programming of the plasma chamfering unit

8/10/2019 Programming of the Plasma Chamfering Unit

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Programming of thePlasma Chamfering Unit

For NC Controller NCE 520


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Contents

Introduction 4Layout of the Manual 5

Abbreviations used 5

Plasma Chamfering Unit -

Overview 6

Inputs / Settings by the User 6

Capabilities of the Unit 7

Examples for Programming 9

Example 1: Right Angle, Constant

Angle, Light Beam Sensor 10

Programming of the Cutting Contour 23

Example 1a: Constant Chamfer

Angle, Sensor-Sensor 25

Example 1b: Variable Chamfer

Angle per Section 29

Example 2: Circle, Constant Angle 36

Rules for Programming 42

Programming Sequences 42

Variable Chamfering Angle 45

Variable Chamfer Angle Over

Multiple Sections (Over Curves) oran Arc up to a Maximum of 90 47

List of Rules 48

Programming of the Plasma Chamfering Unit 2Change index: 0 for NC Controller NCE 520 (GB)


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Help Functions 55

Organisation Program for

Plasma Chamfering Unit withNCE 520 NC Controller 60

Layout of an organisation program 60

Basic layout of an organisationprogram with sample values 62

Annexes

List of valid pages Z-1


Contents


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Introduction

The Plasma Chamfering Unit is used to produce

vertical and chamfered edges for the assembly of

large components in, for example, shipbuilding.

The chamfering of the edges can be varied. This

means that it can cut not only to fixed set angles, but

it is also possible to vary them continuously during

cutting.

Various kinds of materials, alloyed and unalloyed

steels, can thus be processed with a high cutting

speed without affecting the required cutting and

angle accuracy.

The automation of many sequences which the

Plasma Chamfering Unit offers makes handling of

the machine considerably easier for the user. As a

rule, it is only necessary to take the values for

vertical cutting from a table. The controller adaptsitself to the angle that has been input. This means

that the user does not need to calculate those values.

The Plasma Chamfering Unit is operated together

with the NCE 520 Controller. It is assumed therefore

that the operator has a basic knowledge of this type

of controller. In addition the reader should

understand ESSI programming and the main

terminology of plasma cutting.



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Layout of the Manual

A summary connected to this section states which

details must be input in order to produce a programfor the Plasma Chamfering Unit, and what the

Plasma Chamfering Unit will then be capable of.

In general, this manual has been laid out in such a

way that the user can obtain the required knowledge

for the programming of the Plasma Chamfering Unit

through examples, step by step, and he will be able

to produce his own programs as quickly as possible

without having to read through the entire manual.

Explanations for the individual steps should thus

make it much easier to understand the examples.

The reader is also put in a position where he is able

to program parts with differing inputs.

Tables for cutting speed and the stand-off distance

from the jet to the plate, the organisation table, etc.,

follow after these examples. In addition, the

technical connections which were only touched on

briefly in the examples are explained at this point

with the help of geometrical illustrations.

Abbreviations used

HF Help Functions


Introduction


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Plasma Chamfering Unit-Overview

Inputs / Settings by the User

+ In the case of a chamfered cut, there are always two contours of different

sizes in a component. The user should program the larger contour (visual

edge), regardless of whether this is located on the upper or the lower side

of the plate.

+ There is also thechamfering angle

+ and thelocation of the cut joint.

+ In the case of a variable chamfering angle, it is necessary to input astart

angleand anend angle.

+ x The values forcutting speed,

+ x thewidth of the cut joint

x and thestand-off distance between the burner and the tool are the

same as for a vertical cut.

+ x It is also necessary to input thethickness of the sheet.+ In order to maintain sharp corners when cutting, it is necessary to

program the so-called corner routines: one should cut approximately

10 mm beyond the contour in the same direction as the latter and,

together with a bevel, return to the next contour line in the form of a

triangle.

x Corrective values for any necessary deviations in angle and size are

given in an organisation program, which the user can produce or modify

according to his own requirements.

+ Inputs for the ESSI Program

x Inputs, settings for the controller



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Capabilities of the Unit

The controller recognises from the position of the

cut joint and the signed value of the inputchamfering angle whether the programmed

contour is on the upper side or the lower side of

the plate and travels automatically for the required

amount of sideways offset of the unit.

The cutting speed that was input will be reduced

as the chamfering angle increases.

In the same way, the width of the cut joint is

adjusted with regard to the angle. As the angle increases, and the bevelling angle of

the burner increases likewise, the Plasma

Chamfering Unit is raised and offset sideways to

avoid a possible collision between the jet cap and

the material.

Execution of the corner routine likewise depends

on the angle and on the thickness of the sheet.

The cutting speed is reduced to the extent that the

Plasma Chamfering Unit can turn in the new

direction while it is executing the corner routine. In

doing this the Plasma Chamfering Unit does not

follow the contour line with the rotation but turns

directly from the direction of the most recently cut

contour into the direction of the following contour

of the part to be cut. This is achieved via a special

ESSI help function (HF 118).

A special corner technology achieves correct

execution of the corner routine even with minimal

or maximum sheet thickness or chamfering

angles.


Plasma Chamfering Unit- Overview


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The user merely needs to ensure that he has

included the corner routine when setting the

stand-off distance from the edge of the plate or

from a neighbouring part. Through the use of an organisation program, the

controller corrects for any possible inaccuracies in

angle and size which could be caused by the

cutting process or by the Plasma Chamfering Unit.


Plasma Chamfering Unit- Overview


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Examples forProgramming

The following examples are intended to illustrate the

previous details and help the user to produce his

own programs.

The solutions selected do not necessarily represent

the only option (see the list of ESSI help functions in

the help functions section), they are intended rather

to make the program sequences consistent to a

large extent so that the user is confronted with only a

small number of different cases. The programs

should in the main be produced with a(n) (ESAB)

programming system or directly at the controller.



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Example 1: Right Angle,Constant Angle, Light BeamSensor

Geometry: right angle, first side with chamfer,

all other sides are vertical

Size: 150 x 100 mm

Thickness: 10 mm

Chamfer

angle: -20, constant angle,

negative chamfer

The tangential controller remains switched on in

order to make a transition from a height

measurement with a sensor (at the chamfer) to light

beam measurement.


Examples for Programming


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3

000014000 Program number

4

5

+200+100

639+3175

29 Start sequence

51

76

53

122+200

++50 Start

118

++50 Start

++300

48

77 + 1st Side++700

++100

118

122+0 Corner routine

-100-100

+50+

47

+50+

+800+

48 + (2nd side)

+700+

+100+

118

-100+100 (Corner routine)

+-50

47

+-50

+-300

48 + (3rd side)

+-700

+-100

118

+100+100 (Corner routine)

-50+

47-50+

-500+

(48) + 4th side

(77)

-1000+

(117)

-100+ Exit

54

52 End sequence

38

122+0

0(63)




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Cutting of the parts begins after rapid traverse.

Before starting the actual contour cutting, the burner

which was still vertical for hole punching, places

itself diagonally to the set angle for the followingchamfer. Then the corner routine begins.

The burner sets itself upright again while carrying

out this routine. The remaining sides are cut

vertically. In detail, this is shown as follows:

Start sequence

5

+200+100

6

39+3175

29

51

76

53

122+200

++50

118

++50

++300




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Point 1

39 + 3175

The cutting speed can be taken from the tables.

Always start on the basis of a normal vertical cut.

This gives a cutting speed of 3175 mm/minute for a

thickness of 10 mm. The details in the table are to

be taken as guidelines, and other values may be

necessary according to the type of material.

The controller reduces the cutting speed

proportionally as the chamfering angle increases or

decreases, since the actual cutting length for achamfer is larger than that for a vertical cut.

This means that a vertical cut will be carried out at

the cutting speed that had been input, while the

Plasma Chamfering Unit operates as if one was

using thicker material when cutting chamfers.

29

The cut joint is located to the left of the contour.

Cutting is done in a clockwise direction (this involves

an external contour). HF29 is also used in all further

examples. The location (direction) of the cut joint

affects the input of the chamfer angle (+ or -).

51

The tangential controller is switched on. This insures

that the Plasma Chamfering Unit always follows the

contour and the set angle will always be maintained,

even in the event of a change of direction and also

for an arc-shaped contour.




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76

A sensor is used for automatic height control when

cutting chamfers. This is done either by a feeler foot

or by an inductive sensor. The sensor senses at ashort distance from the jet (approx. 60 mm) from the

plate and ensures that the set stand-off distance

between the plate and the jet will be maintained in

the event of unevenness.

53

The plasma cycle is switched on and cutting can be

carried out.

122 + 200

A chamfering angle is input with this help function,

and the signed value affects the direction of the

angle (positive / negative angle).

Warning:

It is necessary to distinguish between input of

the angle (programmed angle) for the PlasmaChamfering Unit and the chamfering angle of the

(finished) work piece.

In the case of a work piece, a positive angle means

that the contour at the upper side is smaller than the

contour on the lower side of the sheet. The opposite

applies in the case of a negative angle.

Always enter the direction of the angle on the

Plasma Chamfering Unit with HF 122. In order to

determine this, you require the location of the cut

joint in addition to the chamfering angle of the work

piece: if the cut joint is to the left of the contour

(HF29), the chamfering angle to be input is the

opposite of the angle direction of the work piece.

You produce a positive angle at the work piece when

you program a negative angle for the Plasma




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Chamfering Unit. This assumes that the correct

cutting direction was taken into consideration when

programming the contour.

In the example, the positive angle (+200) that was

input takes effect, since a negative chamfer (-20)

was cut on the work piece.

If the cut joint is located to the right of the contour

(HF30), the signed value of the chamfering angle at

the Plasma Chamfering Unit and the work piece are

identical. You must input a negative angle if you

wish to cut a negative chamfer.

Point 1a

118

The Plasma Chamfering Unit does not, as is usual,

turn in the direction of the section which follows

directly after HF118 but turns instead in the

direction of the subsequent section.

In the example, the directions of the first section of

the chamfering and the subsequent first contour

element are identical. Help function HF 118 has no

effect in this case.

Point 2

The start is over, and the actual geometry will be cut.




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Corner routine

Since the plasma jet always lags behind underneath

to some extent in the case of thicker sheets, the

corner of a part will already have been reached on

the upper side, while cutting has not yet reached the

corner on the lower side. A change of direction at

this point would produce a cutting-off or a

rounding-off of the lower corner. It is thus essential

for right-angled or acute angled corners, at least, to

be cut beyond the corner. This is done with a corner

routine. This is not (absolutely) essential for obtuse

angles (e.g. 120 and more). This depends on the

thickness of the sheet and the desired accuracy of

the corner.

34

5

7

48

77

++700

++100

118

122+0

-100-100

+50+

47

+50+




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Point 3

48

Automatic height setting is switched off 70 mm

before the new corner. This is essential when cutting

chamfers with the sensor travelling ahead, since it

can already be ahead of the edge of the plate before

the burner head reaches the corner. The stand-off

distance is a function of the distance between the

burner and the sensor, plus an additional margin for

safety.

77The feeler system with the sensor is turned off. It is

raised. In fact, HF77 selects height measurement

with a light beam, but this only becomes active once

the automatic height setting has been switched on

again.

Point 4

Here begins the geometry for the actual corner

routine. As a rule, it is adequate if you program a

length of 10 mm for the sides of the triangle. This will

be adequate in most cases through automatic

off-setting of the Plasma Chamfering Unit,

corresponding matching of the cut joint and a special

corner technique. In the case of very thick material

and large chamfering angles, a larger corner routine

may be necessary.

The cutting speed is automatically matched to the

slower cutting speed when the Plasma Chamfering

Unit is turning or setting an angle. This ensures that

there is enough time for both operations while the

bevels of the corner routine are being cut.




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Point 5

118

HF118 is used at this point to avoid unnecessary

changes of direction. This is done by ensuring that

the Plasma Chamfering Unit only follows the actual

contour of the part and does not exceed the

maximum possible rotation, which would be the case

if executing only a corner routine (plus geometry).

While the bevels of the corner routine are being cut,

the Plasma Chamfering Unit turns in the opposite

direction, i.e. from the direction of the section whichled up to the corner routine, directly into the direction

of the following section.

122 + 0

The burner is set to the new angle, which is vertical

in this case, and likewise while the bevel is being cut.

Point 7

47

Automatic height setting is switched on so that light

beam stand-off measurement (which had already

been selected) becomes active.




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End sequence

Point 9

(48)

Automatic height setting is switched off before the

end of the section. This is done for the same

reasons as for the corner routine. It is thus

absolutely essential when the last section is to be

cut with a chamfer.

The safety stand-off distance of 100 mm, instead of

70 mm as is used at the corner, represents a value

that is adequate for practically all cases. (If the firstside of the right angle is to be cut with a positive

10

9

11

48

77

-1000+

117

-100+

5452

38

122+0

0

63




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chamfer, the section to be cut on the upper side of

the plate for the last section is in fact shorter than

that programmed.)

In the current example, HF48and the additional

stand-off distance are not essential. But

fundamentally you can operate with them for

simplicity.

(77)

The same applies for this function. It is essential if a

chamfer is to be cut, but in principle it can be used

for reasons of consistency. The sensor system isswitched off and light beam control is selected.

Point 10

(117)

This function ensures that the Plasma Chamfering

Unit maintains the direction of the last section, even

when the next section leads in another direction.

The reason for this application of HF117is the

same as the one for the use of HF 118 in the start

sequence and in the corner routine. An unnecessary

change of direction is avoided, and also the

possibility of exceeding the maximum possible

tangential rotation of the Plasma Chamfering Unit.

Since this ultimately only follows the exit path, the

Plasma Chamfering Unit can maintain the direction

without any danger. In the example, an exit is made

in the same direction as for the previous contour line

and HF117thus has no significance.

With the additional exit in connection with the

programmed contour, this ensures that the contour

is completely cut in every case, e.g., for each

chamfer (e.g., the first side vertical and the last side

with a negative chamfer), as in this case the plasma




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beam lags behind underneath and would not have

reached the programmed corner if the burner were

to stop at the corner.

An exit is made if the last side is to be cut vertically

here, and thus HF177 is not absolutely essential but

is recommended.

Point 11

54

Plasma cutting is switched off.

52Tangential control is switched off.

38

Cut joint compensation is switched off.

(122 + 0)

The angle is set to 0, i.e., the burner is set to

vertical. Since the last contour has already been cut

vertically, this input has no effect here.

0

This terminates the program and the machine stops.

63

Program end. This function is not absolutely

essential.




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Programming of the CuttingContour

When using the ESAB Plasma Chamfering Unit, theuser always programs the visual edge (larger

contour) for a part with a chamfer. He can thus

simply take the dimensional details from the

drawing, regardless of whether he wishes to produce

a positive or a negative chamfer.

In the case of a positive chamfer, the visual edge is

located on the lower side of the sheet. The controller

recognises this from the input by the user and is in a

position to take into account the difference in size

between the upper side of the sheet and the lower

side of the sheet by offsetting the plasma burner and

changing the cut joint.




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Inputs to the Controller

After starting the program, a number of values are

requested at the controller though a menu. The

following details are also required in addition to the

details already input in the program example:

sheet thickness

cut joint

As can be seen from the menu, it is possible at this

point to enter the cutting speed as well. Other values

(sheet thickness or cut joint width) can likewise beentered in the program or at the menu.

Warning:

It is possible to enter values twice. In the event

of differing input values for the same parameter,

the programmed value must be deleted first,

meaning that a programmed value cannot be

corrected through a different value from the

menu. The programmed value must be deleted

first in this case.




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Example 1a: Constant ChamferAngle, Sensor-Sensor

Geometry: right angle, 2 sides with chamfers

Size: 150 x 100 mm

Thickness: 10 mm

Chamfer

angle: constant angle -20/+30

Side 1 - negative chamfer

Side 2 - positive chamfer

The sensor for height measurement will be usedwhen cutting the first two sides (with chamfer), in

which case maintenance of the necessary stand-off

distance between the jet and the sheet will be

controlled by the light beam voltage for the

subsequent vertical cuts. The angle changes from a

negative to a positive chamfer at the first corner after

the first cut. The tangential controller remains

switched on while the entire program runs.




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3


4

5

+200+100

639+3175

29 Start sequence

51

76

53

122+200

++50 Start

118

++50 Start

++300

48 + 1st side

77++700

++100

118

122-300 Corner routine

-100-100

76

47

+100+

+800+

48 + (2nd side)

77

+700+

+100+

118

122+0 (Corner routine)

-100+100

+-50

47

+-50

+-300

48 + (3rd side)

+-700

+-100

118

+100+100 (Corner routine)-50+

47

-50+

-500+

48 + 4th side

77

-1000+

177

-100+ Exit

54

52 End sequence

38122+0

0




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Except for some small changes, the program can be

taken from example 1.

Start sequence

This is exactly the same as the start sequence in

example 1.

Corner routine

Angle < 30 Angle > 30

48 48

77 77

++700 ++700

++100 ++100

118 118

122-300 -100-100

-100-100 76

76 47

122-400

47 +100+

+100+

Point 3

48

Automatic height setting is switched off.

34

5

6




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77

The sensor is raised.

Point 4

Beginning of the corner.

Punkt 5

118

The Plasma Chamfering Unit turns while the corner

routine is being executed in the direction of the next

right-angled side, and the rotation does not follow

the corner routine.

122 - 300

The burner sets itself to the new angle up to the end

of the next section. A positive chamfer (+30) is

produced at the work piece.

Point 6

76

The sensor is lowered. Unlike in example 1, height

measurement with the light beam is not selected,

since a chamfer is to be cut next.

47

Automatic height setting is switched on. As long as

the 5 mm (+50+) are being cut between points 6 and

7, the sensor has time to be lowered. This prevents

height measurement from being activated during thisprocess.

The second corner routine is identical to the first

corner routine from example 1:

transition from a chamfer to vertical cutting.

End sequence

This is exactly the same as the one from example 1.




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Example 1b: Variable ChamferAngle per Section

Geometry: right angle, 2 sides with chamfers

Size: 150 x 100 mm

Thickness: 10 mm

Chamfer

angle: variable angle from -10to -20

and from -20to -10



The sensor for height measurement is used for the

first two sides, and then light beam control for the

vertical cuts.

As compared to examples 1 and 1a, the chamfer

angle changes while the section is being cut. A

chamfer that varies between -10and-20 is

produced on the first side, and on the second side it

varies from-20to-10.




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4

5+200+100

6

39+3175

29 Start sequence

51

76

53122+100

++50 Start

118++50 Start

122+200+1++300

48 + 1st side

77

++700122++100

118

122+200 Corner routine

-100-10076

47

+100+122+100+1

+800+

48 + (2nd side)77

+700+

122+100+118122+0 (Corner routine)

-100+100

+-50

47+-50

+-300

48 + (3rd side)+-700

+-100118

+100+100 (Corner routine-50+

47-50+

-500+

48 + 4th side77

-1000+

117-100+ Exit54

52 End sequence

38

122+0

0




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In this case, the program is also almost exactly the

same as examples 1 and 1a. The main difference is

that a start angle and an end angle must be input for

the variable angles.

Start sequence

Point 1

The same inputs as in example 1 will be required,

except for the angles.

39 - 3175

The cutting speed to be as per the table.

5

+200+100

6

39+317529

51

76

53

122+100

++50

118

++50

122+200+1

++300




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29

The cut joint to the left of the contour (cutting in a

clockwise direction).

51

The tangential controller is switched on.

76

The sensor for automatic height control is lowered.

53

Begin the plasma cycle.

122 + 100

The start angle is set to +10for the Plasma

Chamfering Unit (this produces a negative angle at

the work piece).

Point 1a

118

The Plasma Chamfering Unit turns in the direction of

the first section of the cutting path, and not in the

direction of the start which follows immediately after

HF118.

Point 2

122 + 200 + 1

The end angle is to be entered in this form, i.e., the

angle that is to be reached after cutting off one or

more sections. The angle will vary equally from thispoint up to an end point that is still to be determined:

the Plasma Chamfering Unit changes its angle

during cutting via linear interpolation from +10to

+20. The result is a work piece with a negative

chamfer that begins with -10and increases to -20.




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Corner routine

Angle < 30 Angle > 30

48 48

77 77

++700 ++700

122 122

++100 ++100

118 118

-100-100

122+200 76

-100-100 47

76 122+350

+100+

47 122+100+1

+100+

122+100+1

Point 3

48

Switch off automatic height setting.

77

Raise the sensor.

Point 4

122

HF122 without an angle being input shows the end

of the variable angle. The burner reaches the

previously input end angle (20) at this point. The

angle thus varies in the example from Point 2, with

the start of the first right-angled side over the

34

5

6

8




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sections that were input (++300, ++700 / giving a

total of 100 mm) up to Point 4, which is the end of

this work piece side.

The Plasma Chamfering Unit maintains this angle.

Points 5, 6 and 7 are identical to the same points

from Example 1 up to angle input.

Point 5

118

Counter-rotation of the Plasma Chamfering Unit in

the direction of the following section of the piecebeing cut.

122 + 200

The burner is reset to an angle of +20. Since the

starting angle of this section is the same as the end

angle of the last section, this input would not be

necessary here. The angle is still processed here for

reasons of consistency.

Point 6

76

The sensor is lowered.

47

Automatic height setting becomes active.

Point 8

122 + 100 + 1

The end angle for the following right angle side is

input. The angle varies again from the start of the

right-angled side up to the end of the work piece

side.

In this case the Plasma Chamfering Unit changes

the angle setting from +20to +10, and a negative

chamfer (from -20to -10) is produced at the work

piece.




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The end of the chamfer is shown at the next corner

(second corner routine). The program sequence up

to this point is as follows:

::

+800+

48

77

+700+

122

:

:

This corner routine is identical to the corner routine

from example 1 up to the angle inputs of HF 122 ...

Changeover over from chamfer cutting (height

measurement with sensor) to vertical cutting (light

beam measurement).

The Plasma Chamfering Unit maintains the angle

with HF122. Angle inputs 122 + 0 are thus requiredfor Point 5. The program sequence is as follows:

:

122

+100+

118

122+0

-100+100

+-50

47

+-50

End sequence

This is identical to the end sequence from example 1.




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Example 2: Circle, ConstantAngle

Geometry: circle as inner contour,outer contour

Diameter: 200 mm/300 mm

Thickness: 10 mm

Chamfer

angle: constant angle, negative

chamfer: -20

A program for a ring with a constant chamfer isexplained. The same negative chamfer is produced

for the inner contour and the outer contour. The

sensor is used for height measurement for both

contours.

Apart from the missing corner routine, the execution

of the help functions only differs slightly from the

function sequence for a right angle with constant

chamfer (see example 1).




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3


4

5

+2500+1600

639+3175

29 Start sequence

51

76

53

122+200

+50+ Start

118

+50+ Start

++-1000++ Inner contour

48

77117

-70-70 Exit

54 End sequence

52

38

122+0

5

+201-1061

6

29

51

76 Start sequence

53

122+200

-35+35

118

-36+36 Start

++-1061+1061- Outer contour

48

77

117

+-100 Exit

54

52 End sequence

38122+0

0




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Start sequence

Point 1

39 + 3175

The cutting speed (3175 mm/minute) can be taken

as usual from the table (vertical cutting is taken as a

basis). This is automatically reduced by the

controller according to the chamfering angle.

Above all, the maximum speed of rotation is to be

noted for small circles and thin sheet. While the

controller reduces the cutting speed to the extent

that the rotation can be completely carried out,

cutting quality will suffer under certain circumstances.

29

The cut joint is to the left of the contour, the direction

of cutting is anti-clockwise for the inner contour and

clockwise for the outer contour.

51

The tangential controller is switched off.

76

The sensor is lowered, automatic height setting

becomes active.

53

The plasma cycle begins.




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122 + 200

The burner is set to an angle of 20. A negative

chamfer (-20) is produced at the inner contour and

at the outer contour.

Point 1a

118

The Plasma Chamfering Unit rotates during chamfer

cutting in a circle and not in the direction of the start.

Point 2

The start is ended. The ring contour begins.

End sequence

Point 3

48

Automatic height setting is switched off at the end of

the ring contour, before cutting the exit.

77

The sensor is raised.




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117

The Plasma Chamfering Unit maintains the direction

that it had most recently followed when cutting the

ring contour, up to the following section (exit).

Point 4

54

Plasma cutting is switched off.

52

The tangential controller is switched off.

38Cut joint thickness compensation is switched off.

122 + 0

The angle is set to 0, i.e. the burner is set to vertical.

0

The program comes to an end, the machine stops.




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Rules for Programming

Programming SequencesStart sequence (constant angle)

5 Rapid traverse ON

Rapid traverse path

6 Rapid traverse OFF

39 Cutting speed in mm/min (100%)

29/30 Location of the cut joint

51 Tangential controller ON

76/77 Select light beam measurement/ select height

control with the sensor* and lower the sensor

** (122 angle)53 Plasma cycle ON

122 angle Angle setting of the Plasma Chamfering Unit in 1/10

| Start 1/2

118 The Plasma Chamfering Unit turns in the direction

of the next but one contour element

| Start 1/2

** (29/30)

|

| Parts geometry

|

* The sensor can be a feeler foot or an inductive sensor

** The details in brackets are alternative programming, please see thesection List of Rules for an explanation. Only the alternatives withoutbrackets were included in the section Examples for Programming.



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Corner routine

Point 1

48 Height setting OFF

77 1. Select light beam measurement

2. Lift the sensor if HF 76 already applies

| a Length = stand-off distance from sensor to jet +

safety margin

Point 3

118 The Plasma Chamfering Unit turns in the direction

of the next but one contour element

(from Point 4 = subsequent part contour)

122 + angle Angle setting < 30for the Plasma Chamfering Unit

for the next part contour

> 30= Point 4

Point 4

(76) Select height control with sensor and lower the

sensor - only when the next contour is to be cut with

a chamfer.

Point 5

47 Height setting ON = light beam measurement

Height control with sensor = Point 4

3

4

2

15

6

1/2

a = 70 mm




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End sequence

48 Height setting OFF

77 1. Select light beam measurement

2. Lift the sensor if HF 76 already applies

| 100 mm Length = stand-off distance from sensor to jet,

plus safety margin

117 The Plasma Chamfering Unit maintains the direction

for the following contour element

54 Plasma cycle OFF

52 Tangential controller OFF

38 Cut joint OFF

122 + 0 Burner is set to 0

0 Program STOP




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Variable Chamfering Angle

A variable chamfer - the angle changes continuously

between two defined points - can only be input forsections.

122 start angle Start angle of the chamfer

| (Start)

| (Section of the corner

routine)

According to which point the chamfer begins at

122 end angle + 1 End angle of the chamfer < 90

|

| Geometry

|

The geometry can be for one or more sections or

arcs

122 End of the chamfer

The chamfer varies from the point at which the end

angle (HF 122+ ... + 1) is determined, up to the point

at which the end of the chamfer is input (HF 122).

A corner which is to be cut with variable chamfers for

the previous and the following sections will be

handled as follows:

Point 1

48

77

|

Point 2

122 End of the previous chamfer




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Point 3

118

122 start angle Start angle of the following chamfer < 30

> 30= Point 4

Point 4

76

Point 5 (Height control with sensor = Point 4

47

Point 6

122 end angle + 1 End angle of the following chamfer.

The details relate to the previous illustration, see the

section Corner Routine.




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Variable Chamfer Angle OverMultiple Sections (Over Curves)or an Arc up to a Maximum of

90

If the chamfer is to vary over multiple sections

instead of just one there is no change with respect to

the chamfer angle definition as given in the section

Variable Chamfer Angles. It is only necessary to

ensure that HF 122 (end of the chamfer) is input at

the end of the section, after which the end of the

chamfer is to be reached.

The chamfer can be continuously varied during

cutting for an arc of up to a maximum of 90.




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List of Rules

In the case of acontour with a chamfer, the

larger contouris to be programmed. The following details must or can beentered into

the program(details in brackets):

Angle in 1/10

(Cutting speed) in mm/min

Location of the cut joint

(Cut joint width) in 1/10 mm

(Sheet thickness) in 1/10 mm

All the details in brackets that are not

programmed must be entered in the

menuof the controller before cutting.

Warning:Programmed values take priority.

The stand-off distance between the jet and the

sheet must beset at the machine, from which a

programmed cutting speed can be set

proportionally.

Take the values for vertical cuts as the values for

the cut joint (curve width), cutting speed and

stand-off distance between the jet and the sheet.

Technically related angles and deviations in size

can be equalised (see Section Organisation

Program for Plasma Chamfering Unit with NCE

520 NC Controller).




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Thesense of height control(HF 76) is used

when cutting achamfer, and a light beam (HF 77)

is used for vertical cuts.

It is possible to punchholes diagonally(due tothe slag) or vertically. If you wish to punch holes

diagonally, theangle input(HF 122 .... ) must

be input before the beginning of the plasma cycle

and thusbefore HF 53, or otherwise afterwards.

Normally the cut joint (HF 29/30) is entered before

the first cut, i.e., before the initial chamfering. In

order to cut out an inner contour completely, it is,

however, meaningful to determine thecut jointafter the initial cutting.

The same applies if an outer contour or the start

do not have the same direction as the subsequent

contour.




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In the case of avariable chamfer, an end angle

must also be input and theend of the variable

anglemust be indicated, as for example:

Only the so-called helping float functions may be

used between the end angle and the detail of the

end of the chamfer:

HF 47, 48, 76, 77.

Help functions 117 or 118 can or must be used at

all points at which there is a change of direction

which does not relate to the contour of the

work piece,in order to prevent the maximumrotational capability of the Plasma Chamfering

Unit being exceeded ( 405, standard).

117 - The Plasma Chamfering Unit retains the

direction for the next contour element,

which will for example be used before an

exit.

118 - The Plasma Chamfering Unit turns aboutthe shortest path in the direction of the

contour element which will be the next but

one. The element that was input

immediately after the HF 118 does not

follow the tangential controller.

HF 118 is used if a contour is to be cut

which does not belong to the parts

contour, such as the start or a cornerroutine.




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In the case of acorner routine, the use of HF

118 is unavoidable for cutting (if the tangential

controller - HF 51 - is switched on). Without HF

118, the Plasma Chamfering Unit would turn ateach corner of the contour by 135, in other words

by a total of 270, while itonlyturns in the

opposite direction by90when usingHF 118.

Corner routines are requiredtopreserve sharp

cornerswith acute angles and right angles. In the

case of obtuse angles this depends on the

desired quality.

In most cases10 mmis enough for thesize forthe corner routine. In any case, the corner

routine must not be smaller than the cut joint that

had been input, plus the automatic offset plus any

corrective values from the organisation program.

A larger corner routine may therefore be required

for thick sheet and large angles.

A guidelinevaluefor thestand-off distance

between the part and the plate edge or to thenext partcan be taken by using double the

value of the corner routine. (Corner routine +

any stand-off distance of the cut joint + stand-off

distance for rotation of the Plasma Chamfering

Unit + safety margin for the path that will remain

stationary).

135

135

118

90




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In the caseof achamfer, it is essentialto switch

offthe automatic height control in good time

before a corner, otherwise there is a danger that

the sensor could be located outside the plate orabove a neighbouring part (in the case of a feeler

foot sensor, no cut contour lines may be crossed).

The sensor is located approximately 60 mm

behind the jet. It is therefore adequate to switch

off the height setting70 mm before the corner.

Refer to Corner Routine in this section

concerning the sequence and position of the help

functions for a corner routine. Please note thefollowing:

Height setting may only be switched off in the

case of a feeler foot if this has already definitely

crossed the contour line that has already been cut.

Theheight setting mustlikewise beswitched

off earlier on the last contourof the cut section,

the guidelinevalue is 100 mm before the

corner, if one considers the case that the first

contour must be cut with a positive chamfer and

the last one with a positive or negative chamfer.




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The stand-offdistancemust be evenlargerin the

case ofthick sheet, large chamferingangles andacute angles between the first and last contour.

Inthe case ofa circle, you mustnot switch off

theheight settingbefore theend of the contour

of the part if the sensor is located such that it runs

just inside the circle, in the case of an outside

contour, and just outside the circle in the case of

an inner contour.

If the side lengths for a part for which corner

routines must be cut are not greater than the

stand-off distance given above for switching off of

height setting, then height setting must not be

switched on. If thepartis simplytoo small, only

switch on height setting briefly(at the start).




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Help Functions

0 Program Stop Machine will stop without loss of

information.

3 Ignore on

4 Ignore off

5 Rapid traverse on Machine movement with

maximum cutting speed.

6 Rapid traverse off

7 Cutting cycle on Starts the cutting cycle or a single

burner (middle burner in a three

burner set).8 Cutting cycle off

9 Compressed air marking on

10 Compressed air marking off

11 Compressed air marking tool

offset on

The marking tool return the

position of the middle burner (or of

the single burner).

12 Compressed air marking tool

offset off

Cancels help functions 11 and

114.

13 Left burner on Starts the cutting cycle with the

left burner.

14 Left burner off

15 Right burner on Starts the cutting cycle with the

right burner.

16 Right burner off

19 Cross drive Y2on Cross-drive Y1off.

19 Y2congruent/laterally reversed19+ Y2congruent/laterally reversed

+ stand-off distance

20 Cross drive Y1on Cross-drive Y2off.



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57/66

41+.. Hold time Time input in 1/10 second.

42 Burner bridge on After a section, start of the contour.

42+ Automatic burner bridge on The machine executes the

programmed path (start).

43 Cutting oxygen off HF 7, 13 or 15 start the first section

cycle again.

45 Automatic height setting on To lower the burner slide after a

waiting time, e.g., for marking.

46 Automatic height setting off Automation off and raise burner

slide.

47 Height setting automation on Automation on without waiting time.

48 Height setting automation offThe height at that moment will be

retained.

Switch on the automation again

with HF 47 or 45 (without a waiting

time).

51 Tangential controller on In the case of rotation units for

bevelling.

52 Tangential controller off The plasma-chamfering-unit turns

into the 0 position (starting point).

53 Cutting cycle plasma burner on

54 Cutting cycle plasma burner off

55 Select second pre-heating time The time is given in the menu.

56 Edge start off Start - select selection edge start

off = hole-punching cycle on.

57 Edge start on Start - select edge start

on = hole-punching cycle off.


Help Functions


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61 Machine zero point The machine travels in a direct

path and in rapid traverse to the

machine zero point.

61+n Working range zero point To reach multiple working rangezero points which are at fixed

distances from the machine zero

point and are indicated numerically.

62 Program zero point The machine travels in a direct

path and in rapid traverse to the

machine zero point.

63 Program end All stored help functions are

deleted.

76 Burner height control via a

sensor foot

Cancels help function 77.

77 Burner height control via a light

beam

Selection for the feeler system, to

lift the sensor at the

plasma-chamfering-unit, cancels

HF 76.

81 Absolute dimension

programming on

Incremental programming is

standard.

82 Absolute dimension

programming off

Cancels absolute dimension

programming, returns to

incremental programming.

86++ Zero point off Only in connection with HF 81

absolute dimension programming.

87 2nd absolute zero point Dimension of 2nd absolute zero

point.

88 1st absolute zero point Dimension of 1st absolute zero

point in connection with zero point

offset.


Help Functions


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100 Extract optional set on Extract the following information

into the program.

101 Extract optional set off Cancels HF 100.

102 Optional program stop

110 Powder marking on

111 Powder marking off

114 Powder marking tool offset on The marking tool returns the

position of the middle burner

(or of the single burner).

117 Last position of tangential

controller is retained

Only takes effect for one half

information program block.

Must be repeated.

118 Tangential controller rotates

around the shortest path in the

direction of the next but one

contour

The geometry set following

immediately will thus not be taken

into consideration.

122 Angle input for the plasma

burner in steps of 1/10

+ for angle type of HF 29

- for angle type and HF 29

122...+1 Variable chamfering angle end

angle

Until the next HF 122 or 122.

122 End of the variable angle Only in conjunction with

HF 122 ... + 1.

129+ Material thickness Input in 1/10 mm

161+ Current strength = amperes If the plasma cutting unit is

equipped for this.

163+ Jet stand-off distance control =

volts

If the plasma cutting unit is

equipped for this.


Help Functions


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Organisation Programfor Plasma Chamfering

Unit with NCE 520 NCController

An organisation program is used to compensate for

non-linearities during chamfer cutting.

Layout of an organisationprogram

An organisation program is an ASCII File with the

filename extension.ORG. Only capital letters,

numbers, minus signs, spaces and slashes may be

used in producing this file. Individual input values

must be separated from each other by at least one

space. A slash is used at the beginning to indicate a

comment line. All characters after the slash will be

ignored.

Organisation programs can either be produced on a

PC with an ASCII editor (such as EDIT.COM ), or

with the ANC editor. The ANC must be switched into

service mode for this purpose.

A distinction must be made between upper and

lower programming in the organisation program.

The relevant program time is determined by the

combination of the cut joint, side and the direction of

the bevel.



61/66

Upper programming: Kerf right (HF 30) and negative bevel or

kerf left (HF 29) and positive bevel

Lower programming: Kerf right (HF 30) and positive bevel or

kerf left (HF29) and negative bevel

A series of values for cut joint correction and

correction of the bevel can be input for each sheet

strength. A series of values must be available for

both upper and lower programming to provide cut

joint and bevel correction.The cut joint correction

values are input in 1/10 mm and the bevel

correction values in 1/10 .These characteristic

lines are described by four starting points (angles).

A characteristic line is interpolated in a linear fashion

between the individual starting points.


Organisation Program for Plasma Chamfering Unit with NCE 520 NC Controller


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The NCE is able to run multiple organisation

programs. The software options available determine

which of the organisation programs is to be used.

The name of the organisation program to be loaded

can be input in the cutting package. If only one

organisation program is to be used, it is enough to

make the corresponding entry in the basic cutting

package (PARAM.CUT). If more than one

organisation program is to be used it is necessary to

use additional programmable cutting data. The

corresponding file names can be entered in the SDP

files.

The filename extension for organisation programs is

.ORG.The filename of the organisation program to

be loaded is input in the first cutting set description

line of the plasma process (N1) without the filename

extension. The syntax for this M = FILENAME. In

this example of an SDP file, the name of the

organisation program is N2FER_A.




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03

SP_START

N1

(ST37, F3500, K4.7,M=N2FER_AS=8.0)

(CUTTING GAS, OXYGEN, JETS: 0,187)

M0000000000000000

P105 W140 U65 Q260 ;U-ARC

T10 W0.2 U0.2 Q10.0 ;PLASMA DELAY

T11 W0.1 U0.1 Q0.4 ;RAMP SIGNAL EXTENSION

T2 W2.0 U0.1 Q10.0 ;BURNER ON

P102 W1.7 U0.0 Q4.8 ;INJECTION WATER

P115 W1.8 U0.0 Q4.8 ;PILOT GAS

P126 W3.5 U0.0 Q4.8 ;PILOT GAS TOGETHER WITH CUTTING GAS

P116 W0.0 U0.0 Q0.0 ;PREFLOW CUTTING GAS

P117 W0.0 U0.0 Q0.0 ;CUTTING GAS

T52 W0.5 U0.1 Q1.0 ;CURRENT RISING RAMP

P152 W250 U150 Q400 ;CURRENT RAMP STARTING VALUE

P153 W540 U150 Q600 ;CURRENT RAMP END VALUE

T13 W10 U0.1 Q99 ;TEST OPERATION

T22 W3.0 U2.0 Q10.0 ;PREFLOW TIMEP106 W0 U0 Q99 ;IHS

P156 W10.0 U0 Q10.0 ;EQUALISE POTENTIOMETER FOR PROPORTIONAL VALVES

K4.7

F3500

SP_END

4




65/66

Production of an organisation program for cut joint

and angle compensation in a plasma cutting unit:

1. Set all compensation values in the organisation

program to 0.2. Determine the cut joint for light beam control

(vertical).

3. Produce a test program for 4 test pieces with

angles 0, +10, +30, +45, and cut.

4. Evaluate the angles and dimensions, and enter

them into the organisation program.

5. Repeat the cutting with compensation values

entered into the program and correct as

necessary.




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Annex Z: List of validpages

This instruction manual contains 66 pages.

Date of issue of the basic edition and

of changes:

Edition Version number Date of issue

Basic edition 0

List of pages

Amended pages of this instruction manual are

identified by following symbols:

Asterisk, bar or pointing hand.

The asterisk () identifies pages that have been

affected by the last change.

Page Change index

1 to 65 0

Z-1 0

programming of the plasma chamfering unit

Documents