Modular Control System for Machining Centers

The high integration between the OSAI OPENMill modular control system components for machining centers is designed to provide productivity, high finishing quality and ease of use. According to the company, the new OSAI hardware and software modules allow the optimized management of machining centers from simple 3-axis milling machines up to more complex 5-axis machining centers.

The new OPENMill system is designed to simplify the installation and commissioning for a better time-to-market due to its advanced software modules and hardware components. Features include:

• HMI software with graphic to control program execution
• Conversational editor for the on-board programming of multi-tool complicated machining
• Complete management of the five axes by using Tool Centre Point (TCP)
• Look ahead with 1,024 pre-calculated blocks
• Algorithms for high-speed cutting (HSC)
• Jerk control using advanced algorithms
• Spline algorithms on five axes
• Volumetric offset compensation of both mechanical asymmetries and machine misalignments
• Gantry and dual axes management
• Management of tool magazines, tool life, random tool, multi-pocket tool
• Different operator panel solutions
• Latest generation of OPENcontrol CNC
• Modular drives with rack structure for axes and spindle, with network recover, connected via Mechatrolink III fieldbus
• High performing brushless motors with absolute transducer
• Remote I/O connected via EtherCAT fieldbus.

The OPENMill software programs and controls the machining center by managing the execution of programs from either an external CAD/CAM or locally using graphic and parametric programming of cycles and profiles. According to the company, the programmer does not require any knowledge of ISO language used by the CNC due to the simple to use integrated conversational editor.

The OPENMill software matches the OPENcontrol software configured as OPEN-20 and includes all the functions required to control machines with up to four interpolated axes:

• Axes:
  • Coordinated, spindle, auxiliary
  • Rotary and linear, also rollover type
  • Gantry and dual axes
  • Geometric errors offset on single axis and on work planes (cross compensation)
• Tool magazine
  • Linear, planar and revolver magazines
  • Management of tool with fixed and random positions
  • Life tools and alternative tools management
  • Tool and offset configurable tables
• Movement:
  • Linear, circular, helical, spline movements
  • Acceleration/deceleration parameters independent for each axis
  • Acceleration trapezoidal and sinusoidal ramps
  • Jerk limitation
  • Look ahead (up to 1,024 program blocks)
  • Filters on programmable axis movements
  • Velocity Feed Forward (VFF)
  • Zero shift
  • Multi-block retrace
  • Restart from interrupted programs
• Conversational editor:
  • Drilling and tapping standard cycles
  • Milling standard cycles
  • Definition of open/close milling profiles.

The OPENcontrol software configured as OPEN-30, specifically designed for complex machines with five or more interpolated axes at the same time and up to 64 axes controlled, adds to the OPEN-20 the following features:

• Tool Centre Point (TCP)
• TCP for double twist and prismatic heads with two or three rotary axes, for tilting tables and non-standard kinematics
• TCP with spline (high-speed machine)
• TCP on rotated planes
• Selection of the active kinematics from part program.

PLC Applications

The real-time SoftPLC integrated into the CNC is versatile and allows the interface of the control with any type of machines, from simple 3-axis milling machines up to multi-axes and multi-spindle machining centers. The performances:

• Multitasking real-time execution
• Up to 250 tasks with 10 priority levels
• Cycles task with 250 µsec minimum scheduling
• More than 450 functions available
• Possible to include external software algorithms implemented with high-level languages.

Numerical Control

The OPENcontrol CNCs are scalable and feature a computing power adaptable to any customized requirement with no modifications to the software or the application.

• The OPEN-S COMPACT with 12" operator panel is designed to control medium-complex machines. The user interface is soft key based and offers ease of use. All the buttons of the OPEN-S COMPACT are full stroke type.
• The OPEN-M model, with OPENconsole COMPACT 15" touchscreen operator panel, is a CNC designed to suit more complex machines, such as multi-axis machining centers. The system consists of an operator panel with integrated keyboard and independent CNC to integrate into the electric cabinet.
• The OPEN-XLi model has a structure similar to the OPEN-M but, due to the i5 CPU, best fits machining centers where high performance is required. OPEN-XLi can be completed with the OPENconsole operator panel.

Servo Drives and Servo-Motors

• The OPENMill product can use compact or modular drives with up to 480 VAC power supply and CNC interfaced via Ethercat or Mechatrolink III fieldbus to provide high speed data exchange from CNC to drives.
• Only one regenerative power supply, with power up to 22 kW at 480 V, is used for both axis drives and the spindle drive. The power supply also features a 350% high overload capability for 3 - 5 seconds to improve the dynamic performance during axes acceleration.
• The drives, with power up to 11 kW for axes and 18 kW for spindles, are equipped with integrated Safe Torque OFF and the possibility to manage the main Safety Integrate.
• The servo motors, with medium inertia and continuous torque of 3 - 48 Nm, are equipped with absolute transducer with 20 bit resolution. Maximum torque is up to three times nominal torque and motor speeds are up to 5,000 RPM.
• Spindle motors are from 4 - 18 kW and feature speeds up to 10,000 RPM.

For more information contact:

Ivica Simunic

National Sales Manager

OSAI USA

711 East Main Street

Chicopee, MA 01020

413-598-5200

sales.osai.usa@primaelectro.com

www.osaicnc.com