The InTurn 4th Axis Mill/Turn Motor Control System Manual de usuario

InTurn™

4th Axis Mill/Turn

Motor Control System

Generation II

Installation Instructions

Featuring:

External High Speed DSS

Additional Serial Port (optional)

Smooth RPM Ramping

On-Screen Parameter Entry

Separate External Power

Matched Interface Board

400khz Differential Signals

Integrated Swapaxis function

Digital Signal Synthesizer

Stackable with companions

™

the

Contents

Introduction:............................................................................................................................................................ 4

MACH3 new PROFILE creation:........................................................................................................................... 5

Download, UnZIP and Copy Files:......................................................................................................................... 6

MACH3 Brain Programs ........................................................................................................................................ 7

Drivers..................................................................................................................................................................... 8

Install the Arduino Drivers (only if this is a new install) ................................................................................... 8

Configuring MACH3.............................................................................................................................................. 9

Tell MACH3 to use the new screens:................................................................................................................. 9

Tell MACH3 to use the new Brain Programs:.................................................................................................... 9

Tell MACH to use the included Macro Pump.................................................................................................. 10

Set up ModBus in MACH: ................................................................................................................................... 11

ModBus notes:.................................................................................................................................................. 11

Enter ModBus Parameters ................................................................................................................................ 12

Test ModBus Communication with the InTurn™ Controller: ........................................................................ 13

Input/Output ASSIGNMENTS............................................................................................................................. 15

Hardware and Wiring............................................................................................................................................ 18

4th axis HOME INDEX SENSOR connection:................................................................................................ 18

Controller Combo Board Functions.................................................................................................................. 18

PRE-WIRED CONNECTIONS: InTurn™ controller to combo board........................................................... 19

Connect wires to Your Servo Drive:................................................................................................................. 19

Connect wires to Your Break Out Board:......................................................................................................... 19

‘A’ Axis STEP (color choice and Pin number choice by User) ................................................................... 19

‘A’ Axis DIRection....................................................................................................................................... 19

Connect wires to a 5 Volt DC power supply. ................................................................................................... 19

5V Power (Color choice by user –Red is suggested)................................................................................... 20

POWER GROUND (color choice by user –Black is Suggested)................................................................ 20

Adding your system Parameters into the InTurn™ Controller............................................................................. 21

AutoConfigure .................................................................................................................................................. 21

* Maximum motor RPM –this is the motor itself and not the 4th axis spindle............................................ 21

* Encoder resolution. This need to be in ‘counts’ or ‘steps’ and not ‘lines’ ................................................ 21

* Main Drive Ratio –this is the belt ration without double reduction (back gear). ..................................... 21

* Back Gear Ratio –borrowing the term from lathes, ‘Back Gear is the extra............................................ 21

*Drive Multiplier –many drives have step multipliers or ‘electronic gearing’. .......................................... 21

Addendum A........................................................................................................................................................ 23

Release Notes.................................................................................................................................................... 23

Addendum B......................................................................................................................................................... 26

Listing of Provided Macros .............................................................................................................................. 26

Addendum C......................................................................................................................................................... 27

Definitions......................................................................................................................................................... 27

CNC Terminology: ....................................................................................................................................... 27

Computer Terminology:................................................................................................................................ 27

InTurn™ Terminology: ................................................................................................................................ 28

MACH Terminology:.................................................................................................................................... 29

Servo Motor Terminology: ........................................................................................................................... 30

Signals and Hardware Terminology:............................................................................................................ 30

Introduction:

At the end of this document is an addendum that provides both the definition and a short description

of the long list of ‘keywords’ used in CNC and also in General Digital Communications.

It is not necessary to understand all of the terms used in this document since each task is presented

with the specific information you will need to provide and also the specific points where you need to

enter that information.

For those who would like a better understanding of the underlying processes provided by the device

they are installing as well as the device they are installing it on, each technical term that is blue in the

text will have a corresponding definition and brief description in the addendum. Often, only this little

bit of extra information can make a mysterious topic far more comprehendible.

The InTurn™ 4th axis Motor Control System is designed specifically to provide Mill/Turn capabilities

for Mach3 and Mach4 CNC control Software for any CNC mill.

Mill/Turn is a capability of high-end Machining Centers that have a starting price tag around

US$100,000, so it is a very significant achievement to bring some of those capabilities to an existing

benchtop of full size CNC mill for under US$5,000.

Mill/Turn requires the 4th axis to have the capability to spin continuously at high speed with a

significant amount of power over a wide range of speeds, and ALSO have the ability to stop spinning

and return to the conventional indexing process. To be useful as a CNC add-on capability, all of this

has to be controllable by the CNC system itself with minimal or no intervention by an operator.

While MACH software provides for indexing on a rotary axis, it has no ability to spin that axis

continuously. The InTurn™ 4th axis Motor Control System adds that basic capability and a lot more,

all controllable both from custom on-screen controls and also via macros embedded in the G-code for

a fully automated CNC process.

So let’s get on with the Installation!

Note: In the text, where the name of a parameter will vary from one system to another, or from one

version to another, the variable portion is represented by ‘placeholders’ using ‘xx’ to represent

numbers and square brackets around a descriptive word like ‘[date]’ to represent the variable part of a

filename or folder name. The actual name will contain the number or date, for example ‘COM10’ or

‘InTurn™Parameter041215.brn’

“Interviews are good if you want to be an actor because they raise your profile.” - Jack Gleeson

MACH3 new PROFILE creation:

Using the MACH ‘loader’ to start MACH, make a new profile by ‘cloning’ whatever profile you are

currently using. Name the new profile ‘InTurn™’.

Close Mach3 and restart using the new profile name. You can do this one of two ways:

1) Start Mach3 by starting the Mach3 Loader program and selecting the InTurn™ profile

2) Create a shortcut that starts Mach3 while automatically using the InTurn™ profile.

To create a Shortcut, follow these steps:

A) Using a RIGHT click and hold, drag the file C:\Mach3\Mach3.exe desktop.

B) On release of the mouse button, you will be presented with choices. Select ‘Shortcut’

C) Locate the new shortcut on your desktop and RIGHT click on the icon

D) Change the parameters to match the following screen shot:

All of your MACH3 settings should be retained in this new profile. Now we will change or add those

that pertain to the new InTurn™ controller and screen set.

Download, UnZIP and Copy Files:

Files are obtained by downloading. Links will be provided via e-mail for new controllers,

updates or upgrades.

Using the provided link, download the zip file and move it into C:\ and then unzip the file.

The files will be unzipped into folders that match the corresponding MACH folder name except that

the names have the prefix ‘InTurn_’ added. The InTurn files can be safely stored in these folders

since MACH does not recognize the folder names and therefore will not overwrite them.

Simply copy the entire contents of the unzipped ‘InTurn_[name]’ folders into the matching Mach

folders. For example, copy all of the files in “InTurn_MillBitmaps” into the \Mach3\Bitmaps\MillBitmaps

folder. Do the same with all of the new InTurn folders that appear after unzipping the file.

In the end, you need to have:

New macros from “InTurn_Macros” into the directory \Mach3\macros\InTurn

Note: Mach has a special macro named ‘HiddenScript.m1s which contains ALL of the macros

associated with the screen controls. This is a reserved name (cannot be changed) so there is no way

to know the version of the macro or what screen it goes with. For this reason, the InTurn™ version is

named ‘HiddenScript[date].m1s’. Do not change the name of this file. Instead, copy the file, for

example ‘HiddenScript012514.m1s’ into the Mach3\macros\InTurn folder and then change the name

of that file by removing the date.

Note: Some versions of MACH3 will unexpectedly overwrite the entire macro folder without warning

or notice. This will stop the InTurn™ from functioning. The remedy is to copy the macros from your

backup; “InTurn_Macros’ into the \Mach3\macros\InTurn folder again and then remove the date

from the name of ‘HiddenScript[date].m1s”.

MACH3 Brain Programs

“Why, I outta BRAIN ya” – the three Stooges

Copy the following from InTurn_Brains into C:\Mach3\Brains

InTurn4thAxis[date].brn

InTurnE-stop[date].brn

InTurnAxisFraction[date].brn

InTurnParam[date].brn

Note: for these brain programs, the date can be left in as part of the file name.

Later, you will activate the brains using the entire name including the date.

“Everyone can do simple things to make a difference, and every little bit really does count.” - Stella McCartney

Screen Bitmaps from “\InTurn_Bitmaps”into “\Mach3\Bitmaps\MillBitmaps”

Note: after copying the files into the above directory, look in the folder and there should be Cube

Studio specific graphics similar to those shown below.

There is one exception to the folder naming convention used in the InTurn™ distribution.

Copy the screen set ‘\InTurn_Screenset\InTurn1920[suffix].set’ into C:\Mach3

Note: The suffix is typically two letters, but in any case, use the actual filename as it

appears in the unzipped folder.

Drivers

“A careful driver is one who honks his horn when he goes through a red light.” - Henry Morgan

A folder named ‘InTurn_Drivers’appears after unzipping;

Install the Arduino Drivers (only if this is a new install)

Plug in the USB cable to any USB port on your computer.

Windows should complain about the new USB device.

Tell windows to look in the folder:

C:\InTurnMotorControllerDist2015-xx\InTurn_Drivers

Note: Bolded numbers are year and rev and may be different than shown.

Windows will find and install the drivers then be happy with the new USB device.

To determine which COM number the driver created, use the following steps

Make sure MACH3 is NOT running.

Power OFF the InTurn™ Controller.

Power ON the InTurn™ Controller.

On the menu bar at the lower left of the WINDOWS screen, click the following sequence:

Start->Control Panel -> System -> Hardware (tab) -> Device Manager (button) -> Ports (COM & LPT)

There should be a ‘Communications Port’ Identified as Arduino Mega and a COM# after it. Write the

port number of your InTurn™ Controller below. You will need it later.

___________ InTurn™ Communication Port Number

Configuring MACH3

“I've always been bossy.” - Shirley Temple

Tell MACH3 to use the new screens:

At the top of the MACH screen click on ‘view’, then ‘load screens’ then navigate to where you copied

‘InTurn1280IY.set’ and select it. The new screen should appear. Close Mach3 and restart it.

Tell MACH3 to use the new Brain Programs:

On the MACH3 screen, click on Operator. Choose Brain Control from the drop down list.

Find ‘InTurn4thAxis[date].brn’ on that list and click on it to highlight it.

If that name does not show up on the list, the file is probably in the wrong place.

Brain programs must be located in the folder . . . \Mach3\Brains

With the name highlighted, click the enable box.

Now do the same with ‘InTurnE-stop[date].brn’

And also with InTurnParam[date].brn

And lastly with InTurnAxisFraction[date].brn

Note: other listings in the window will not be related to the InTurn™.

Now click the OK button. Close Mach3 and restart it.

Tell MACH to use the included Macro Pump.

Check the box next to ‘Run Macro Pump’ on this ‘General Configuration’ screen accessed from the

‘Config’ drop down on the main MACH screen.

Add ‘M4444’ to the end of whatever is in the Initialization String.

Note: Mach will only run one ‘M’ code in this String, so if there is already an ‘M’ code, it will either

have to be removed or combined with the M4444 macro.

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