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MDSI-OpenCNC® BostoMatic Retrofit Packages
In response to requests for an alternative to the available OEM CNC retrofit, G&W-Services performed an in depth review of commercially available CNC retrofit packages. Various design criteria along with customer expectations were considered, such as:
- A PC based system was attractive, providing an abundant availability of serviceable hardware with "off the shelf" components, thus avoiding costly OEM repair parts. The CNC system needed an "open architecture" design to provide the end-user freedom to configure and expand their own systems. Lastly, a realistically priced total retrofit package with cost effective software updates and maintenance. These decisive factors along with overall CNC operational features seemed to be universal among all of our customers.
G&W-Services as a machine re-builder and retrofitter needed a CNC system that provided maximum flexibility to integrate to a wide range of BostoMatic® product lines. A simultaneous 5-Axis CNC control with abundant part program storage and editing, file transfer capabilities via Ethernet, Floppy or CD, tool compensations and fixture offset with easy shop floor operations. A CNC system which could be integrated with existing servo and spindle drives, tool changers, pallet systems, probes and other auxiliary devices, minimizing the need for expensive add-ons, thus maintaining customer cost expectations.
A CNC system that could be configured to emulate BostoMatic operational features and for our machine rebuild and re-calibrating purposes; leadscrew, backlash, and rotary compensations were essential features.
Finally, to link all these requirements together, was the necessity for an established product with a good track record and a corporate commitment to on-going product development with competent in-house and field support for both the integrator and eventually the end-user.
OpenCNC Retrofit Package
Following our review of OEM and alternate CNC retrofits, G&W's choice was MDSI OpenCNC® software. Designed to run on a PC based system, accommodating a wide selection of commercially available servo, encoder/dac, I/O, Ethernet and other interface cards, a software definable closed servo loop for either velocity of torque mode operations, eliminating proprietary servo boards.
All coupled with full CNC operational functions provided through a 15 inch touch screen interface with provisions for user definable touch and hard buttons, handwheel and override potentiometers.
MDSI's OpenCNC® has been used in production since 1993, the first production proven, hardware independent, unbundled CNC software for a PC based system on the market.
MDSI's OpenCNC® satisfied our customer's needs and our own integrator requirements by providing essential software tools and diagnostic features for customizing servo, spindle, ATC and other hardware interface operations. Unique and specific applications can be developed and integrated with MDSI's OpenCNC providing unlimited system enhancement. OpenCNC runs either in a stand-alone or client server network configuration allowing multiple controls access to a central server. Overall, MDSI's OpenCNC® package provided the greatest flexibility to design and customize an advanced CNC Machine Tool Control system. G&W-Services installed its first OpenCNC control system in February of 1997, that system has run five years without a failure. G&W continues to build and install OpenCNC retrofits specific to BostoMatic® equipment
Utilizing MDSI's OpenCNC® as the operating platform, G&W-Services has designed a control retrofit package with soft-logic and operational control features specific to BostoMatic machines equipped with either SPC-I or II and BDC3200 controls. The retrofit uses industrial rated, UL/CSA and CE components with state of the art technology in its hardware system. Control components are enclosed in a NEMA 12 cabinet to meet tough industrial standards and demands. This hardware/software combination creates a truly open CNC architecture, fully serviceable and expandable by the end-user, with the freedom and power to meet current and future needs.
Performance evaluations have shown the system to process 10 times faster than SPC-I / II controls and comparable with the BDC3200 Control. Customer NC programs have achieved feed rate profiles 3 to 6 times faster without part program modification or data starvation. Coupled with a high gain, torque mode, 5-Axis, 1000 blocks per second, software closed servo loop, with block look ahead mode for cornering and a soon to be released velocity feed forward feature will enable machines to hold tighter tolerances at greater contouring feedrates. Backlash, Leadscrew and Thermal compensations improve original machine accuracy, extending the equipment's productivity life at very cost effective prices.
Software:
- Microsoft Windows XP Professional
- MDSI - OpenCNC 3, 4, 5 Axis - CNC Software
- GWSI Soft PLC Logic - BostoMatic Version
Hardware:
- Intel Pentium IV Processor
- 256MB Ram Memory
- 40GB Hard Disk (or larger)
- 52x CD-ROM
- 1.44 MB Floppy Drive, PC Style Keyboard / Mouse
- 100/10 Base T Ethernet
- 15" Flat Panel Touchscreen Monitor
- Roll Around, Nema 12, Power Coated Enclosures
Control Panel:
- EOA Series II Push Button Switches for;
- Console Power ON and Emergency Stop
- Cycle Start / Cycle Stop / Spindles On/Off
- Coolant and Clamp On/Off
- Nemicon Pulse Generator (Handwheel)
- 0-100% Potentiometer Over-ride control for
- Spindle speed and Feed rate.
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