OSAI OPENcontrol Technical Overview

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OPENcontrol - Technical overview

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Page 1 OPENcontrol - Technical overview...
Page 2 osaicnc.com...
Page 3: Table Of Contents
Standard ready-to use Machine Logic WinNBI Process Controller IsoView Internationalization Connectivity Custom Operator Interfaces OPENcontrol for Metal Cutting and Milling OPENCut – Plasma and Oxyfuel cutting OPENCut – Laser cutting OPENMill - Millling machines software Software Key Features Axes Management Axes Motion...
Page 4 List of G-codes CNC Offline Simulator Hardware OPENcontrol models OPEN-XS OPEN-M, OPEN-XL, OPEN-XLi Operator Panels OPENconsole OPENconsole COMPACT 15’’ Industrial Monitors with Touch Screen TOP5 – Remote Operator Console OD700 Servodrives & Motors YASKAWA combined Spindle & Servo System Input/Output Modules...
Page 5: Opencontrol - Overview
OPENcontrol - Overview OPENcontrol is a comprehensive product line for automation, consisting of a full range of hardware and software solutions addressing the most diverse application requirements. The central unit can be chosen within the complete OPENcontrol CNC family, where several models of Numerical Controls are available according to machine requirements.
Page 6 OPENcontrol reaches the best performances combining OSAI EtherCAT or Mechatrolink III modules, but the central unit provides more fieldbuses. EtherCAT (SoE and CoE profiles), Mechatrolink III, Mechatrolink I and II, OS-Wire (OSAI custom), Profibus and CANopen allow the connection to a wide variety of peripherals whether they are servo-drives, I/O modules or special devices.
Page 7: Software Scalability
ƒ are an important aspect that points to the scalability of OPENcontrol. Windows CE is the real time Operating System used for OPENcontrol product line: while maintaining all the key features of Windows, Windows CE provides steady and reliable real-time performances.
Page 8: The Embedded Softplc
The fast execution, respecting the required priority, reduces the execution time of the part program which increases machine productivity. The OPENcontrol PLC allows the creation of real application programs that interact with the system at all levels: ƒ...
Page 9: Standard Ready-To Use Machine Logic
The pre-defined OSAI section is easy to use and to configure and it can be updated with new versions without requiring any change of the user section. User section, instead, can use all the flexibility of the integrated PLC to develop special cycles and machine customizations.
Page 10: Process Controller
WinNBI consists of different applications, each one with specific functionality: End User toolkit Windows desktop Windows CE ● ● CNC boot manager BootController ● ● CNC main and auxiliary screens manager and builder ProcessController ● ● System journal SystemHistory ● ●...
Page 11: Isoview
A new CNC communication method, based on cross platform Web Services (WSDL file and SOAP protocol), has been developed in OPENcontrol to support such a flexible, network based, architecture. It has the same performances of the previous protocol (historically based on COM/DCOM technology) with the advantage to allow development of the HMI in different O.S.
Page 12: Opencut - Plasma And Oxyfuel Cutting
Software products developed by OSAI, supported by pre-defined machine logic, designed for specific application sectors, simplify both commissioning and machine use, adding high-level performances. In addition to the WinNBI graphical suite, OPENcontrol can be supplied with: ƒ OPENCut Plasma, for Plasma and Oxy-fuel cutting machines ƒ...
Page 13 OPENCut CAM increases according to user requirements, from 2D cutting and manual nesting, up to completely automatic Bevel applications. As typical for the whole OSAI product range, software is designed in combinable modules. Library with predefined 2D parts. Easy conversational programming based only on graphical elements and geometric data.
Page 14 Graphic preview of the Profile and dynamic display of the torch position and path. 3D realistic simulator OPENCut CAM also includes: DXF and DWG files import ƒ ƒ Double torch management (Plasma) and multiple torch management (Oxy) ƒ ƒ Drilling heads management ƒ...
Page 15: Opencut - Laser Cutting
Manual motion of the axes and restart • Restart from selected icon/profile Selectable dynamics per jobs ƒ ƒ Change of cutting parameters on the fly ƒ ƒ Configurable diagnostics and maintenance with custom pages ƒ ƒ ƒ Automatic selection of technology ƒ OPENcontrol Technical overview...
Page 16: Openmill - Millling Machines Software
OPENMill is also the new OSAI HMI interface dedicated to milling. end-user environment, specifically designed to expedite CNC use, requires few commands, from soft-keys or touch-screen, to use the main functions of the CNC.
Page 17 Selection of geometrical element. Generated profile display. An ambient specifically designed for technology, allows the setting of tool parameters and machine origins. Technological data table. Import functions of DXF files generated by CAD increase the operating possibilities of OPENMill. OPENcontrol Technical overview...
Page 18: Software Key Features
Software Key Features Axes Management Coordinated, Auxiliary, Pseudo and Spindle axes The OPENcontrol CNC can manage different kinds of axes: Coordinated Axes (or Process axes) moved by the Operator via manual or ƒ ƒ programmed movements. They are managed by the Process Interpolator.
Page 19: Axes Motion
A polynomial curve built on the circular and linear points, describes the trajectory to follow. This trajectory will pass through the programmed points towards the set thresholds. OPENcontrol Technical overview...
Page 20 ƒ Point to Point and Continuous Mode with Look Ahead In point to point mode (G29) OPENcontrol executes the programmed movements stopping the axes at the end of each move. In continuous mode (G28) the system executes all movements at the programmed feedrate, without stopping the axes at the end of each move.
Page 21 In order to increase speed on the profile and to reduce machine mechanical vibrations, with OPENcontrol it is also possible, through the FLT command (accordingly with velocity leap axes parameter), to configure and to enable filters acting on the geometry and on the dynamics of axis movements.
Page 22: Motion Features
Zero Shift OPENcontrol CNCs have two “zero shift” registers that can modify “on the fly” and in real-time, the physical axis position, even overlapping the programmed motion, while the axis is moving. These registers are managed by the machine logic and allows the implementation of many features like “automatic tool height control”, “grinding wheel...
Page 23: Tool Centre Point (Tcp)
Active Reset Part Program execution time estimation In order to estimate the machining cost, OPENcontrol can rapidly simulate the whole Part Program. When simulation is done, information provided are: Total execution time of the program ƒ...
Page 24 Software Key Features TCP for Machine with Double Twist or Prismatic Head Allows the programming of a machine with 4/5 axes (3 linear and 1 or 2 as part of the rotary head) referred to the tool tip (positions referred to the part) instead of the centre of the head (positions referred to machine zero).
Page 25: High Speed Machining
High Speed Machining With OPENcontrol, new Interpolation algorithms have been developed to respond to the increasing requirement for machining cycles with high speeds and high quality surface finishing, particularly on 5 axes machines. The High Speed Machining (HSM) can be activated when one of the available Tool Center Point kinematics is enabled (TCP programmed).
Page 26: Multi-Axis Electronic Cam
Software Key Features Cylindrical Coordinates This feature is used when a linear X axis and a rotary B axis are moved by programming the axes positions on a Cartesian (e.g. WX) plane. Virtual X axis movements are the same as X physical axis movements, whereas every virtual W axis movement corresponds to an arc that -depending on the cylinder radius is translated into an...
Page 27: Volumetric And Cross Compensation, Axis Calibration
ƒ Volumetric and Cross Compensation, Axis Calibration OPENcontrol CNC can offer even higher working precision for the machine tool, using the Volumetric Compensation algorithm. This algorithm has been designed to take into account and correct for any positioning errors, which occur as a result of any mechanical distortions created by the machine tool in the working volume.
Page 28: List Of G-Codes
Software Key Features List of G-codes Description Rapid axes positioning Linear interpolation Circular and helical interpolation CW Circular and helical interpolation CCW Dwell at end of block FeedHold at the end of the movement FeedHold at the beginning of the movement Deceleration at end of block Linear interpolation with rapid dynamic parameters.
Page 29 Inverse time (V/D) feed rate programming mode Feedrate programming in ipm or mmpm Feedrate programming in ipr or mmpr Constant surface speed (feet per minute or metres per minute) Spindle speed programming in rpm Axis pre-setting with mirror Delete G92 or G98 OPENcontrol Technical overview...
Page 30: Cnc Offline Simulator
With OPENcontrol Offline Simulator the same software can be run on the PC as the one running on the CNC. This is true for all modules: the real time OPENcontrol CNC algorithms, the Part Programs execution, the PLC program execution as well as all programming and HMI tools (4Control, WinNBI).
Page 31: Opencontrol Models
Program) and axes, number of fieldbuses and devices used or by specific configurations. OPEN-XS A particularly flexible element of the OPENcontrol family, the OPEN-XS is a modular system that offers both a solution for the control of servo-drives and I/O modules distributed on a digital fieldbus and also for controlling Analog or P&D axes and integrated...
Page 32 Hardware The 4 axes slave modules (A-432 / P-432), (also called “bridges”). ƒ ƒ Connected to the real-time unit via EtherCAT bus, they are an integrated solution that offers a wide set of local I/O and the electronics for controlling axes driven with an analog (A-432) or Pulse &...
Page 33 OPEN-XS (EtherCAT and CANopen) CNC dimensions, front and side view 174.9 151.7 OPEN-XS (MLIII, EtherCAT and CANopen) CNC dimensions, front and side view OPENcontrol Technical overview...
Page 34 Hardware Technical Data OPEN-XS MLIII OPEN-XS EtherCAT Part Number 2SMPM6396/0C 2SMPM5990/0C Intel®Atom 1.6GHz Storage Compact Flash 1 GB / 4GB / SSD 128GB 2 GB Monitor port Ethernet 1 x 100/1000 Mbps 3 x 2.0 Serial Line 2 x RS232 – 1 x RS232/422/485 Fast Input Fast Output Emergency Stop...
Page 35 1 x encoder ABZ Power Supply 24 VDC Power Supply Digital I/O board 24 VDC Operating Temperature 0°C …+50°C Relative Humidity 90% no condensation IP protection IP20 89.3 6Analog Axes slave module A-664dimensions, front and side view OPENcontrol Technical overview...
Page 36: Open-M, Open-Xl, Open-Xli
Hardware OPEN-M, OPEN-XL, OPEN-XLi The highly scalable OPENcontrol systems have performances that increase with OPEN-M, OPEN-XL and OPEN-XLi models. They can be fitted with various types of axes cards for controlling digital servo-drives. The axis cards, implementing the most modern fieldbus, allow management of a wide...
Page 37 With the same ease the software can be configured to run Windows CE only (the real time O.S. adopted by the OPENcontrol family) or both Windows CE and Windows Embedded simultaneously (Dual Operating System) to execute both applications available from the marketplace and the real-time CNC software on the same hardware.
Page 38 Hardware OPEN-M and OPEN-XL CNC dimensions...
Page 39 1 x 16 bit Analog Out + 1 x Inc. Encoder Input Analog In. 2 x 12 bit ±10V (or 4-20 mA on channel one) Fast In. 4 (or 3 + Touch-Probe) Fast Out. Power 1 (fast out 24V) enabling OPENcontrol Technical overview...
Page 40: Operator Panels
Hardware Operator Panels Each OPENcontrol CNC model can be combined with different operator interfaces, from the simple Touch Screen monitor for General Motion applications to OPENconsole, the High End modular Operator Panel which is provided with all the components needed to manage the Numerical Control unit.
Page 41 This module contains both a standard 101 keys keyboard and a pointing device ergonomically positioned. The pointing device can be either a touch-pad or track-ball, according to the required application or preference. OPENconsole 19” Monitor module dimensions - front and side view OPENcontrol Technical overview...
Page 42 Hardware OPENconsole 19” Monitor module - bottom view OPENconsole 17” Monitor module dimensions - side and rear view OPENconsole 17” Monitor module - bottom view OPENconsole OPENconsole 17” Monitor module 19” Monitor module Part Number 2SMPM6257/0C 2SMPM6211/0C Display size 17” 19”...
Page 43 OEM custom keys On additional module Connection to CNC EtherCAT bus Power Supply 24Vin 24 VDC 1A Power Supply 24Ve (Drive ON/OFF) 24 VDC 0.6A Operating Temperature 0°C to +50°C Relative humidity 10 to 90 % no condensation OPENcontrol Technical overview...
Page 44 Hardware OPENconsole Keyboard module dimensions - side and front view OPENconsole OPENconsole Keyboard with touchpad Keyboard with Trackball Part Number 2SMPM6024/0C 2SMPM6025/0C Layout US 101 keys Pointing device Touchpad Trackball Key technology Bubble keys with metal dome Power Supply Through USB Operating Temperature 0°C to +50°C Relative humidity...
Page 45: Openconsole Compact 15
ƒ ƒ The Control Panel section includes all the commands needed for complete OPENcontrol CNC management (mode selection, cycle start/stop, reset, feed rate, speed rate). It is fully customizable as well as the Control Panel extension including 6 keys, with LED, configurable by means of custom graphics and specific PLC management.
Page 46 Hardware Technical Data OPENconsole COMPACT Part Number 2SMPM6222/0C Power Supply 24 VDC Monitor Section Display size 15'' Backlight Resolution (pixels) 1024 x 768 Connection VGA / DVI Display ratio Touch Screen Resistive Control Panel Section Emergency Stop Optional Mechanical push buttons 2 general purpose (optional) CNC Mode selector Cycle Start, Cycle Stop (Hold), Reset,...
Page 47: Industrial Monitors With Touch Screen
Industrial Monitors with Touch Screen An extensive line of industrial monitors for panel mounting complete the range of OPENcontrol family HMI systems. All monitors have a resistive touch screen, several types of input ports and metal frame for heavy applications.
Page 48 Hardware Dimensions (mm) CUT OUT (mm) 10,4” 15” 17” 10,4” 15” 17”...
Page 49: Top5 - Remote Operator Console
Touch Screen that displays what requested by the controller to which it is connected. When TOP5 is connected directly or through a PC to an OPENcontrol CNC, it can be configured in a simple and intuitive way using the WinNBI (Windows™...
Page 50: Od700 Servodrives & Motors
All models are equipped with the integrated security function STO (Safe Torque Off) to cut the power supplied by the motors and allow the safe intervention of the operator without cutting power to the machine tool. OSAI offers two series of high-power sinusoidal brushless servomotors, with high inertia and high dynamics.
Page 51 Local browser connected to drive through Ethernet port also available Cooling Forced cooling Operating: -20÷55 °C Operating: -20÷45 °C, from 45÷55 °C (with de-rating -3% for each °C) Temperature Storage: -25÷70 °C Humidity 10% - 90% no condensation OPENcontrol Technical overview...
Page 52 Hardware XML MOTORS Voltage 230V 400V Model SA01 SB02 SB04 SC06 SC10 SE15 SE22 SEP09 SEP15 SEP22 SEP30 SFP50 Flange Dimension (mm) Stall torque (Nm) 0,32 0,64 1,27 1,91 3,19 4,77 2,86 4,77 9,55 15,92 Stall current (A) 1,38 1,63 2,89 3,58 5,37...
Page 53: Yaskawa Combined Spindle & Servo System
YASKAWA combined Spindle and Servo System Thanks to the partnership between Osai - Prima Electro and YASKAWA, the YASKAWA SIGMA-5 SD drives & motors are part of the OPENcontrol product line. Sigma-5 SD servodrives The Sigma-5 SD combined spindle & servo...
Page 54 Hardware Specifications of Power Regeneration Converter Model Code 50% ED Rating Continuous Rating 15 kW 11 kW 18.5 kW 15 kW 480 VAC 22 kW 18.5 kW Three-phase 380 to 480V (50/60 Hz) --> DC 540 V Main Circuits Allowable voltage fluctuation: +10% to -15% L1, L2 and L3 Allowable frequency fluctuation: ±5% Input...
Page 55 SGMGV Spindle Motor Series Standard type UAKAJ-**C Rated Output Output (50%ED) 18,5 Max Output (10s) kW Rated Speed 1500 Max Speed 10000 7000 Rotor Moment of kg·m 0,0071 0,014 0,021 0,025 0,069 0,069 Inertia Flange Size Length Weight OPENcontrol Technical overview...
Page 56: Input/Output Modules
Hardware Input/Output Modules OPENrio SL I/O modules OPENrio SL is an I/O modular system extremely compact, controlled by EtherCAT bus, to be installed on a standard 35 mm DIN rail. The system is composed of a wide range of modules allowing the use in several application fields: EtherCAT Bus coupler ƒ...
Page 57 Pt100/Pt1000 – Ni100/ Ni1000 PWM Module 8SMPM022-1BB90 Number of Output 2 Output Current for each output 0,5A Switching frequency Max. 40 kHz Encoder Input Module 8SMPM050-1BA10 Maximum input frequency 500 kHz Auxiliaty Power Module 8SMPM007-1AB00 Supported current OPENcontrol Technical overview...
Page 58: Openrio E901 - Pwm Module For Laser
Hardware OPENrio E901 - PWM module for Laser OPENrio E901 is a configurable module specifically designed for laser sources management. The module, supplied in combination with a Bus Coupler based on the EtherCAT protocol, constitutes a dedicated laser control unit. E901 includes: 4 Digital Input, with status LED ƒ...
Page 59 Analog Output Number of I/O Output range 0÷10 V Resolution 14 bit plus sign Protection Short circuit Bandwith 20 KHz Analog Input Number of I/O Input range 0 ÷10 V Resolution 14 bit plus sign Bandwith 20 KHz OPENcontrol Technical overview...
Page 60: Openrio V-200 - Bus Coupler And Modules
Hardware OPENrio V-200 - Bus coupler and modules OPENrio V-200 is a compact and modular remote I/O product line to control sensors and actuators through CANopen fieldbus. The modular structure of each RIO block guarantees a high level of flexibility, reducing the installation and maintenance costs: in fact, in case of a malfunction, each block can be easily replaced without disconnecting the cables.
Page 61 Cable length shielded 1000m Cable length unshielded 600m Output currentfor signal “1” 0.5A Total current for group All the modules Dimension (W x H x D) 25.4x76x88 mm Operating temperature 0°C +60°C Relative humidity 5% to 95% non condensing OPENcontrol Technical overview...
Page 62: Cnc Turnkey Solution
Software The OSAI CNC Turnkey is ready to use not only regarding the hardware; in fact, it is offered with a complete preset machine logic program (active on the SoftPLC integrated in the CNC), which allows rapid commissioning and considerably reducing the time to...
Page 63 400V with Sincos transducers (incremental or absolute). From 0,6 to 2,8 kW Motors XML line: 400V with incremental encoder. From 0,9 up to 3kW 200V with incremental encoder. From 0,1 up to 1,4 kW Double contactor, safety relay (optional), STO on all servo-drives, Safety emergency button OPENcontrol Technical overview...
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Page 66 Production/Service: Via Torino, 14 – 10010 Barone Canavese (TO) Italy t. +39 011 9899 800 f. +39 011 9899 804 OSAI – UK Ltd Sales and Service: Mount House, Bond Avenue, Bletchley Milton Keynes, MK1 1 SF – United Kingdom t.