Integrating the fixtures into collision monitoring (option 140)

Application

The Simulation function determines the position of a 3D model in the Set up fixtures workspace, matching the real fixture in the machine envelope. Once the fixture has been set-up, the control considers it in Dynamic Collision Monitoring (DCM).

Requirements

  • Dynamic Collision Monitoring (DCM version 2, software option 140)
  • Workpiece touch probe
  • Permitted fixture file matching the real fixture
  • Options for fixture files

Description of function

The Set up fixtures function is available as a touch probe function in the Setup application of the Manual operating mode.

The Set up fixtures function determines the fixture position, using various probing processes. First one point on the fixture is probed in every linear axis. The position of the fixture is defined in this way. After probing one point in all linear axes, further points can be integrated in order to improve positioning accuracy. After defining the position in one axis, the control changes the status of that axis from red to green.

The revision diagram shows by which value the 3D model is shifted on the real fixture resulting from the individual probing processes.

Revision diagram

Extensions of the Simulation workspace

In addition to the Probing function workspace, the Simulation workspace offers graphic support for setting up the fixture.

VB_5_29_19_Spannmittel_Einrichten_Und_Arbeitsbereich_Simulation_Geoeffnet
Set up fixtures function with open Simulation workspace
  • When the Set up fixtures function is active, the Simulation workspace shows the content below:
  • Current position of fixture as viewed by the control
  • Probed points on the fixture
  • Possible direction of probing by means of an arrow:
    • No arrow
    • Probing is not possible. The workpiece touch probe is too distant from the fixture or the workpiece touch probe is positioned within the fixture, as seen by the control.

    • Red arrow
    • Probing in the direction of the arrow is not possible. The angle between the workpiece touch probe and the fixture is not correct.

       
      Tip

      Probing on edges, corners or heavily curved fixture areas fails to deliver precise measuring results. This is why the control blocks probing in these areas.

    • Yellow arrow
    • Probing in the direction of the arrow is possible. Probing will presumably not improve the set-up process, e. g. the probing point in the displayed axis direction is too close to an already probed point.

    • Green arrow
    • Probing in the direction of the arrow is possible. The angle between the workpiece touch probe and the fixture is correct and the distance is right.

Icons and buttons

The Set up fixtures function contains the following icons and buttons:

Icon or button

Function

XY Clamping plane

This selection menu defines the plane in which the fixture is in contact with the machine.

  • The control offers the following planes:
  • XY clamping plane
  • XZ clamping plane
  • YZ clamping plane
 
Tip

Depending on the selected clamping plane, the control displays the axes in question. In the XY Clamping plane, the control displays e. g. the axes X, Y, Z and C.

AS_5_Tastsystemzyklen_Name_Des_Spannmittels

Name of fixture file

fixtureSetUp_2minus

Shifts the position of the virtual fixture by 10 mm or 10° in the negative axis direction

 
Tip

Shifts the fixture in mm in a linear axis and in degrees in a rotary axis.

fixtureSetUp_minus

Shifts the position of the virtual fixture by 1 mm or 1° in the negative axis direction

fixtureSetUp_0

Enter the position of the virtual fixture directly

fixtureSetUp_plus

Shifts the position of the virtual fixture by 1 mm or 1° in the positive axis direction

fixtureSetUp_2plus

Shifts the position of the virtual fixture by 10 mm or 10° in the positive axis direction

AS_5_Tastsystemzyklen_Status_Rot

Status of axis

  • The control displays the following colors:
  • Gray
  • The axis is hidden in this set-up process and is not considered.

  • White
  • At the beginning of the set-up process, i. e. before probing points are calculated, the control displays the status of all axes in white.

  • Red
  • The position of the fixture in this axis is not unambiguously defined.

  • Yellow
  • The position of the fixture in this axis already contains information. The information is not meaningful yet.

  • Green
  • The position of the fixture in this axis is unambiguously defined.

AS_5_Tastsystemzyklen_Pfad_des_Spannmittels

Path of fixture file

The control automatically saves the fixture file in the initial folder. The fixture file name can be edited.

Save and activate

This function saves all obtained data in a CFG file and activates the measured fixture in Dynamic Collision Monitoring (DCM).

 
Tip

When using a CFG file as the data source for the measuring process, the existing CFG file can be overwritten by Save and activate at the end of the measuring process.

When creating a new CFG file, enter a different file name in the path.

When using a datum clamping system and for this reason, one axis (such as Z) is not to be considered when setting up the fixture, the axis in question can be deselected by a switch. The control will not take deselected axes into account in the set-up process and positions the fixture by considering the remaining axes only.

Revision diagram

Every performed probing restricts the possible positioning of the fixture more and more and puts the 3D model closer to the actual position in the machine.

The revision diagram shows the curve of revisions performed during the setting-up process. The set-up process is successfully completed when only revisions in the accuracy range of e. g. 0.05 mm appear.

  • The factors below influence the accuracy that can be achieved when measuring fixtures:
  • Accuracy of workpiece touch probe
  • Repeatability of workpiece touch probe
  • Accuracy of 3D model
  • Condition of the actual fixture, e. g. existing wear or score marks
AS_5_29_19_Aenderungsdiagramm
Revision diagram in the Set up fixtures function
  • The revision diagram of the Set up fixtures function shows the following information:
  • Mean deviation (QMW)
  • This area shows the average distance of the measured probing points from the 3D model in mm.

  • Shift
  • This axis shows the course of the revised model position by means of the added probing points. The individual values show by which value the 3D model was shifted by the respective probing process.

  • No. of probe point
  • This axis shows the numbers of the individual probing points.

Example of sequence of fixture probing points

The following probing points can e. g. be set for different fixtures:

Chucking equipment/fixtures

Possible sequence

Schraubstock
Probing points for a vice with a fixed vice jaw
  1. The following probing points can be set when measuring a vice:
  2. Touching the fixed vice jaw in Z–
  3. Touching the fixed vice jaw in X+
  4. Touching the fixed vice jaw in Y+
  5. Touching the second value in Y+ for rotation
  6. To improve accuracy, touching the check point in X–
Backenfutter
Probing points with a three-jaw chuck
  1. The following probing points can be set when measuring a three-point chuck:
  2. Touching the jaw chuck body in Z–
  3. Touching the jaw chuck body in X+
  4. Touching the jaw chuck body in Y+
  5. Touching the jaw in Y+ for rotation
  6. Touching the second value at the jaw in Y+ for rotation

Measuring the fixed-jaw vice

 
Tip

The desired 3D model must meet the requirements of the control.

Options for fixture files

  1. To measure a vice using the Set up fixtures function:
  2. Affix a real vice in the working space
ManualMainIcon

  1. Select the Manual operating mode

  1. Insert the workpiece touch probe
  2. Manually position the workpiece touch probe above the fixed vice jaw at a striking point
  3.  
    Tip

    This step makes the subsequent steps easier.

  1. Select the Setup application
ffa

  1. Select Set up fixtures
  2. The control opens the Set up fixtures menu.

  1. Select a 3D model matching the real vice
SF_4_Datei_Oeffnen_Oeffnen

  1. Select Open
  2. The control opens the selected 3D model in the simulation.
fixtureSetUp_2plus

  1. Pre-position the 3D model by using the buttons for the individual axes within the virtual working space
  2.  
    Tip

    For pre-positioning the vice, use the workpiece touch probe as a point of reference.

    At this point in time, the control does not know the precise position of the fixture, but of the workpiece touch probe. Pre-positioning the 3D model in accordance with the position of the workpiece touch probe and by using e. g. the table's T-slots produces values close to the position of the real vice.

    Even after recording the first measuring points, the shifting functions are still available for correcting the fixture position manually.

  1. Specify the clamping plane, e. g. XY
  2. Position the workpiece touch probe until a green down arrow appears
  3.  
    Tip

    As the 3D model is only pre-positioned at this point in time, the green arrow cannot provide any reliable information about whether the desired surface of the fixture will actually be touched. Check if the fixture position in the simulation and in the machine match and if touching in the direction of the arrow is possible on the machine.

    Do not touch directly near edges, chamfers and roundings.

679843_56

  1. Press the NC Start key
  2. The control probes in the direction of the arrow.
  3. The control displays the status of the Z axis in green and shifts the fixture to the touched position. The control marks the touched position by a point in the simulation.

  1. Repeat this process in axis directions X+ and Y+
  2. The status of the axes turns green.

  1. Touch another point in axis direction Y+ for the basic rotation
  2.  
    Tip

    To achieve maximum accuracy when touching the basic rotation, the probing points should be as far apart from one another as possible.

  3. The control changes the status of the C axis to green.

  1. Touch the check point in axis direction X–
  2.  
    Tip

    Additional check points at the end of the measuring process improve the matching accuracy and minimize the faults between the 3D model and the real fixture.

SF_5_Tastsystemzyklen_Speichern_Und_Aktivieren

  1. Select Save and activate
  2. The control closes the Set up fixtures function, saves a CFG file with the measured values at the path specified above, and integrates the measured fixture into Dynamic Collision Monitoring (DCM)

Notes

 
Notice
Danger of collision!
To touch the exact position of the fixture on the machine, the workpiece touch probe must be properly calibrated and the value R2 properly defined in the tool management. Otherwise, incorrect tool data of the workpiece touch probe may cause inaccurate measurement and possibly a collision.
  1. Calibrate the workpiece touch probe at regular intervals
  2. Enter parameter R2 in the tool management
  • The control cannot identify modeling differences between the 3D model and the real fixture.
  • At the time of set-up, Dynamic Collision Monitoring (DCM) does not know the exact position of the fixture. In this condition, collisions with the fixture, the tool or other non-machine components such as fixing clamps in the work envelope may occur. The non-machine components can be modeled on the control using a CFG file.
  • Editing CFG files with KinematicsDesign

  • If you cancel the Set up fixtures function, DCM will not monitor the fixture. In this case, any fixtures previously set up are also removed from the scope of monitoring. The control displays a warning.
  • Only one fixture can be measured at a time. To monitor several fixtures simultaneously by DCM, the fixtures must be integrated into a CFG file.
  • Editing CFG files with KinematicsDesign

  • When measuring a jaw chuck, the coordinates of the axes Z, X and Y are determined just as when measuring a vice. The rotation is determined from one single jaw.
  • The saved fixture file can be integrated into the NC program with the FIXTURE SELECT function. This can be used for simulating and executing the NC program, considering the real setup situation.
  • Loading and removing fixtures using the FIXTURE function (option 40)