16 3HP w PTSM3 CNC TRAK K4S 3 TRAK K4 Knee Mill 32 x16 1 2 5HP w PTSM3 CNC The 3 designation above indicates that the machine has been fit with the Z axis motor and ballscrew assembly for three axis CNC operation 16 2 Machine Overview SPINDLE MOTOR Figure 16 2 The TRAK K3S overview Shown here as a two axis CNC machine 135 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 16 3 Machine Dimensions PIVOT O
177. set is the incremental X offset from event to be repeated Y Offset is the incremental Y offset from event to be repeated Z Offset is the incremental Z offset from event to be repeated Z Rapid Offset is the incremental Z rapid offset from event to be repeated Repeats is the number of times events are to be repeated up to 99 Feed the percentage of the feeds programmed in the repeated events 100 is assumed Tool is the tool number you assign 9 10 2 Mirror Press the MIRROR soft key First Event is the event number of the first event to be mirrored Last Event is the event number of the last event to be mirrored if only one event is to be mirrored the last event is the same as the first Cutting Order input 1 to cut from the lowest mirrored event to the highest forward and 2 to machine from the highest mirrored event to the lowest backward This way you can keep all the machine motion in a consistent direction as it moves from the original shape to the mirrored shape and keep all cutting either climb or conventional Mirror Axis is the selection of the axis or axes to be mirrored input X or Y or XY SET X Offset is the distance from Y absolute 0 to the Y axis line of reflection Y Offset is the distance from X absolute 0 to the X axis line of reflection 9 10 3 Rotate Press the ROTATE soft key First Event is the event number of the first event to be rotated Last Event is the event number of the last eve
178. should raise your quill out of the pocket Press GO and the tool will move at rapid to the beginning of the next step and then there will be a prompt for you to SET Z for you to position the tool for the depth you want In the Set Up Mode you may check your tool path for hidden areas The yellow X s show points where you will receive a prompt to move the quill The red dashed lines show the rapid moves 8 5 5 Conrad in Pocket Events A conrad may be added to the last event of an Irregular Pocket The conrad will be inserted between the end of the last event and the beginning of the next event 8 6 Islands Within the Pocket event choices you may also select a circular rectangular or irregular island An island is a shape that is left standing when the surrounding material is removed The ProtoTRAK gives you the ability to machine almost any shape as an island within a rectangular pocket Both the shape of the island and the dimension of the surrounding pocket are defined within the island event The tool path for machining the island event is that the tool will machine the perimeter of the island offset by the island finish cut Then the tool will machine the material in the pocket in a spiral path moving away from the island in the programmed clockwise or counterclockwise direction It will continue this outward spiral motion until it encounters the programmed rectangular perimeter or pocket It will then follow the perimeter offset by the
179. ss I J and K for the X Y and Z axes The number following the J and K are incrementally referenced from the starting point of the arc Radius values are not allowed Tool Numbers and Tool Changes the format of the tool number is from T1 to T99 During program run the ProtoTRAK will rapid to home for a tool change and pause for the tool to be loaded manually and the operator to press GO Feed rates the ProtoTRAK is programmed in inches or mm per minute using the F address Spindle speed the ProtoTRAK SM does not have spindle speed control so S values are ignored The VM uses S values File name use the CAM extension so the ProtoTRAK will recognize the file as a CAM file and convert it into ProtoTRAK events when it is opened File names may include up to 20 alpha numeric characters 122 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 14 14 2 Convertible G Codes The following G codes may be used in a CAM file that you want to have converted to a ProtoTRAK program G Codes that are not on the list below have no correspondent operation in the ProtoTRAK events and will be ignored when the program is converted If a G Code is essential to your program and you do not see it here you can do one of two things Convert the file from CAM to ProtoTRAK and add an event to the resulting ProtoTRAK program Run the program as a GCD file See Section 13
180. stablish a reference for the rest of your tools 2 To establish a reference put a cutting tool or some other reference setting tool into the spindle and touch the tool to a surface We recommend that you use something besides a tool that you intend to use machining the job Ideally you will have a reference tool that you keep handy for setting up your tools every time That way a reference point can be easily re established later 3 We also recommend that you use the top of the vice or table as your reference surface because it is constant and never changes 4 With the highlight on the screen on the words NOT SET and the tool touching some reference point press SET NOTE If you do use a tool as your reference tool and it breaks you must retouch off all tools 85 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 5 The words will change from NOT SET to SET and the highlight will shift to the DIAMETER column of Tool 1 Note that you may not be interested in setting up Tool 1 if it is not one of the active tools of the program If this is the case use the DATA softkeys to move to a tool you are interested in 6 Input the diameter for the tool and press SET 7 The highlight will move to the Z OFFSET column Put this tool in the spindle and touch it to the same surface as you used to touch the reference tool in Step 2 above 8 Press set 9 The
181. t Defaults to 0 known print dimension Conrad 15 Sets Conrad of 0 15 Radius Press Page Forward now as no further Chord Length data is required Chord Angle EVENT 4 AGE MILL NOTES Tangent 1 Selects tan mill X End Inc set By default X will remain the same Y End 5 505 abs Known print dimension Conrad Press Page Forward now as no further Angle End data is required Length Line Angle EVENT5 AGE ARC NOTES Tangent 1 Selects tan arc Direction 2 CCW arc direction X End data forward Unknown Endpoint Y End data forward Unknown Endpoint X Center 1 17 abs Known Center Y Center 5 505 abs Known Center Conrad data forward Radius 0 15 abs Known print dimension Chord Length Press Page Forward now Chord Angle 128 Southwestern Industries Inc TRAK Knee Mill amp Proto TRAK SM CNC Retrofit Safety Programming Operating amp Care Manual EVENT 6 AGE ARC NOTES Tangent 1 Selects tan arc Direction 1 CW arc X End Data Forward Unknown data Y End Data Forward Unknown Data X Center Data Forward Unknown Data Y Center Data Forward Unknown data Conrad Data Forward Radius 9 abs Known print dimension Chord Length Press Page Forward now as no further Chord Angle data is required EVENT 7 AGE ARC NOTES Tangent 1 Selects tan arc Direction 1 CW X End data forward Unknown value not required Y End data forward Unknown value not required X Center 2 43 abs Known print dimension Y Center 4 55 abs Known print dimension Conrad data forward
182. t the current position Note This will also reset the incremental dimension if the absolute position is being displayed when it is reset 25 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual Preset Absolute Reference Press X or Y or Z numeric data ABS SET to set the selected axis absolute to a preset location for the current machine position Note This will also reset the incremental dimension if the absolute position is being displayed when it is preset Recall Absolute Position of All Axes Press INC ABS Note the dimension for each axis is labeled INC or ABS Press INC ABS again to revert to the original reading Recall Absolute Position of One Axis Press X or Y or Z INC ABS Note the INC or ABS label for each axis Repeat to get selected axis back to original reading 6 3 Jog The servomotors can be used to jog the table saddle and ram a b h Press the JOG soft key A flashing message will appear saying CAUTION J OG KEYS ARE ACTIVE To jog press the X Y or Z hard keys To stop jogging release the key The speed of jog is displayed in the box next to the words Feed Rate on the lower left side of the LCD screen Press the hard key to reverse direction When the number in the Feed rate box is negative this indicates the minus direction Press the RATE keys to reduce and to increase the jog speed in 10 percent i
183. t the top of the screen will display e The mode e The program name for the program in current memory if any e Whether the ProtoTRAK SM CNC is in two or three axis The Look In area shows the storage areas or drives and directories that are being displayed below in the listing area In the listing area the biggest part of the screen appears all the files and folders for the location shown in the Look In box The C drive of the ProtoTRAK SM CNC is not accessible for program storage The File Name box shows the program file on which the operation will be performed Parts of the screen unique to specific operations will be discussed below 98 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 14 3 14 4 14 2 2 Softkeys in the Program In Out Mode Screens Use the softkeys to move around any of the screens in the Program In Out Mode TAB Moves the highlight between the parts of the screen Where applicable tabbing to an area will cause a drop down box to appear showing all the selections possible DATA FWD DATA BACK Moves the highlight up and down through the list Press and hold for automatic advancement OPEN FOLDER Use this key to open a highlighted folder that contains program files When the highlight is on the root directory this will collapse the list displayed and show the next level up The root directory is represented by a folder with an up
184. tate Copy is very useful With copy you can Edit the events that are being repeated mirrored or rotated without changing the original events Connect so that the quill will not move up to the Z Rapid position and back down unnecessarily However to be connective you must be certain that the X Y Z begin of the first event once offset or rotated coincides with the X Y Z end of the last event Program an event parallel to X or Y where the geometry is the easiest to describe rotate it to the desired position and then delete the original Use the Clipboard to paste previously stored events from another program into the current program After you press the Clipboard key you will enter the offset from the previous program s absolute zero to the current program s absolute zero see figure below For information about putting events into the clipboard see Section 11 4 49 Southwestern Industries Inc TRAK Knee Mill and Proto TRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 8 11 DESTINATION PROGRAM i00965 Figure 8 10 In the above example the offset that puts the group of holes in the desired location is X 1 50 and Y 1 00 Finishing Teach Events Teach events are either POSN DRILL or MILL events that are originated in the DRO Mode see Section 6 6 The Teach events that are started in the DRO Mode must be finished in the Program Mode before running Teach events are of these diff
185. then follow the perimeter offset by the pocket finish cut It will proceed in this manner through the number of programmed passes On the final pass it will machine the island finish cut then the pocket finish cut If a Z finish cut is programmed it will do this in the same spiral pattern as the roughing passes between machining the island and pocket finish cuts The tool will ramp away from the finish cut by the amount of the finish cut before it rises out of the part 9 7 1 Circular Island Press the Circle Island soft key if you wish to mill a circular island Prompts for the Circle Pocket X CENTER is the dimension of the center of the Island Y CENTER is the dimension of the center of the Island Z RAPID is the Z dimension of the transition from rapid to feed Z END is the Z dimension at the bottom of the pocket incremental is from the previous event RADI US is the finish radius of the Island DIRECTION is the milling direction clockwise or counterclockwise PASSES the number of roughing passes to the depth ENTRY MODE choose between zigzag ramp and plunge The plunge will machine straight down Z to the appropriate Z depth The zigzag ramp will move in a zigzag pattern to depth See the previous section for more information about the zigzag ramp FIN CUT ISL Finish cut for the Island If 0 is input there will be no finish cut See the previous section for a bottom finish cut 57 Southwestern Industries Inc TRAK Knee
186. to machine a rectangular island Prompts for the RECT ISLAND X1 ISLAND X dimension for one corner of the rectangular island Y1 I SLAND Y dimension for one corner of the rectangular island X3 ISLAND X dimension for the opposite corner of the island Y3 ISLAND Y dimension for the opposite corner of the island CONRAD ISL the value of the tangential radius in the corners of the island DIRECTION is the milling direction clockwise or counterclockwise FIN CUT ISL Finish cut for the Island If 0 is input there will be no finish cut X1 POCKET X dimension for one corner of the rectangular pocket that surrounds the island Y1 POCKET Y dimension for one corner of the rectangular pocket that surrounds the island X3 POCKET X dimension for the opposite corner of the rectangular pocket that surrounds the island Y3 POCKET Y dimension for the opposite corner of the rectangular pocket that surrounds the island CONRAD PCKT the value of the tangential radius in the corners of the rectangular pocket that surrounds the island FIN CUT PCKT finish cut along the perimeter of the pocket If 0 is input there will be no finish cut FEEDRATE the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 FIN FEEDRATE the finish milling feedrate for both the island and pocket finish cuts TOOL is the tool number you assign 43 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Op
187. to the highest forward and 2 to machine from the highest mirrored event to the lowest backward This way you can keep all the machine motion in a consistent direction as it moves from the original shape to the mirrored shape and keep all cutting either climb or conventional Mirror Axis is the selection of the axis or axes to be mirrored input X or Y or XY SET X Offset is the distance from Y absolute 0 to the Y axis line of reflection Y Offset is the distance from X absolute 0 to the X axis line of reflection 8 9 3 Rotate Press the ROTATE soft key First Event is the event number of the first event to be rotated Last Event is the event number of the last event to be rotated if only one event is to be rotated the last event is the same as the first X Center is the X absolute position of the center of rotation Y Center is the Y absolute position of the center of rotation Angle is the angle of rotation of the repeated events positive is counterclockwise negative is clockwise Repeats is the number of times events are to be rotated up to 99 8 10 COPY Events Copy Events are programmed exactly like Subroutine Events The only difference is that in Copy the events are rewritten into subsequent events If for example in Event 11 you Copy Repeated Events 6 7 8 9 10 with 2 repeats Events 6 10 would be copied with the input offsets into Events 11 15 and recopied into 16 20 Copy Events may be Repeat Mirror or Ro
188. toTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual The prompts for the rectangular pocket X1 is the X dimension to any corner Y1 is the Y dimension to the same corner as X1 X3 is the X dimension to the corner opposite X1 incremental is from X1 Y3 is the Y dimension to the same corner as X3 incremental is from Y1 Z Rapid is the Z dimension to transition from rapid to feed Z End is the Z dimension at the bottom of the pocket incremental is from the previous event Conrad is the value of the tangential radius in each corner Direction is the clockwise input 1 or counterclockwise input 2 direction for milling Passes is the number of cycles to machine to the final depth spaced equally from Z Rapid to Z End hint keep Z Rapid small Entry mode choose between a zigzag ramp and a plunge The plunge will machine straight down Z to the appropriate Z depth The zigzag ramp will move in a zigzag pattern to depth See Section 9 6 5 for more information about the zigzag ramp Fin Cut is the width of the finish cut If 0 is input there will be no finish cut Z Feedrate is the Z feedrate from Z rapid to Z end See Section 9 6 7 for a bottom finish cut XYZ Feedrate is the milling feedrate in in min from 1 to 100 or mm min from 5 to 2540 Fin Feedrate is the milling feedrate for the finish cut Tool is the tool number you assign 9 6 3 Irregular Pocket Press the IRREG PCKT soft key if you wish to mill a
189. toTRAK or TRAK CNC Result The Irregular Pocket will be converted to an Irregular Pocket however the ProtoTRAK or TRAK CNC will display an error message that there are Hidden Areas in the Irregular Pocket We recommend that you separate the Irregular Pocket into two or more Irregular Pockets using the ProtoTRAK SM before conversion The routine will be ignored in the converted program We recommend that you reprogram the Tap Events into Drill or Position events before conversion Copy Repeat Subroutines with Feed or RPM The Feed or RPM function does not exist on the ProtoTRAK or TRAK CNC The Feed or RPM information will be removed from the Copy Repeat Subroutines The programmed feed rates will be run We recommend that you inspect the feed rates before running the program on the ProtoTRAK or TRAK CNC when the s are other than 100 Tool Path Programming Zig Zag Entry Mode Ramps Only Part Geometry programming is supported on the ProtoTRAK or TRAK CNC This routine does not exist in the ProtoTRAK or TRAK CNC You can only transfer Part Geometry programs to the ProtoTRAK or TRAK CNC The routine will be converted to a Plunge routine We recommend that you check your Z feedrate to make sure it will be correct for a plunge Event Comments Thread Mill Event comments are not supported on the ProtoTRAK or TRAK CNC This routine does not exist in the ProtoTRAK or TRAK CNC Event comm
190. top may be adjusted by rotating the micrometer dial nut It is locked in place with the knurled nut 17 10 Quill Feed Several devices are used in controlling the fine quill feed process Each of these devices are described in the 17 10 1 thorough 17 10 4 subsections below Subsections 17 10 5 and 17 10 6 describe the hand and automatic feed procedures 17 10 1 Power Feed Engagement Lever COUNTER CLOCKWISE CLOCKWISE Figure 17 10 1 i00166 The power feed is engaged or disengaged with this selector Pull out the knob and rotate it clockwise to disengage power feed Rotate it counterclockwise to engage power feed 141 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual CAUTION It is recommended that the selector be engaged when the spindle is not running Never have the feed engaged when the spindle RPM is over 3000 Always leave the selector in the disengaged position unless the feed function is being used 17 10 2 Fine Feed Direction Shaft NEUTRAL sN ae se IN RN FA Figure 17 102 i00166 The direction of the fine feed is set by the position of the fine feed direction shaft IN sets the direction down OUT sets the direction up and NEUTRAL in the middle 17 10 3 Quill Feed Selector Figure 17 10 3 Quill Feed Selector for the K2 amp K3 Figure 17 10 4 Quill Feed Selector for the K4 This selector is used to set the quill
191. ty Programming Operating amp Care Manual 3 6 3 7 3 4 3 Remote Stop Go Switch For the convenience of operation while running the program a Remote Stop Go switch may be purchased This switch is on a ten foot cable and operates like the FEED Stop and Go keys on the display 3 4 4 Work Light An optional halogen work light is available It mounts to the left side facing of the column and plugs into a 110v outlet in the electrical cabinet 3 4 5 Coolant Pump The optional coolant pump is mounted in the back of the machine column When used with a 3 axis CNC and auxiliary functions it is plugged into the electrical cabinet to operate as commanded by the auxiliary functions For use with a two axis CNC a manual switch is provided 3 4 6 Auxiliary Functions available for use with the 3 axis CNC Auxiliary functions are controlled through the ProtoTRAK SM CNC either in the program or with the accessory key on the front panel The Auxiliary functions consist of the following e Spindle off command Note This function is not available for retrofits e An air solenoid to control spray misters or other pneumatically activated peripheral equipment Shop air should not exceed 125 psia e Switched and fused 120 VAC 8 Amp outlet s for coolant pumps automatic oilers etc e INPUT OUTPUT to interface with programmable indexers dividing heads etc o Output from ProtoTRAK SM CNC 3 is 3 second actuation of a solid state relay betwe
192. ty does not apply if chips have been allowed to enter the mechanism Accidental damage beyond the control of SWI is not covered by the warranty Thus the warranty does not apply if an instrument has been abused dropped hit disassembled or opened Improper installation by or at the direction of the customer in such a way that the product consequently fails is considered to be beyond the control of the manufacturer and outside the scope of the warranty
193. uill glass scale 139 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 17 2 Table Saddle Knee Clamps The table clamps are located on the front of the saddle Rotate them clockwise until snug overtightening is not necessary The saddle clamp is located on the left side of the saddle Pull forward to clamp the table until snug overtightening is not necessary The knee clamps are located on the left side of the knee for the K2 and K3 mills and on the right side for the K17 CAUTI ON Do not run ProtoTRAK SM program unless the table and saddle clamps are free 17 3 Raising Lowering the Knee The knee is raised and lowered using the hand crank located on the left front of the knee Clockwise rotation moves the knee up while counterclockwise rotation moves the knee down Be sure the knee is unclamped before raising or lowering 17 4 Spindle Brake The mechanical spindle break is activated pulling it down or pushing it up When the lever arm is in the horizontal position the brake is off CAUTI ON Be certain that the spindle brake is released before starting the motor Never attempt to activate the spindle brake when the motor is on 17 5 Draw Bar The draw bar holds the R8 or 40 NST tool holders into the spindle taper The bar has a 5 8 11 right hand thread and should be tightened with a 23mm wrench from the top of the head When tighte
194. ul routines for more extensive program changes The changes you make in the Edit Mode affect only the program in current memory In order to preserve the changes for future use the program must be stored again under the same name in the In Out Mode 11 1 Delete Events To delete a group of events in the program press Delete Events The Data Input Line will prompt for the first event to be deleted Input the event number of the first event and press set Next the Data Input Line will prompt for the last event number to be deleted Put in the last number and press Set The remaining events will be renumbered 11 2 Spreadsheet Editing Spreadsheet Editing allows you to view program inputs in a table and make global changes to the program This is particularly useful if you are working with a large program and you need to make a change to many events When you press the SEARCH EDIT softkey the screen will load a table that contains data for every event See Figure 11 2 1 EDIT PIN RO424 11 TOOL 1 3 AXIS INCH Z XYZ EVT TYPE TOOL oN Z RAPID CONRAD FEED 4 POSITION 2 DRILL 1 0 2500 5 0 3 BOLTHOLE 1 0 2500 50 4 mut 20 3750 5 0 10 0 5 mut 2 3750 50 10 0 6e mit 2 3750 5 0 10 0 7 arc 2 0 3750 50 10 0 CIRC PCKT 2 0 3750 5 0 10 0 o b 3 TAP 3 0 1875 10 HELIX 3 0 1875 5 0 10 0 11 HREAD MILL 4 0 2400 5 0 10 0 FEED FEED 0 0000 0 0
195. urfaces and ball screws 16 7 2 Head Lubrication Once Each Week 1 Fill the oil cup on the front of the head with SAE 30 or 30W oil This oil lubricates the Hi Lo range shifter 2 Fill the ball oiler located in the front lower right corner of the speed hanger housing This oil lubricates the speed changer shaft 3 Extend the quill fully and apply a coating of SAE 30 or 30W oil to the outside diameter of the quill Every Four Months Apply a good grade of general purpose grease through the grease fittings on the back of the head and on the left side of the head The grease lubricates the low range gear set and the feed change gears respectively 138 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 17 0 Machine Operation If you purchased your ProtoTRAK SM CNC as a retrofit please refer to the user manual that came with your machine 17 1 Spindle On Off Forward Reverse The spindle switch is located on the left side of the milling head e Turn the Spindle switch to left to 1 for forward clockwise spindle rotation if the Hi Lo Neutral lever is in the low position e Turn the Spindle switch right to 2 for forward clockwise spindle rotation if the Hi Lo Neutral lever is in the high position e Turn the Spindle switch straight ahead for off MICROMETER QUILL i00906 Figure 17 0 TRAK K3 Mill head front view Shown without the standard q
196. urpose of this manual we will focus on their most basic forms 14 12 3 A Word of Advice Before Setting up Your Network Setting up a network can be very tricky Getting all the necessary components to install correctly and to communicate with your software properly can literally require hours of troubleshooting even by experts If you are very knowledgeable about networking and or have set up a network before then we encourage you to proceed through the following set of instructions If you have little or no experience with computers or networking then we strongly urge you to find a computer consultant to help you set up the network with your new ProtoTRAK SM CNC control You can find these people in the Yellow Pages 14 12 4 Peer to Peer Networking The most basic type of networking is called peer to peer networking This involves simply connecting two or more computers together with a cable attached to a network interface card which is installed into each computer Network I nterface Card also known as an Ethernet Card an electronic circuit adapter card that is placed inside a computer and allows it to attach to a special network cable Network Cable The network cable is what physically plugs into a network interface card to allow the computers to communicate with one another There are many types of network cables The network interface card inside the ProtoTRAK SM CNC control requires a twisted pair category 5 rated network cable wh
197. using it in the program in current memory Put the new tool in the spindle Go to the Set Up Mode tool table Enter the diameter Touch the new tool to the same surface as the reference Press SET O OT E SA If the surface is not available it will be necessary to establish a new reference before adding the new tool See Section 12 1 9 below Once the reference is reset use the procedure above on the new surface used to set the reference 12 1 7 Replacing a Tool If you need to replace a tool that was not used as the reference simply do the following 1 Put the replacement tool in the spindle 2 Put the highlight in the correct row for the tool number 86 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 3 Reenter the diameter if different 4 Touch the tool to the same surface that was used to touch off the reference 5 With the highlight in the Z OFFSET column for the correct tool number press SET If you need to replace a tool that was used as a reference we recommend that you press the ERASE TABLE softkey and start all over again Not to nag but that is why it is a good idea to have a separate reference setting tool and use a constant reference surface If you work with programs that use a lot of tools this practice can really save time 12 1 8 Z Modifiers Z modifiers make it easy to adjust the depth of cut of particular tools without
198. ut To do a trial run press the TRIAL RUN soft key from the screen shown in Section 13 1 The message box will read Ready to begin trial run Press GO to start Be certain the table is positioned so that if it moves through the part program it will not reach its travel limit Also check that the quill is fully retracted Press GO to begin 95 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual 13 9 Data Errors In order to run a program must make sense geometrically For example you can t machine a 250 inch diameter circular pocket using a 500 inch end mill Data errors will nearly always be detected when the ProtoTRAK SM CNC runs through a program either as a Trial Run or on an actual part run They may also be detected in the Set Up mode when using the Tool Path Graphics routines Whenever the ProtoTRAK SM CNC detects a data error a message will appear that will tell you the error number you may wish to record this number for troubleshooting purposes and the event where the error was detected This is not necessarily the event that is in error since the system often looks ahead to make sure there is compatibility from one event to another In addition an explanation is given for each data error type as well as a suggested solution Press the RETURN soft key to go back to the Select Mode screen correct your error and proceed 13 10 Fault Messa
199. w you will need to share and map at least one drive in order to be able to transfer files back and forth between two networked computers Sharing a drive determines what folders on your computer you want to share with the rest of the network Mapping sets up a drive on your computer as a shortcut to a shared folder across a network Depending on your needs you would most likely want to share a folder on your PC and map it on your ProtoTRAK 17 To share a drive folder on your computer first you must locate it using Windows Explorer Double click on MY COMPUTER then on C DRIVE Find the folder you wish to share then using the right mouse button click on it and select SHARING You can also share the entire C drive if you d like making everything on your hard drive available for sharing You should get a window like the one below C Properties 2 x General Tools Sharing C NotShared Shared As Share Name c Comment Access Type Read Only C Depends on Password Passwords Read Only Paseword Full Access Password Figure 14 12 5 6 Sharing 18 Make sure you select the option Shared As and most likely you will want to select Full access type so that you can open AND save files across the network Click on OK when you are finished 19 To map a drive on your ProtoTRAK go into Windows 98 and then double click on NETWORK NEIGHBORHOOD on your desktop You should be able to see the name of
200. work Overview A more complex type of network often found within an office environment involves the use of a server and individual clients Connecting more than two computers requires the addition of a hub Server a computer that is dedicated primarily to the task of providing shared resources such as hard drives and printers to other users on a network Client a computer that has access to a network server and shares its resources Hub a device that allows multiple computers to communicate with each other 116 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual We recommend that you use a DHCP switch instead of a simple hub The switch will automatically assign IP addresses subnet masks and gateway addresses in addition to performing the distribution functions of a hub This will make setting up multiple CNCs or computers easier Simply use the default settings shown in Section 14 12 6 and plug the devices into the switch 100847 TAPE BACKUP Hub CLIENT FIGURE 14 12 7 Typical server and client set up diagram 117 Southwestern Industries Inc TRAK Knee Mill amp ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual In many companies a main database is often kept on the server and is accessed by the clients The client can be thought of as an individual desktop computer in an of
201. xis CNC programming 35 Southwestern Industries Inc TRAK Knee Mill and ProtoTRAK SM CNC Retrofit Safety Programming Operating amp Care Manual When the MORE soft key is selected the soft keys change to ENGRAVE BACK io1062 FIGURE 7 9 2 When the More soft key is selected these additional event types are available in three axis CNC programming After an event type is selected from the soft keys the prompts for that event will appear on the right side of the screen The data you need to enter to program the event will appear in the Data Input Line As soon as you enter one piece of data by pressing the INC SET or ABS SET key the next prompt will appear in the Data Input Line PROG P N0806 BRACKET 3 AXIS INCH EVENT 0 EVENT 1 BOLT HOLE PROGRAM NAME 0806 BRAC DRILL OR BORE DRILL SCALE 1 000 HOLES DWELL REQUEST NO X CENTER AUXILIARY FUNCTION NO Y CENTER EVENT COMMENTS NO Z RAPID MULTIPLE FIXTURES NO Z END DIMENSION DEFINITION PART GEO RADIUS ANGLE PECKS FOR DRILL Z FEEDRATE TOOL HOLES E i01061 FIGURE 7 9 3 Here a Bolt Hole event was selected The ProtoTRAK SM CNC is prompting you to enter the number of holes 7 10 Editing Data While Programming While programming an event all data is entered by pressing the appropriate numeric keys and pressing INC SET or ABS SET If you enter an incorrect number before you press INC SET or ABS SET you may clear the number by pressing R

SM2 & SM3 Knee Mill Programming Manual (6.6MB PDF)

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SM2 &amp; SM3 Knee Mill Programming Manual (6.6MB PDF)

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SM2 & SM3 Knee Mill Programming Manual (6.6MB PDF)