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Step-by-Step


1. XY Cutter Interface (DC Motor-Controlled Z Axis)

The XY Cutter interface is designed for machines using DC motors to control the Z Axis. In this setup:

  • The Z Axis is controlled via output links:
    • C-Zfree,1 for upward movement.
    • C-Zfree,-1 for downward movement.

This simple control method does not involve pulse and direction signals, making it suitable for basic XY cutting machines. Operators can activate the outputs to move the Z Axis up or down as required.

2. XYZ Cutter Interface (Manual Stepper/Servo-Controlled Z Axis)

The XYZ Cutter interface is intended for machines using stepper or servo motors in manual mode. In this configuration:

  • The Z Axis is controlled via pulse and direction signals, directly connecting to the Axis control pins.
  • Operators can manually adjust the Z Axis position during toolpath execution to ensure the cutting tool (e.g., plasma torch) maintains the correct height from the workpiece surface.

This interface is particularly suited for applications where manual intervention is required to maintain precision during operation.

3. XYZ Cutter + THC Interface (Automatic Stepper/Servo-Controlled Z Axis)

The XYZ Cutter + THC interface is designed for machines where the Z Axis operates in automatic mode, managed by the THC (Torch Height Control) module. This configuration relies on feedback from the plasma unit's arc voltage:

  • Feedback Voltage Control:
    • As the plasma arc length increases, the feedback voltage from the plasma unit rises.
    • Conversely, as the arc length decreases, the feedback voltage drops.
  • Automatic Adjustment:
    • The Z Axis dynamically adjusts its height based on the feedback voltage to maintain the optimal cutting distance.

The THC module ensures real-time adjustments, providing consistent and precise cutting performance. This interface is ideal for high-precision plasma cutting machines where automatic height control is critical.


Interface workspace

1- Study about different part of interface which is named and indicated in photo it means that you should get familiar with all elements like Buttons , screen , bars , volume , values , … anything on interface you have accesses


  • Top Status Bar

  • Online (Yellow Light): Indicates the machine's connection status. Yellow may mean a standby mode or that it's not fully online.
  • X Axis, Y Axis, Z Axis (Green Lights): These lights show the operational status of each axis. Green typically means these axes are active or ready.
  • Alarm, Emergency (Brown Lights): Indicators for critical safety statuses. When activated, they may change color (e.g., red) to signal an alarm, emergency stop.

Position and Speed Readouts (Right Panel)

  • Position :

This position is shown based on where the reference point has been selected.

  • Velocity (Below Relative Position): Shows the current operational speed in mm/s, useful for monitoring real-time cutting or movement speeds.

Real-Time Reference Adjustment in Radonix Interfaces

Home:

Machines goes to home sensors.

Set Reference :

Radonix interfaces offer a dynamic reference adjustment feature, allowing operators to redefine the reference point at any moment during the operation. This feature enhances flexibility and precision in workflows, making it suitable for diverse applications.

it means that operator can change start point of workpiece on the table.

Go to Reference

by pressing this button machine goes to the start point


  • Manual Jogging Controls :
  • Arrows (X+, X-, Y+, Y-): These buttons manually jog the machine along the X and Y axes, allowing for precise positioning adjustments by moving the tool head incrementally.

You can switch the jog mode by pressing this button according fig 01-05 and it will change to figure 01-06, changing from continuous to incremental movement. This means you can define a value in this section according fig 01-07 which has been indicated in red area , and after pressing the coordinate axis jog, the axis will move by the amount you have entered.


Feed Rate and Tool Parameters (Lower Right Panel)

  • V (mm/s) and Step**(mm)**: Input fields for setting feed rates and movement limits along each axis. "V" controls the velocity (or speed) in mm/s, and "L" could define the step size for each manual jog.

Scroll (Vertical Slider on Bottom Right ):According to figure 01-08 which is demarcated with red area or Allows for real-time adjustment of the feed rate or speed as a percentage. This control can quickly change the speed without directly altering program values.


Main Program Controls

  • Settings (Gear Icon): Opens the configuration menu, where detailed settings for the CNC machine can be adjusted.

  • The Exit icon allows you to close the program
  • The Minus icon lets you minimize it.
  • The $ icon create a report from the workpiece and operator can estimate the price

Interface specification :

This section of the interface displays the current status and features of the system. It also updates to show alarms and processes every second. For a detailed report, double-click on this section.


Main Program Controls (Bottom Center)

  • Open File (Folder Icon): Opens a file dialog for loading a CAM (Computer-Aided Manufacturing) file, typically a G-code or DXF program.

This section is dedicated to controlling G-Code execution:

  • RUN: This button starts the G-Code process.
  • Backward: The Backward button provides operators the ability to step back within the G-Code toolpath execution process. This feature is essential for troubleshooting, rechecking, or re-executing specific portions of the G-Code.
  • Pause: This button halts the toolpath.
  • Reset: This button resets the toolpath.

Essentially, once the interface is installed, it comes with a default setup, and everyone can change the order of the input ports. For instance, we include necessary Inports which are effective and suitable for the initial launch .

The first recommended step for providing protection against any errors or mistakes is to define the Emergency link. This can be connected to a button that either stops the motors or turns off the digital outports.


Inports

In this section, we will examine the configuration of the Inputs.

Essentially, when the Inports branch is opened, these settings will appear.

Setting Up Inputs: General Overview

Configuring inputs in our CNC system is an essential step to ensure smooth operation, precise control, and safety. Inputs can be categorized into two main types based on their configuration and purpose: Hardware-Based Inputs and Software-Based Inputs. This flexibility allows the system to adapt to a wide range of applications and machine requirements.

1. Hardware-Based Inputs

Hardware inputs involve physical devices connected to the controller, enabling direct interaction with the machine's environment. These inputs are crucial for safety, machine control, and real-time feedback.

The digital inputs of Radonix controllers are named as I.[n], where n is a number greater than zero and represents the input number. These inputs are isolated by optical couplers and have low noise tolerance due to their low impedance.

The digital inputs on Radonix controllers have the capability to switch between NPN and PNP modes depending on the output of the device or sensor. The mode changeover switch must be set to PNP position for devices with PNP output and NPN position for devices with NPN output.

In various branches of industrial automation, there are equivalent terms for PNP and NPN. Some examples of these terms include: NPN = Sink = Low Active PNP = Source = High Active

  • In this section, we will examine the configuration of the Inputs.

Setting Up Inputs: General Overview

Configuring inputs in our CNC system is an essential step to ensure smooth operation, precise control, and safety. Inputs can be categorized into two main types based on their configuration and purpose: Hardware-Based Inputs and Software-Based Inputs. This flexibility allows the system to adapt to a wide range of applications and machine requirements.

Switching Between PNP and NPN Modes in Radonix Systems

The ability to switch between PNP (positive logic) and NPN (negative logic) modes in Radonix controllers depends on the specific board model being used. This flexibility allows the system to be compatible with different wiring and sensor configurations.

  • PC Pro LAN:
    • A small DIP switch is present on the board.
    • This switch allows users to toggle between PNP and NPN modes.
    • How to Use:
      • Locate the DIP switch on the board.
      • Toggle the switch to the desired mode (PNP or NPN).
      • Ensure the board is powered off before making changes to prevent damage.

Examples of Hardware Inputs:

  • Limit Switches: Define physical boundaries for axis movement.
  • Home Sensors: Establish the reference (Home) position for the machine most of them are Proximity
  • Emergency Stop Buttons: Ensure immediate halting of operations in emergencies.
  • Other Proximity Sensors: Detect objects or tools in the machine's workspace.
  • Push Buttons and Selector Switches: Trigger specific machine functions or modes.
  • Scanners: Measure or detect specific properties, often used in specialized processes such as Glass or gold CNC operations.

Configuration Process:

  1. Connection: Physically connect the hardware component (e.g., a switch or sensor) to the designated input pin on the controller.
  2. Input Definition: Use the controller software to define the role of the input (e.g., HomePin, LimitPin, or a custom input for specific functions).
  3. Polarity Settings:
    • Set the input type as Normally Open (NO) or Normally Closed (NC) based on the connected hardware's default state.
    • For example:
      • An NC emergency stop button remains active (closed) until pressed.
      • An NO proximity sensor activates (closes) only when an object is detected.

2. Software-Based Inputs

Software-Based Inputs provide simple logical functionality to configure arbitrary links and integrate them with related physical hardware .They facilitate quick and simple installation without the need for microprogramming. Users can simply select options from a list and configure settings to maximize efficiency.

image.png

As illustrated in the figure, each input is divided into three sub-branches, as detailed below:

  1. Enable: This sub-branch can be set to two values: True or False.
  2. Link: Specifies the duty or task that needs to be performed or checked. This includes any device that can serve as an input, such as sensors, buttons, and switches.
  3. NC: Determines whether the specific input is Normally Open (NO) or Normally Closed (NC).

Examples of Software Inputs:

  • Virtual Limit Switches:
    • Use software parameters to define axis movement boundaries based on the machine's table size.
  • Logical Triggers: Define conditional triggers for specific operations (e.g., When the axis reaches the limit switch ).
  • Simulated Inputs: Use for testing or scenarios where physical components are unavailable.

Configuration Process:

  1. Access Configuration Interface:

    • Open the controller's software settings to manage inputs.

  2. Define Parameters:

    As an example to set limit Switch :

  • setting —→ System —→ In ports —→ Enabled= True

    Linked = LimitPin,X

    NC= True

  • Configure additional logical conditions for interlocks or simulations.

  1. Validate Settings:
    • Test the software by CAM Pro TEST input configurations to ensure proper functionality and safety.

Outputs

In this section, we will examine the configuration of the Outputs.

Setting Up Inputs: General Overview

In Radonix systems, Outports are critical components that manage the output signals controlling various peripherals, such as relays, actuators, alarms, and other devices. Outputs can be categorized into two main types based on their configuration and purpose: Hardware-Based Inputs and Software-Based outputs. This flexibility allows the system to adapt to a wide range of applications and machine requirements.

Hardware-Based Outputs

Hardware outputs involve physical signals sent from the controller to external devices, enabling direct control of the machine’s environment. These outputs are critical for operational safety, machine actuation, and real-time command execution, ensuring efficient workflow and coordination within the CNC system.

The digital outputs of Radonix controllers are named O.[n], where n is a numerical identifier greater than zero and represents the output number .

Radonix controllers incorporate robust protection mechanisms for Outports to ensure durability, safety, and reliability. These mechanisms vary between different models, specifically the PC-Pro and PC-Smart boards, each with distinct protection features and failure handling processes.

Output Behavior in PC-Pro LAN Models

  • The PC-Pro LAN model outputs are fixed in NPN mode.
  • How It Works:
    • When an output is ON, it provides 0 volts by pulling the signal to ground.
    • When an output is OFF, it is in a high-impedance state, effectively disconnecting the circuit.
  • Wiring Consideration:
    • Connected devices must be compatible with NPN logic, where the load receives voltage from a positive source and is activated when the output pulls the circuit to ground.

2. Output Behavior in PC-Smart Models

  • The PC-Smart model offers a flexible configuration where outputs can operate in PNP mode or NPN mode, depending on the connection of the COM Pin.
  • How It Works:
    • The voltage provided by the outputs depends on what is connected to the COM Pin:
      • COM Pin Connected to 24V: Outputs will provide 24 volts when activated.
      • COM Pin Connected to Ground: Outputs will provide 0 volts when activated (NPN mode).
  • Flexibility:
    • This design allows PC-Smart models to adapt to different wiring requirements and device logic preferences.

Configuration Process for Outputs:

  1. Connection:

    • Physically connect the hardware component (e.g., relay, electric valve , Barke , alarm) to the designated output pin on the controller.
    • Ensure proper wiring based on the required logic (PNP or NPN) and voltage compatibility.

  2. Output Definition:

    • Use the controller software to define the role of the output (e.g., C-CutPin, Brake, or a custom output for specific functions).
    • Assign the output to its intended device or operation in the system settings.

  3. Logic Settings:

    • Set the output logic based on the connected device's requirements:
      • Active High (PNP): The output sends voltage (e.g., 24V) when activated.
      • Active Low (NPN): The output pulls the signal to ground (0V) when activated.

  4. Testing and Validation:

    • After configuring, test the output to ensure it operates as intended in CAM Pro Test application.
    • Use a multimeter or other diagnostic tools to verify output voltage and behavior.

    2. Software-Based Outputs

    Software-Based Outputs provide simple logical functionality to configure and integrate them with related physical hardware. These features are crucial for enhancing control capabilities. They facilitate quick and simple installation without the need for microprogramming. Users can simply select options from a list and configure settings to maximize efficiency.


As illustrated in the figure, each output is divided into three sub-branches, as detailed below:

  1. Enable: This sub-branch can be set to two values: True or False.
  2. Link: Specifies the duty or task that needs to be performed or checked. This includes any device that can serve as an output, such as actuators, lights, and alarms.
  3. NC: Determines whether the specific output is Normally Open (NO) or Normally Closed (NC).

Examples of Software Outputs:

  • Virtual Relays:
    • Use software parameters to define activation boundaries for devices based on operational needs.
  • Logical Triggers: Define conditional triggers for activating specific outputs (e.g., alarms or Relay for specific function ).
  • Simulated Outputs: Employ these for testing or in scenarios where physical components are not available.

Configuration Process:

  1. Access the Configuration Interface:
    • Navigate to the controller's software settings to manage outputs.
  2. Define Parameters:

    • To configure an output like an order to forward the VFD, enter parameters.

    • setting —→ System —→ Outports —→ Enabled= True

      Linked = C-CutPin

      NC= True


  1. Validate Settings:
    • Test the configured software outputs to ensure they function correctly and safely, verifying their effectiveness in real-world applications.

Setting Up Inputs: Simple and Intuitive Configuration

In Radonix system, configuring inputs or Outputs is designed to be as user-friendly as possible, without requiring any microprogramming or advanced technical knowledge. All you need to do is navigate to the Inputs section of the controller interface, open the settings drawer, and select the item you need to configure. The same process applies to other sections, such as Outputs or any other functional areas.

Step-by-Step Configuration Process

  1. Access the Desired Section:
    • Go to the section you want to configure, such as Inputs or Outputs, depending on the functionality you are setting up.
  2. Open the Settings Drawer:
    • Within the selected section, locate the specific input branch or subsection.
    • Click or expand the settings drawer to reveal the available options.
  3. Select the Required Item:
    • Choose the input type or functionality you want to configure (e.g., limit switch, home sensor, emergency stop, or custom inputs).
    • Define the specific role for the input, such as C-ZFreePin,1
  4. Set Parameters Easily:
    • Adjust the necessary parameters, such as polarity (Normally Open or Normally Closed), response delays, or logical behavior, directly from the interface.
  5. Save and Test:
    • Save your settings and validate them through the controller interface to ensure everything is functioning as intended.
    • In the end in order to finalizing you have to close program to save everything

  • 1-Emergency Stop (E-Stop): A critical response mechanism in industrial settings used to halt machinery and equipment immediately in order to protect against imminent danger. This action is typically engaged through an emergency stop button or switch that, when activated, interrupts the power supply and ceases all operations, effectively minimizing the risk of accidents, injuries, or damage to the machinery and personnel.
    • Configurable Emergency Mode: An advanced feature in control systems that allows users to define and set up custom emergency responses through the system settings. This mode can be programmed to engage different levels or types of responses depending on the nature and severity of the threat detected.

This variable is used to determine the operation that occurs when the Emergency button is pressed.

  • None: When this mode is selected, the machine operation is similar to a pause. The device stops all activities but cannot be resumed from the same point if this mode is triggered.
  • ClearOutPorts: Activating this mode stops the axes and turns off all digital output ports of the controller. This ensures that no further commands affect the machine's operation until reset.
  • ClearAnalog: This mode stops the axes and turns off all analog outputs. It's used to ensure that any variable outputs controlling aspects like tool pressure or spindle speed are deactivated.
  • DisableAxes: In this emergency mode, the axes of the machine are stopped and become inactive, which means the motors that drive the axes are disengaged, allowing them to move freely if manually pushed but not under power.
  • ResetToolPath: This mode stops the axes and resets the toolpath to the start of the program. This is useful in scenarios where the process needs to be started from the beginning, either to prevent damage or to correct an error.
  • ClearOutPorts+ClearAnalog: This comprehensive emergency mode combines the effects of ClearOutPorts and ClearAnalog, stopping all digital and analog outputs, disabling the axes, freeing the motors, and resetting the toolpath to the first coordinate. This is effectively a full reset of the system's operating state.
  • All: Selecting "All" activates all the above emergency responses, providing the maximum level of immediate system shutdown. All outputs, both digital and analog, are turned off; axes are stopped and freed; and the toolpath is reset.

  • **2-Home Sensors : As a usual in XY Cutter CNC machines Home sensors does not use because of the length of axis .**Home sensors are so crucial for positions it means that thanks to these sensors the position become meaningful , they are impact in defining table size the sensors are machine zero point or machine origin point when axis reach the sensors the controller detect them and it causes that a red table is created in Black Grid space so with this option each point in this area has its own position than sensors ın each axis

    Indeed, home sensors are integral to the function and accuracy of CNC machines. Let's explore further how these sensors interact with the CNC controller and influence the machine workspace setup:

    Role and Functionality of Home Sensors:

    1. Defining the Origin: Home sensors establish the machine's zero point or origin. This point serves as the reference for all other positions within the machine's operational space. It ensures that the machine knows the starting point for all axes (typically labeled X, Y, and Z).
    2. Impact on Table Size and Work Area Definition: The detection of the home position by these sensors directly impacts the definition of the machine’s table size. This is because the machine controller uses the origin point to calculate and define the extents of the machine’s operational area or table. The movements and operations of the machine are confined within these calculated boundaries to ensure precision and to prevent the machine from moving beyond its capable limits, which could cause damage or errors.
    3. Visualization on Controller Interface: When the home sensors are triggered, the CNC controller can visually depict this on its interface, often illustrated as a "red table" laid out on a "black grid" background. This visual representation helps operators to see and understand the active working area of the machine. It shows where tools can safely travel and operate, providing a clear demarcation of the workspace.
    4. Positional Accuracy: Each point within this defined red table area has a specific position relative to the machine’s origin point, determined by the home sensors on each axis. This arrangement allows for precise control over the machine's movements and operations, ensuring that every motion made by the machine is accurately accounted for relative to the origin, enhancing both the precision and reliability of the work performed.
    5. Operational Reliability: Regularly using home sensors to reestablish the machine’s origin point helps maintain operational accuracy and reliability, crucial for long-term consistent output, especially in precision-dependent applications.

    Overall, home sensors not only provide a safety mechanism by defining the limits of machine operation but also enhance operational precision by establishing a clear and reliable reference point for all machining tasks. This setup ensures that every point within the operational area is accurately positioned relative to the origin, making the machine's functioning both predictable and precise.

To ensure precise cessation of axis movement after issuing the Home command, the appropriate input links must be configured prior to pressing the Home button, as depicted in the above explanation. This configuration ensures that the machine accurately detects the home position for each axis.

For example:

  • The input HomePin,X is assigned to detect the X-axis home position. This means that when the X-axis sensor aligns in front of its designated home sensor, the system identifies it as the home position.

  • Similarly, other axes such as Y , C , Z require their respective input links, such as HomePin,Y or HomePin,C, to be properly set based on the machine's axes and sensor alignment.

    This structured setup allows the machine to halt each axis movement accurately when it reaches its home position, ensuring safe and reliable operation during homing procedures.


  • 3-Limit pin :In CNC machines, limit pins serve as an essential safety feature to prevent the machine axes from exceeding their physical boundaries. These pins are linked to hard limit switches, which are mechanical or sensor-based devices that stop the machine when triggered.

    Key Points about Limit Pins:

    1. Hard Limits:
      • Hard limits rely on physical limit switches installed on the machine.
      • When an axis reaches the limit switch, the corresponding input link (e.g., G-LimitPin,X, G-LimitPin,Y, or G-LimitPin,Z) is triggered.
      • The machine automatically stops to avoid damage to mechanical components.
    2. Soft Limits:
      • Soft limits are defined within the Radonix settings.
      • The operator sets the allowable movement range for each axis through software, ensuring the axis does not move beyond these defined boundaries.
      • These limits are monitored digitally and act as a preventive measure before reaching the physical hard limits.
    3. Dual Safety Mechanism:
      • Combining hard limit pins with soft limits ensures maximum protection:
        • Soft Limits act as the first line of defense to stop movements within software-defined boundaries.
        • Hard Limits serve as a final physical safeguard to prevent any accidental overrun of the machine axes.

    Configuration of Hard Limit Pins:

    To set up hard limits in Radonix controllers:

    1. Navigate to System > InPorts in the Radonix software.
    2. Assign the input links for the respective limit switches:
      • G-LimitPin,X for the X-axis hard limit.
      • G-LimitPin,Y for the Y-axis hard limit.
      • G-LimitPin,Z for the Z-axis hard limit.
    3. Ensure the Enabled parameter is set to True.

limitPin,X

LimitPin,-X /// LimitPin,Y /// LimitPin,-Y /// LimitPin,Z /// LimitPin,-Z


  • 4-Calibration : calibration refers to the process of aligning the motion value of an axis with one of the standard units or with a specific value. Common units in industrial devices are usually millimeters, centimeters, meters, inches, feet, degrees, etc., which are available for use based on the need. Therefore, the concept of calibration for the millimeter unit can be expressed as the alignment of the motion value of the desired axis with the millimeter unit. That is, in the case of measuring with measuring tools, the numerical value of the motion of the axis should be consistent with the measured value in millimeters.

At fırst step of calibration , Electronic Gear Box must be set :

An Electronic Gear Box is an integral component in modern servo systems, especially in applications that involve servo motors, like those used in automation and robotics. This technology essentially functions as a virtual gearbox that adjusts the speed and torque of a motor electronically, rather than mechanically. By manipulating the frequency and amplitude of the motor’s input signals, an electronic gearbox can change the output characteristics of the motor to suit specific tasks without needing physical gear changes.

Next step is essential for this subject is : Encoder Resolution

Encoder Resolution is a fundamental specification of servo motors, indicating the number of pulses an encoder emits for each complete revolution of the motor's shaft. This specification, expressed in pulses per revolution (PPR), is crucial for defining the precision with which the motor's position, speed, and acceleration can be controlled.

For instance, the Delta servo motor's B2 model features an encoder resolution of 160,000 pulses per revolution. This means that for every full turn of the motor shaft, the encoder generates 160,000 distinct signals. In contrast, the A2 model from the same brand boasts a much higher resolution of 1,280,000 pulses per revolution. This higher resolution allows for even finer control and more precise adjustments, which is essential in applications requiring meticulous positioning and detailed motion control.

High-resolution encoders are particularly beneficial in fields like robotics, CNC machinery, and automated assembly lines, where exact movements are paramount. The greater the encoder resolution, the smaller the movement that can be detected and controlled, enhancing the system’s accuracy and the quality of the output. This capability is crucial for optimizing the performance of high-precision tasks, ensuring that each component operates within tight tolerances and adheres to strict quality standards.

Understanding and setting the encoder resolution appropriately is a critical first step in the calibration of automated systems. It ensures that the machine operates smoothly and that each part produced meets precise specifications, thereby reducing errors and increasing overall efficiency in manufacturing processes. This detailed control over motor movements is what makes modern automated systems capable of performing complex tasks with high reliability and accuracy.


General Guide to Setting the Electronic Gear Ratio (E.G.) in Servo Drives

Overview

Configuring the Electronic Gear Ratio (E.G.) for servo drives is crucial for optimizing their performance in applications requiring precise motion control. This guide provides a generic approach to setting E.G. in servo drives, using the Delta B2 servo drive as a specific example to illustrate the process.

Requirements

  • Servo drive with an integrated encoder
  • Controller capable of generating pulse signals (e.g., a CNC controller)
  • Technical specifications for both servo drive and controller

Step-by-Step Configuration

Step 1: Understand Encoder Resolution

  • Objective: Recognize the encoder resolution, which is the number of pulses needed for one complete rotation of the servo motor's shaft.
  • General Info: Encoder resolution is specified in pulses per revolution (PPR). It determines the precision with which the servo drive can control the motor position.

Step 2: Calculate Motor Speed in Rounds Per Second

  • Objective: Convert the desired motor speed from RPM (revolutions per minute) to RPS (revolutions per second) to match the controller's output frequency.
  • Procedure:
    • Formula: RPS=RPM/60
    • This calculation adjusts the time base from minutes to seconds, facilitating synchronization with pulse output.

Step 3: Determine Required Pulses Per Second

  • Objective: Calculate the total pulses per second required based on the RPS and encoder resolution.
  • Procedure:
    • Objective: Calculate the total pulses per second required based on the RPS and encoder resolution.
    • Procedure:

      • Multiply the RPS by the encoder resolution to get the required pulses per second.

      • Example Formula: Pulses per Second=RPS × Encoder Resolution

        Pulses per Second=RPS ×Encoder Resolution

Step 4: Set the Electronic Gear Ratio (E.G.)

  • Objective: Adjust the electronic gearing to enable the controller's output to meet the servo motor's pulse requirements.
  • Procedure:

E.G. Ratio Definition

The E.G. ratio is calculated by dividing the required pulse count by the controller’s pulse output capability:

E.G. = Required pulses per second / Controller’s pulse capability

To ensure proper operation, configure the controller so that its pulse capability meets or exceeds the calculated E.G. ratio.

Example: Delta B2 Servo Drive

Motor speed: 3,000 revolutions per minute (RPM)

Encoder resolution: 160,000 pulses per revolution (PPR)

Controller’s pulse capability: 500,000 pulses per second

Calculation

Convert the motor speed from RPM to revolutions per second (RPS):

3,000 ÷ 60 = 50 RPS

Determine the required pulses per second:

50 RPS × 160,000 PPR = 8,000,000 pulses per second

Calculate the E.G. ratio:

8,000,000 pulses ÷ 500,000 pulses = 16

Set the controller’s E.G. ratio to 16 : 1.


Testing and Validation

  • Objective: Ensure that the servo system functions correctly under the new settings.
  • Procedure:
    • Conduct a test run to check the accuracy and responsiveness of the servo drive.
    • Observe the motion to confirm that it aligns with expected parameters.

Additional Notes

  • Refer to specific servo drive manuals for detailed specifications and advanced settings.
  • Regular maintenance checks and recalibration are recommended to sustain optimal performance.

This comprehensive approach ensures that various types of servo drives can be efficiently integrated and operated in systems requiring high precision, such as in automation and robotics.

now based on this E.G calibration process can be feasible through two ways

1- Radonix CAM Calibrator and Measurement

2-Mathematics Calculation


1-Computational

In the calibration method that relies on physical measurements using tools and instruments, the process directly depends on the accuracy of these tools and the inherent mechanical precision of the device being calibrated. This measurement-based method, while not as precise as computational approaches that utilize exact mathematical models and software simulations, is nonetheless popular in many practical applications. It offers a straightforward approach when detailed information about the motor, gearbox, pulley, and gears is unavailable or incomplete.

The fundamental principle of this calibration method involves measuring the actual displacement that occurs for a given number of pulses emitted by the system. By doing so, it allows for direct observation and adjustment based on real-world outcomes, which is particularly valuable in scenarios where theoretical data may not fully capture the dynamics of the mechanical system. The method's reliance on physical measurements means that any error in the measuring tools or mechanical inaccuracies in the system can significantly affect the quality and reliability of the calibration.

Despite its limitations in precision compared to computational methods, this approach is widely adopted because it provides a practical, hands-on way to ensure that machinery and systems are performing within acceptable limits. It is particularly useful in maintenance scenarios or when setting up new equipment in a manufacturing line where detailed specifications of components are not readily available. This method ensures that operators can still achieve effective calibration, maintaining operational efficiency and reducing downtime due to misalignment or other issues arising from improper calibration.

To enhance accuracy and speed in calibration by measurement, Radonix provides a complimentary software tool, CAM-Pro Calibrator. This tool is automatically installed with the main Radonix software suite. It efficiently calculates the step value by measuring the physical displacement of the axis and the required number of pulses for achieving this displacement.


Since pulse counting in this method is managed by the controller, there is no measurement error associated with pulses. Therefore, the measurement accuracy in this method is directly related to the accuracy of the physical measurement. Additionally, increasing the distance between two measured points results in a higher pulse count, effectively enlarging the denominator of the fraction. With the error remaining constant, the calculated step value becomes more precise. Consequently, calibration based on two widely spaced points will yield more accurate results .

Please note that two Radonix software programs should never be run simultaneously. If they are, one of the programs will not be able to connect online. Therefore, always ensure that all other Radonix software programs are closed before running the desired application.

As explained in the previous section, the CAM-Pro Calibrator software is installed alongside the CAM-Pro software. There are two methods to locate the calibrator software after installation. According to the first method, simply go to the installation location, which by default is on the C drive of Windows. Then navigate to the 'Program Files (x86)' folder, open the Radonix folder, and you will find the Radonix CAM-Pro file where the CAM-Pro Calibrator software can be seen. According to the second method, just use the Search feature from the Start menu (Figure 1, Step 1), search for 'Radonix CAM-Pro Calibrator', and run it

This program consists of two windows. The first window only appears if there are multiple active interfaces on a computer (Figure 3). Through this window, you can select the desired interface and launch it by pressing the 'Ok' button. If there is only one active interface on the computer, the interface selection window will not open, and the main window will open directly.

When you open the CAM-Pro Calibrator software, you will see Figure (4), which components are as follows:


  1. Connection:
    • ProLan controllers must be set to LAN mode.
    • ProUSB controllers must be set to USB mode.
  2. Serial:
    • Displays the controller's serial number.
  3. Activation Code:
    • Displays the 16-digit code used to activate axes.
  4. Active Axes:
    • Shows the number of activated axes using the activation code.

Axis Section

5.Axis:

  • Allows selecting the desired axis for calibration.

6.Direction:

  • Select the appropriate movement direction for standard axes:
    • Negative: Movement towards the negative direction.
    • Positive: Movement towards the positive direction.

7.Step:

  • Sets the step size for calibration or output pulses. After calibration, the step is automatically recorded in the settings.

Continuous Jog Section

8.Negative Jog:

  • Enables manual movement in the negative axis direction.

9.Jog Mode:

  • Allows selecting the jog movement type:
    • Continuous: Smooth, uninterrupted movement.
    • Incremental: Moves in defined steps.

10.Positive Jog:

  • Enables manual movement in the positive axis direction.

11.Length:

  • Defines the incremental movement distance when the Incremental mode is active.

Velocity Section

12.Velocity:

  • Used to set the speed for manual movements.
  • The positive and negative buttons next to the Velocity option increase or decrease the speed of manual movements.

Calibration Section

13.Start:

  • Button to initiate the calibration process.

14.Location 1:

  • Used to set the initial position for calibration.
  • This position must be relative to a fixed point on the measured axis.

15.Location 2:

  • Used to set the final position for calibration.
  • This position must also be relative to a fixed point on the measured axis.

16.Calibrate:

  • Button to complete the calibration process and calculate the calibration factor.

17.Exit:

  • Button to exit the calibration program.

To calibrate an axis, follow these steps:

First, select the desired axis from the Axis section for calibration. Then, by selecting a low speed and moving the axis, ensure the direction of movement is correct. If the movement direction is incorrect, choose the appropriate direction using the Direction section. Next, move the axis to one of the two ends of its travel range. Since the starting direction in this method is not important, it does not matter which end of the axis is chosen as the starting point. Once the axis is in the correct position, measure a point on the axis relative to a fixed point on the machine using an appropriate measuring tool, record this at Location 1, and press the Start button. Note that unit selection is entirely optional, so if calibration with a specific unit is required, all measurements should be based on that unit. For example, the device can be calibrated in units of inches, meters, centimeters, millimeters, or even micrometers.

Move the axis to the opposite end. If measurements at greater distances are possible and the measuring tool is sufficiently accurate, measurements over longer distances will yield more precise results. After moving the axis to the second point, measure this point similar to the first relative to the fixed point on the machine, record this at Location 2, and then press the Calibrate button. Using these measurements, the calibration step or factor is calculated and automatically registered in the designated interface. The calibration process can be repeated as many times as needed for each axis.

Please note that if the activation code has not been entered, an error message will be displayed when opening the CAM‑Pro Calibrator software.

2‑Mathematics Calculation

Computational Method

To align the axis movement with the desired unit, a calibration coefficient called “Step” is used. To access this variable, first open the software and then navigate to the Setting window, proceed to the System branch, and the sub‑branch Axis n (where n represents a number between 1 and 6, indicating the axis number). The Step variable is located within these sub‑branches, and each axis has its own specific Step variable.

If the unit of axis movement is in millimeters, the unit of this variable will be millimeters per pulse. If the movement unit is centimeters, inches, or any other unit, the Step variable will also be expressed in that unit per pulse. Essentially, this represents the amount of movement of the desired axis per one pulse transmitted to that axis’s motor driver. Therefore, to calculate this variable, one must understand the relationship between the motor’s movement amount per input pulse to the driver and the conversion ratios of gearboxes, pulleys, and any other type of motion transmission. For a better understanding of these calculations, consider the following examples:

Example 1: Consider a linear axis of a CNC machine where the measurement unit is in millimeters, and it is equipped with Panasonic A5 motors that have a 10:1 gearbox ratio. This motor is connected via a pinion with an effective diameter of 66 millimeters to a rack. Now, calculate the Step value for the specified axis.

Please note that each piece of information plays a crucial role in these calculations and can be used to compute the step size of the axis for calibration purposes. For example, knowing the type of motor driver and its specifications determines the relationship between the input pulse to the driver and the resulting movement of the motor shaft.

In Panasonic A5 motors, at a rate of 500,000 pulses per second, the motor reaches a speed of 3000 rpm. In the first step, we calculate the motor’s rotational speed per second. Here, the figure 3000 represents the number of motor revolutions per minute, which we convert to seconds by dividing by 60, the number equivalent to one minute. The result is 50, meaning the motor makes 50 rotations per second. Therefore, the equation can be written as: Motor rotational speed per second = 3000 rpm / 60 s = 50 r/s. In the second step, we need to calculate the amount of axis movement per one rotation of the motor.

In fact, in this example, the distance traveled will be equal to the circumference of a circle, and the circumference of a circle is calculated as the diameter of the circle multiplied by π (pi) or approximately 3.1415. As mentioned in Example 1, a pinion with a diameter of 66 millimeters and a 10:1 gearbox are used in the mechanics, so we will have. The amount of axis movement per one revolution of the motor is calculated as (1/10) × 66 mm × 3.1415 = 20.7339 mm. The result obtained is the amount of axis movement per one rotation.

The final step is to write the ultimate equation and find the unknown value, which in this case is the Step variable. As observed, all calculations are based on 500,000 pulses sent by the controller and a motor speed of 3000 rpm. Therefore, to calculate the movement or distance traveled per 1 pulse, the result obtained needs to be divided by 500,000. However, as stated earlier, this motor makes 50 revolutions per second. Thus, it is important to note that while the amount of movement was calculated per 1 revolution in the second step, the motor completes 50 revolutions per second. Therefore, the number obtained in the second step must be multiplied by 50 to find the total distance traveled per second by the motor. Now, we will rewrite the overall equation once more.

Step (mm/pulse) = 50 (r/s) ∗ 20.7339 (mm) / 500000 (pulse/s) = 0.00207339 mm/pulse


From this equation, the Step value is calculated. This value means that the motor moves 0.0207339 millimeters per 1 pulse received.

Please note that the computational method used in Example 1 is intended for the calibration of linear axes.

Step(unit/pulse) = The value of the axis movement per one rotation of the motor * the number of motor rotations per second / Number of pulses sent by the controller per second

Example 2: Consider a rotary axis of a CNC machine where the measurement unit is in degrees. It is equipped with Panasonic A5 motors, which have a 25:1 gearbox connected to a 12-tooth pulley. This pulley is then linked via a belt to a 44-tooth pulley. Now, calculate the Step value for the specified axis.

Motor rotational speed per second = 3000 rpm / 60 s = 50 r/s.

In the final step, we must multiply the effective values, such as the gearbox ratio, the pulley ratio, and the motor's rotational speed per second, by 360. As we observed, all calculations are based on 500,000 pulses sent by the controller and a motor speed of 3000 rpm. Therefore, to calculate the movement per 1 pulse, we must divide the obtained value by 500,000. This simple estimation will yield the Step value.

Step= 50(r/s)∗(1/25)∗(12/44)∗360 / 500000(pulse/s) = 0.000392727272

From this equation, the Step value is calculated.

The general equation for calibrating rotary axes is as follows: Step(unit/pulse) = Rotation amount per second in the motor * effective value * 360 * / Number of pulses sent by the controller per second

Please note that whether calculating linear axes or rotary axes, the more significant digits we use, the more precise the calculation results will be.

Please note Pulse divisions in stepper motors directly impact these calculations. For simplicity, one can first calculate the motor rotation for a specific pulse value and then incorporate the result into the equations above.

Please Note In drives where the number of pulses required to reach the maximum motor speed exceeds the number of pulses produced by the controller, one can achieve the maximum motor speed by increasing the electronic drive ratio to a specific extent. For example, if a drive requires 4 million pulses per second to reach the maximum motor speed, and considering that Radonix produces 500,000 pulses per second, an electronic drive ratio of 8 should be considered to achieve the maximum rotational speed of the motor.


Outputs

In this section, we will examine the configuration of the Outputs.

Setting Up Inputs: General Overview

In Radonix systems, Outports are critical components that manage the output signals controlling various peripherals, such as relays, actuators, alarms, and other devices. Outputs can be categorized into two main types based on their configuration and purpose: Hardware-Based Inputs and Software-Based outputs. This flexibility allows the system to adapt to a wide range of applications and machine requirements.

Hardware-Based Outputs

Hardware outputs involve physical signals sent from the controller to external devices, enabling direct control of the machine’s environment. These outputs are critical for operational safety, machine actuation, and real-time command execution, ensuring efficient workflow and coordination within the CNC system.


The digital outputs of Radonix controllers are named O.[n], where n is a numerical identifier greater than zero and represents the output number .

Radonix controllers incorporate robust protection mechanisms for Outports to ensure durability, safety, and reliability. These mechanisms vary between different models, specifically the PC-Pro and PC-Smart boards, each with distinct protection features and failure handling processes.

Output Behavior in PC-Pro LAN Models

  • The PC-Pro LAN model outputs are fixed in NPN mode.
  • How It Works:
    • When an output is ON, it provides 0 volts by pulling the signal to ground.
    • When an output is OFF, it is in a high-impedance state, effectively disconnecting the circuit.
  • Wiring Consideration:
    • Connected devices must be compatible with NPN logic, where the load receives voltage from a positive source and is activated when the output pulls the circuit to ground.

2. Output Behavior in PC-Smart Models

  • The PC-Smart model offers a flexible configuration where outputs can operate in PNP mode or NPN mode, depending on the connection of the COM Pin.
  • How It Works:
    • The voltage provided by the outputs depends on what is connected to the COM Pin:
      • COM Pin Connected to 24V: Outputs will provide 24 volts when activated.
      • COM Pin Connected to Ground: Outputs will provide 0 volts when activated (NPN mode).
  • Flexibility:
    • This design allows PC-Smart models to adapt to different wiring requirements and device logic preferences.

Configuration Process for Outputs:

  1. Connection:
    • Physically connect the hardware component (e.g., relay, electric valve , Barke , alarm) to the designated output pin on the controller.
    • Ensure proper wiring based on the required logic (PNP or NPN) and voltage compatibility.
  2. Output Definition:
    • Use the controller software to define the role of the output (e.g., C-CutPin, Brake, or a custom output for specific functions).
    • Assign the output to its intended device or operation in the system settings.
  3. Logic Settings:
    • Set the output logic based on the connected device's requirements:
      • Active High (PNP): The output sends voltage (e.g., 24V) when activated.
      • Active Low (NPN): The output pulls the signal to ground (0V) when activated.
  4. Testing and Validation:
    • After configuring, test the output to ensure it operates as intended in CAM Pro Test application.
    • Use a multimeter or other diagnostic tools to verify output voltage and behavior.

2. Software-Based Outputs

Software-Based Outputs provide simple logical functionality to configure and integrate them with related physical hardware. These features are crucial for enhancing control capabilities. They facilitate quick and simple installation without the need for microprogramming. Users can simply select options from a list and configure settings to maximize efficiency.


As illustrated in the figure, each output is divided into three sub-branches, as detailed below:

  1. Enable: This sub-branch can be set to two values: True or False.
  2. Link: Specifies the duty or task that needs to be performed or checked. This includes any device that can serve as an output, such as actuators, lights, and alarms.
  3. NC: Determines whether the specific output is Normally Open (NO) or Normally Closed (NC).

Examples of Software Outputs:

  • Virtual Relays:
    • Use software parameters to define activation boundaries for devices based on operational needs.
  • Logical Triggers: Define conditional triggers for activating specific outputs (e.g., alarms or Relay for specific function ).
  • Simulated Outputs: Employ these for testing or in scenarios where physical components are not available.

Configuration Process:

  1. Access the Configuration Interface:
    • Navigate to the controller's software settings to manage outputs.
  2. Define Parameters:

    • To configure an output like an order to forward the VFD, enter parameters.

    • setting —→ System —→ Outports —→ Enabled= True

      Linked = C-CutPin

      NC= True

  3. Validate Settings:
    • Test the configured software outputs to ensure they function correctly and safely, verifying their effectiveness in real-world applications.

Setting Up Inputs: Simple and Intuitive Configuration

In Radonix system, configuring inputs or Outputs is designed to be as user-friendly as possible, without requiring any microprogramming or advanced technical knowledge. All you need to do is navigate to the Inputs section of the controller interface, open the settings drawer, and select the item you need to configure. The same process applies to other sections, such as Outputs or any other functional areas.

Step-by-Step Configuration Process

  1. Access the Desired Section:
    • Go to the section you want to configure, such as Inputs or Outputs, depending on the functionality you are setting up.
  2. Open the Settings Drawer:
    • Within the selected section, locate the specific input branch or subsection.
    • Click or expand the settings drawer to reveal the available options.
  3. Select the Required Item:
    • Choose the input type or functionality you want to configure (e.g., limit switch, home sensor, emergency stop, or custom inputs).
    • Define the specific role for the input, such as C-ZFreePin,1
  4. Set Parameters Easily:
    • Adjust the necessary parameters, such as polarity (Normally Open or Normally Closed), response delays, or logical behavior, directly from the interface.
  5. Save and Test:
    • Save your settings and validate them through the controller interface to ensure everything is functioning as intended.
    • In the end in order to finalizing you have to close program to save everything

Updated about 10 hours ago