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January 2014

January 2014. The new OPENcontrol family. OPEN control family OPEN control – Control Units OverView Configurations Software architecture HW Platforms HMI solutions Modular Operator Panel OPENconsole Compact Panel Monitors and PanelPC Hand helded console TOP5

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January 2014

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  1. January 2014

  2. The new OPENcontrol family • OPENcontrol family • OPENcontrol – Control UnitsOverView • Configurations • Software architecture • HW Platforms • HMI solutions • Modular Operator Panel OPENconsole • Compact Panel • Monitors and PanelPC • Hand helded console TOP5 • OPENcontrol family devices • OPENrio and other I/Os • OPENdrive • Utilities

  3. OPENcontrol line The new family of Hi-Tech Numerical ControlsOsai Prima Electro Numerical control

  4. OPENcontrol: Synthesis of the Motion Control • The OPENcontrol comes up with the purpose to combine into a family of products the Prima Electro experience within the Motion Control market • The OPENcontrol integrates the features developed for Laser Cutting Machines Controls for Prima Industrie Group and the general purpose market oriented features OsaiPrima ElectroNumericalcontrol

  5. The new line of OPEN products Software Functionalities Hardware Computing Power

  6. Scalability at all levels… Performance Scalability Functional Scalability Software Hardware

  7. System overview – HW configurations

  8. System overview – OPENcontrol Stand Alone Drives • CNC + Monitor • Drives and I/Os can be on the samefieldbus OPENcontrol Drive fieldbus Monitor DVI/VGA Modular I/O USB I/O fieldbus MTB panel Dashedlines for OPTIONAL modules Keyboard • Windows CE real time O.S. • Dual Operating Systemoption (WinCE + WES2009)

  9. System overview – OPENcontrol Multi Platform OPENcontrol Monitor • CNC + Industrial PC (or Panel PC) • Drives and I/Os can be on the samefieldbus Industrial PC Drive fieldbus TCP/IP over Ethernet DVI/VGA Modular I/O USB MTB panel I/O fieldbus Drives Dashedlines for OPTIONAL modules Keyboard

  10. System overview – SW architecture

  11. Development Tools - WinPLUS • SoftPLC: WinPLUS • Development environment and machine logic debug through a tool within the Windows IEC 61131-3 environment • Windows development environment based on IEC 61131-3 which can be programmed in IL, LD, ST, FB, SFC • Integrated machine logic environment • Multi-tasking real-time execution • Max 250 tasks, 10 priority levels • Cyclic task with min. scheduling of 250 µSec. • User event-driven tasks • Event tasks associated to M, S, T functions • On-line debugging (tracing, breakpoint etc.) [Continuity with 10/Series and SyncMotion]

  12. Development Tools - WinNBI • HMI & Configuration: WinNBI • “Configurable Network Based Interface” • Standard user screen panels • Screen panels customization based on graphical obejcts • DLL Available for the development of custom graphical interfaces [Continuity with 10/Series and SyncMotion]

  13. WinNBI - End User applications PathView System History Boot Controller ProcessController standard layouts File Browser MachinePlot Digicad Table Editor

  14. WinNBI - OEM applications O-Scope ODM Security

  15. WinNBI applications availability

  16. ConversationalEditors • Conversational Editor for 3 axes milling machines • SawCAD • SketchCAD Running on PC and on CNC (Windows CE)

  17. Conversational Editor – MillingMachines • Drilling • All drilling patterns include the ability to include standard drilling cycles: • Spot Drilling • Peck Drilling • Deep Hole Peck Drilling • C’Sink with Dwell • Normal Tapping • Reverse Tapping • Boring Cycle w/Rapid Extraction • Boring Cycle w/Extraction at a Feedrate • Custom Drill Cycle Creation • Drilling Patterns include: • Bolt Circle Pattern • Line-At-An-Angle Pattern • Grid Pattern • User defined locations • Machinist Toolbox for reference to shop floor formulas such as : • IN-MM conversion • RPM-SFM Conversion • Drill Point Length Calculations • Feedrate Conversions • Tap Drill Reference Chart • Screw Dimensioning Chart • Speed / Feed Database • Tapping Calculator Milling • Face milling • Round Pocketing • Square/Rectangular Pocketing • Round Boss • Square/Rectangular Boss • Straight/Linear/Radial Slotting • Hexagon Boss Milling • Triangular Pocket Milling • OD Helical Milling • ID Helical Milling • OD Thread Milling • ID Thread Milling Straight Line Engraving Full HELP Manuals accessed via F key • Program Text Editor specifically designed for G code editing with the following features : • Re-Sequence programs with N numbers • Remove N numbers • Add / Remove Spaces • Search / Replace • Paint / Highlight with user defined paint pallet • Mark / Cut / Copy Text • Rotate existing G code programs • Non-TraditionalMachining • Conversational-To-G-Code Programming Assistant (KipwarePA® ) • SketchPad allowing users the ability to draw the desired toolpath. • DXF to SketchPad Converter for importing DXF files into the SketchPad.

  18. P0 P1 Raggio Profondità nel piano Distanza di rallentamento Distanza di rallentamento/2 SawCAD for stone market

  19. SketchCAD for stone market

  20. SW architecture - real-time modules

  21. SW architecture - HMI and Communication OPENcontrol real-time module Remote PC WinNBI Utilities COM client COM client DCOM proxy COM client WinPLUS PC Hardware Ethernet

  22. SW architecture - Dual Operating System OPENcontrol real-time module Windows XP Windows CE WinNBI Utilities COM client COM client DCOM proxy COM client WinPLUS PC Hardware Virtual Network Ethernet

  23. CNC SW key features Axes Management • Coordinated, Auxiliary, Pseudo and Spindle axes • Linear and Rotary Axes • Rollover Axes • Diametral Axes • Gantry Axes (Split) • Dual Axes • Master/Slave axes • Dynamic follower axes Special Features • Multi-Axis Electronic Cam • Bidirectional axis calibration • Cross Compensation • Volumetric Compensation Virtualization • Programming on Rotated Plane • Polar Coordinates • Cylindrical Coordinates • Non orthogonal axes management Axes Motion • Linear, Circular, Helical and Spline Interpolation • Motion Modality (RAMP parameters) • Independent acceleration/deceleration parameters for • Linear Ramp • S Ramp • Trapezoidal Ramp • S Ramp with Jerk limitation • Point to Point and various Continuous Mode • Axis motion filters programming • Velocity Feed Forward (VFF) • Zero Shift • Constant or Variable Pitch Threading (G33) • Multi-start threading • Multi Block Retrace • Memory Search (Restart) • Look-ahead 3D Axes Motion • Circular 3D interpolation • Tangential axis control • Tool Centre Point (TCP) • TCP for Double Twist and Prismatic Heads with 2 or 3 rotary axes. • TCP for non standard kinematics • TCP with Spline (High Speed Machine) • Tool Direction axis movement • TCP on rotated planes • Selection by program of active kinematics Various • Unit of measure change • Shared Axes • Axis Migration • Parametric (macro) language • Machining canned cycles • Probing cycles • Part-program subroutines • XML macro interpreter

  24. CNC Control Unit HW platforms

  25. “Typical” hardware/software configurations

  26. OPENcontrol OPEN-XS – Modularity concept FactoryEthernet Sigma-5 SD • Digital BUS • Mechatrolink III • EtherCAT option • (CANopen option) • ATOM N270 1.6 GHz • 1 LAN • USB (3) • 4 RS232 (1 as RS232/RS422/RS485) • Windows CE • Dual Operating System option (WinCE + WES2009) Mechatrolink III • VGA EtherCAT CANopen fieldbus • OPENrio modular I/O • Optional CANopen devices

  27. OPENcontrol OPEN-XS – Modularity concept FactoryEthernet Digital DRIVES EtherCAT • Digital BUS • EtherCAT (SoE + Coe) • CANopen option • ATOM N270 1.6 GHz • 1 LAN • USB (3) • 4 RS232 (1 as RS232/RS422/RS485) • Windows CE • Dual Operating System option (WinCE + WES2009) • VGA • OPENrio • modular I/O • Optional CANopen devices CANopen fieldbus

  28. OPENcontrol OPEN-XS – Modularity concept FactoryEthernet Drives with analog interface EtherCAT Analog • A432 module • 4 Analog axes • 2 Analog output • 1 Analog output (Spindle) • 1 ABZ 5V Encoder input (handwheel) • 4 Analog Input • 32 Digital Input • 32 Digital Output • A664 module • 6 Analog axes • 1 Analog output (Spindle) • 1 ABZ 5V Encoder input (handwheel) • 4 Analog Input • 64 Digital Input • 64 Digital Output • VGA CANopen fieldbus • Optional • Modular I/O • Optional CANopen devices

  29. OPENcontrol OPEN-XS – Modularity concept FactoryEthernet Drives with Pulse & Direction interface EtherCAT P&D • P432 module • 4 P&D axes • 1 Analog output (Spindle) • 1 ABZ 5V Encoder input (handwheel) • 4 Analog Input • 32 Digital Input • 32 Digital Output • P664 module • 6 P&D axes • 1 Analog output (Spindle) • 1 ABZ 5V Encoder input (handwheel) • 4 Analog Input • 64 Digital Input • 64 Digital Output • VGA CANopen fieldbus • Optional • Modular I/O • Optional CANopen devices

  30. OPENcontrol OPEN-XS – Modularity concept IntegratedCNC (Monitor + Control Panel + Control Unit) Control Unit EtherCAT Mechatrolink III CANopen

  31. OPENcontrol OPEN-M and OPEN-L • Celeron M 1.5 GHz / Pentium M 1.8 GHz • 2 GB RAM • 2 LAN 10/100/1000 • 4 USB v2.0 • 4 RS232 (1 as RS232/RS422/RS485) • 2 slots PCI • 1 GB or 4 GB Compact Flash • 32 GB SSD SATA option • 1 or 2 Axes modules • 3 different axes boards for fieldbusses flexible management (see above) • HMI • VGA Monitor on WinCE • VGA Monitor on WES2009 side in case of Dual Operating System • Remote PC connected via LAN • Windows CE • Dual Operating Systemoption (WinCE + WES2009)

  32. OPENcontrol OPEN-XL – Dual Core – Dual O.S. • Core 2 Duo 2.26 GHz • 2 GB RAM • 2 LAN 10/100/1000 • 4 USB v2.0 • 4 RS232 (1 as RS232/RS422/RS485) • 2 slot PCI • 1 GB or 4 GB Compact Flash • 32 GB SSD SATA option • 1 or 2 Axes modules • 3 different axes boards for fieldbusses flexible management (see above) • HMI • VGA Monitor on WES2009 side in case of Dual Operating System • Remote PC connected via LAN • Dual Operating System(WinCE + WES 2009)

  33. OPENcontrol: data table…

  34. OPENcontrol: …data table

  35. Dual Operating as offline real CNC environment • Offline OPENcontrol CNC • Windows XP + Virtualization SW + Windows CE on desktop/laptop PC • The same software used on the real CNC • Part Program development and testing • Machine Logic development and testing

  36. PRIMAlogic – Entry level GMC

  37. PRIMAlogic: Entry level GMC • PRIMAlogic • Compact SoftPLC • Axes control through CANopen bus • Windows CE real-time Operative System • The same F.B. libraries used for OPENcontrol • The same development/debug/tuning tool used for OPENcontrol • OSAI Prima Electro standard remote HMI (WinNBI) • Immediate and transparent scalabity on higher level products (OPEN10, 20 and 30)

  38. PRIMAlogic: entry level GMC • Same architecture and • same development environments • used for OPENcontrol • Windows CE • PLC IEC 61131-3 • HMI: LCD 4 rows of 40 alphanumerical characters • WinNBI (only remote) • CPU ARM 9 200 MHz • Communication: • Ethernet • RS485/USB • CANopen • Modbus • Digital and analog local I/O

  39. PRIMAlogic: entry level GMC • Same architecture and • same development environments • used for OPENcontrol • 16 Digital Input • 4 Digital output • 4 n.o. single contact relay Output • 2 Switch relay Output • 2 Frequency/counter Input • 4 Analog Input • (also for pressure sensor management) • 4 Analog Input • (also for temperature sensor management) • 4 x 12 bit analog Output

  40. HMI solutions

  41. OPENconsole - Modular Operator Panel Display Main panel Secondary panel Keyboard

  42. OPENconsole - Design

  43. OPENconsole - Display Panel Models • Industrial Monitor 17” • Industrial Monitor 19” Features • Element for • stand alone monitor • USB port • Resolution 1280 x 1024 • Touch Screen Option • IP65 front protection level • 19 “ rack size • 24V Power Supply • 4/3 format • VGA/(DVI) connection (till 20 meters) • USB and VGA(DVI) extender option (till 20 meters or till 80 meters versions)

  44. OPENconsole – Main MTB Panel • Features • EtherCAT fieldbus • Emergency push-button • Drive ON , Drive OFF • CNC ON/OFF • Jog +, Jog - • Cycle, Reset, Hold • Auto mode, Manual mode, mode lock key • Feed (configurable)

  45. OPENconsole – Secondary MTB Panel Wires connection with Main Panel for easy maintenance and I/O save • Features • 7 elements (keys, push-buttons, lamps etc.) as required by OEM • Simple connection to main MTB panel

  46. OPENconsole – Keyboard and Pointing Device • Features • 101 keys US keyboard • Touch Pad or Track Ball • Ergonomic positioning • USB port

  47. OPENconsole Compact, all-in-one Operator Panel Models • 15” Monitor (1024 x 768) • 15” OPEN-XS integrated Features • Single, light, flat frame • Panel mounting • IP65 front protection level • “Bubble keys” keyboards • Standard QWERTY 100 keys keyboard • OEM Control Panel standard keys • OEM Control Panel custom keys • Configurable Feed knobs • USB port • Touch pad • Touch Screen option • Emergency push button (option) • 2 Electro-mechanical push-button (option)

  48. Monitor

  49. Panel PC

  50. TOP5 - Remote Programming Console • Windows CE • Communication: • Ethernet TCP/IP • USB • Safety: • Emergency stop push-button • Double push-button (left and right) with double contact for dead man and live man • HMI: • TFT 6.4” graphical display with touch-screen • Local WinNBI • Local keyboard with customizable keys • Keyboard with dedicated keys • Jog • Hold • Run • Selection of the operative modalities

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