Re: [Emc-users] EMC as an alternative to Heidenhain iTNC 530, Siemens 840D, etc.

2010-09-09 Thread Michael Büsch
On Thu, 2010-09-09 at 17:33 +0200, Florian Rist wrote: 
> Hi Michael
> 
> >> G-code which consists of many many short G01-segments.
>  >
> > What about adding a G64 P... or similar?
> 
> I was about to mention that, too. I relay helps a lot. And on simple, 
> not very rigid mills, it even improve the surface quality, especially in 
> free from milling.

Note that it also enables the naive cam detector. That means if you
program several points in an (almost) straight line, it will not slow
down at all and drive in a straight line. Whether dots are in a straight
line is decided by the G64 parameters (P and Q).

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Re: [Emc-users] EMC as an alternative to Heidenhain iTNC 530, Siemens 840D, etc.

2010-09-09 Thread Florian Rist
Hi Michael

>> G-code which consists of many many short G01-segments.
 >
> What about adding a G64 P... or similar?

I was about to mention that, too. I relay helps a lot. And on simple, 
not very rigid mills, it even improve the surface quality, especially in 
free from milling.

Flo

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Re: [Emc-users] EMC as an alternative to Heidenhain iTNC 530, Siemens 840D, etc.

2010-09-09 Thread Florian Rist
Hi

> Would they sell this bare bones?

Well, as far as I know yet, no. So I'd have to buy an unnecessary 
controller.

> Since it wouldn't make much sense to pay for the control and then not use it.

Right, the only good think would be that I could use the new mill 
immediately as a 3+2 axes mill and later on "upgrade" to 5 axes

> If they want a sell, ask if they can sell it with a Simodrive 611U
> instead of 611D, the 611U would take analog inputs and then emc2 would
> have no issues making this work with mesa cards.

I see. It sound like a good idea to try to avoid the latest highly 
integrated digital servo drivers.

> Tell them what you try to do and see how far you can talk them out of
> a complete machine. I would think they make more money on their
> machine than the control and if they are a competent builder, they
> should be able to sell a control-less machine with the digital drives
> replaced by Siemens' analog drives.

I'll talk about this with the sales guy on the next meeting.

> Obviously i am applying an highly idealistic "Kunde ist Koenig"
> thinking...

The big problem right now is, the the economy crises is over and the 
manufacturers don't need to accommodate there customers. We just had a 
manufacturer sell a machine, we already agreed on buying after longer 
negotiations, to someone else (probably at a higher price), just while 
the documents were waiting to be sighed by the right person here. :-(

See you
Flo

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Re: [Emc-users] EMC as an alternative to Heidenhain iTNC 530, Siemens 840D, etc.

2010-09-09 Thread Michael Büsch
On Thu, 2010-09-09 at 13:47 +0300, Anders Wallin wrote: 
> > The basic question I guess is would EMC be able to provice the same tool
> > path quality as the (lower end) Siemens or Heidenhain controllers?
> 
> You should run EMC in simulator mode, and use halscope or halstreamer
> to record all the joint positions to disk. Then you can analyze this
> data later for correctness/smoothness.
> 
> It is fairly easy to "choke" the EMC interpreter/traj-planner with
> G-code which consists of many many short G01-segments. It could be
> argued that these should be filtered to longer lines, arcs, biarcs or
> NURBS G-code, but if you have a CAM-program that only outputs these
> short G01-segments this could become a problem.

What about adding a G64 P... or similar?
Even with a very small P of a few hundredth of a millimeter it improves
the situation significantly.

I have some experience on the 840D and I do not think that it behaves
differently. 
If you run the 840D in G60 mode (default), it will also stop after each
G1/0 move and re-accelerate. So I do not think there's a difference between
840D and EMC here. The machine does what you program. So if you program a stop
every 5 microns, it will completely halt every 5 microns.

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Re: [Emc-users] EMC as an alternative to Heidenhain iTNC 530, Siemens 840D, etc.

2010-09-09 Thread Anders Wallin
> The basic question I guess is would EMC be able to provice the same tool
> path quality as the (lower end) Siemens or Heidenhain controllers?

You should run EMC in simulator mode, and use halscope or halstreamer
to record all the joint positions to disk. Then you can analyze this
data later for correctness/smoothness.

It is fairly easy to "choke" the EMC interpreter/traj-planner with
G-code which consists of many many short G01-segments. It could be
argued that these should be filtered to longer lines, arcs, biarcs or
NURBS G-code, but if you have a CAM-program that only outputs these
short G01-segments this could become a problem.
Even with a hobby mill this is an issue. We have 5m/min rapids on our
machine and when programming a contouring operation at say for example
2m/min feedrate, if the CAM-program outputs lots and lots of short
G01-segments the EMC interpreter/traj-planner will not handle it well
and the actual feedrate may be 1m/min or even lower. You should be
able to test for this in simulator mode (see above).

Improving the trajectory-planner is not an easy task. I think the
consensus reached last time we were discussing this is that it is a
very hard task indeed _unless_ some restrictions are added. For
example restricting traj-planner to only 3-axis trivkins and/or
restricting feed-override to 0-100% (not >100%). Also I think there is
a restriction of one G-code block (or canon-command) per servo thread
cycle. If you run a normal servo-thread at 1ms that means 1000-lines
of G-code per second (in theory). If your CAM-program outputs more
than this you will get the slowed down feedrate I mentioned above.

As mentioned by other posters this is a problem you rarely encounter
with hobby-grade machines because it only occurs with "bad" CAM-code
which consists of the many many small G01 segments and with high-speed
machinery where you want to cut at 5m/min or 10m/min (or more!). When
you have this kind of cash invested in the machine, the tooling, and
are under time-pressure to have to run your machine at 10m/min then
suddenly I think investing another 10k or 20k in a pro controller is
not a problem...  (contrast to sitting down, learning all the innards
of emc2, learning trajectory-planning math/geometry, and attempting to
write a high-speed traj-planner for EMC2)

Anders

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Re: [Emc-users] EMC as an alternative to Heidenhain iTNC 530, Siemens 840D, etc.

2010-09-09 Thread Florian Rist
Hi Ulf

 > If you have money for a dmg machine  of this new age, maybe emc is not
 > what you need.

That's what I'm trying to figure out. At present state I do not really 
know how much EMC might save me, probably 20k EUR. Depending on how 
difficult the conversion would be this could be worth it or not.

I'll certainly lose a lot of nice features of the professional 
controllers, but mostly features that I don't need. But it would 
certainly take a few weeks to do the conversion.

 > The Siemens 810 is fully digital and fitting emc with the other digital
 > controls would require much rewiring.

That's a good point, I have to make sure it's possible to link the 
digital servo drives to EMC. I didn't think of this problem yet, because 
I never worked with these new digital servo controllers.

Do you have any details on that?

 > It would be better and simpler to upgrade the 810 to 840.

Would be an option indeed, I'll try to figure out how much that would be.

 > Maybe you should look for a good old machine on ebay?

I thought about that, but having the machine under the manufacturer 
warranty is a good thing. Of course I will lose warranty as soon as 
starting the conversion, but I could wait for a few month and use the 
new machine in its original 3+2 set-up at first.

See you
Flo

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Re: [Emc-users] EMC as an alternative to Heidenhain iTNC 530, Siemens 840D, etc.

2010-09-08 Thread Daniel Goller
Would they sell this bare bones?
Since it wouldn't make much sense to pay for the control and then not use it.
If they want a sell, ask if they can sell it with a Simodrive 611U
instead of 611D, the 611U would take analog inputs and then emc2 would
have no issues making this work with mesa cards. And you would get to
keep quality drives/servos.
Tell them what you try to do and see how far you can talk them out of
a complete machine. I would think they make more money on their
machine than the control and if they are a competent builder, they
should be able to sell a control-less machine with the digital drives
replaced by Siemens' analog drives.
Obviously i am applying an highly idealistic "Kunde ist Koenig"
thinking, but if i had the budget to get a well build new machine w/o
control and add emc2 to it as means of ultimate budget extension, to
go from 3+2 to full 5 axis control, i would go for it.
EMC2 may have made this thinking even worse, i want my cake and eat it too now.

I sure hope our lathe emc2 conversion works out well, because taking
emc2 to the mills would be even more interestingI like mills more
than lathes :)

On Wed, Sep 8, 2010 at 1:00 PM, Florian Rist  wrote:
> Hi,
> I need a new machine for (rather light, no heavy machining of cast iron
> or stainless stsel) 5axes simultainus milling in research and
> development and education. Since I'm on a short budged I start thinking
> about getting a cheep 5axes machine, not capable of 5aces milling by
> default, but equipped with strong enough servos and good encodes on the
> aces rotary axes and then replace the 3+2 axes controller by EMC
> (capable of 5 axes interpolation).
>
> One of the machines that might be used for that conversion the the DMU
> DMG eco 50 (haven't verified it the rotary aces hardware is strong
> enough, yet) : http://www.dmgecoline.com/de-DE/30-dmu-50-eco
>
> So, what do you think, would EMC be able to keep up with the Siemens
> 810D controller? In terms of features, especially on-line programming,
> it certainly doesn't, but I don't need these features. All the
> programming, simulation, collision checking etc, is done off-line using
> CATIA, HyperMill, SprutCAM or self made CAD-to-CAM scripts (no collision
> checking her, hu...). Is anyone using EMC on a new 5axes machine?
>
> The basic question I guess is would EMC be able to provice the same tool
> path quality as the (lower end) Siemens or Heidenhain controllers?
>
> See you
> Flo
>
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Re: [Emc-users] EMC as an alternative to Heidenhain iTNC 530, Siemens 840D, etc.

2010-09-08 Thread a
> I don't understand the situation
>
> "Newer 5 axis machine", "840D" and  "budget limitation" generally do not
> all go into the same paragraph..  ;-)
>
> An 840D with the right options can easily run a 5 axis mill, but cheap,
> or economical it is not.
>
> Dave
>
> On 9/8/2010 2:37 PM, Ulf Dambacher wrote:
>> Hi Flo
>>
>> If you have money for a dmg machine  of this new age, maybe emc is not
>> what you need.
>> The Siemens 810 is fully digital and fitting emc with the other digital
>> controls would require much rewiring.
>> It would be better and simpler to upgrade the 810 to 840.
>>
>> Maybe you should look for a good old machine on ebay?
>>
>> Bye
>> Ulf
>>
>> Am 08.09.2010 20:00, schrieb Florian Rist:
>>
>>> Hi,
>>> I need a new machine for (rather light, no heavy machining of cast iron
>>> or stainless stsel) 5axes simultainus milling in research and
>>> development and education. Since I'm on a short budged I start thinking
>>> about getting a cheep 5axes machine, not capable of 5aces milling by
>>> default, but equipped with strong enough servos and good encodes on the
>>> aces rotary axes and then replace the 3+2 axes controller by EMC
>>> (capable of 5 axes interpolation).
>>>
>>> One of the machines that might be used for that conversion the the DMU
>>> DMG eco 50 (haven't verified it the rotary aces hardware is strong
>>> enough, yet) : http://www.dmgecoline.com/de-DE/30-dmu-50-eco
>>>
Hi
Will you change servomotors or use existing servomotors. Will EMC2 work
with existing motors?



>>> So, what do you think, would EMC be able to keep up with the Siemens
>>> 810D controller?
>>>
>>>
>>
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Re: [Emc-users] EMC as an alternative to Heidenhain iTNC 530, Siemens 840D, etc.

2010-09-08 Thread dambacher-retrofit.de
Am 08.09.2010 21:08, schrieb Dave:
> I don't understand the situation
> An 840D with the right options can easily run a 5 axis mill, but cheap, 
> or economical it is not.
> 
> Dave
Hi Dave

You are right, but I would not recommend to retrofitting a machine running with
a siemens 810 to emc:
a) one  needs to teach emc how to connect to simatic, sinamic and other digital
interfaces.
And the current status of emc is that it is not even able to run can or
something like ethercat(TM)  ethernet/ip.
(I will give  etherlab a try when I get the hardware next week)

b) one has to switch the digital drives built in to accepting pulse signals as
stepper simulation or even worse accept analog input. and for plc one has to
either rewire the sps inputs or use an external s7 sps to drive the simatic 
i/o's.

Either way one will need a simens technican.
And the costs of doing this will outweight buying a 840.

bye
Ulf

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Re: [Emc-users] EMC as an alternative to Heidenhain iTNC 530, Siemens 840D, etc.

2010-09-08 Thread Florian Rist
Hi Thomas

 >> DMG eco 50
 >
 > that machine is not cheap and is precision

Well, cheaper than the once which are able to do 5axes interpolation out 
of the box.

> and you can get great information about how rigid it is from
> DeckelMahoGuildemeister

I hope so, I'm afraid it might just use the servos on the two rotary 
axes to position it and then use brakes to lock the axes in place. In 
that case I'd not be possible to convert it to 5 axes just by replacing 
the controller.

See you
Flo

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Re: [Emc-users] EMC as an alternative to Heidenhain iTNC 530, Siemens 840D, etc.

2010-09-08 Thread Dave
I don't understand the situation

"Newer 5 axis machine", "840D" and  "budget limitation" generally do not 
all go into the same paragraph..  ;-)

An 840D with the right options can easily run a 5 axis mill, but cheap, 
or economical it is not.

Dave

On 9/8/2010 2:37 PM, Ulf Dambacher wrote:
> Hi Flo
>
> If you have money for a dmg machine  of this new age, maybe emc is not
> what you need.
> The Siemens 810 is fully digital and fitting emc with the other digital
> controls would require much rewiring.
> It would be better and simpler to upgrade the 810 to 840.
>
> Maybe you should look for a good old machine on ebay?
>
> Bye
> Ulf
>
> Am 08.09.2010 20:00, schrieb Florian Rist:
>
>> Hi,
>> I need a new machine for (rather light, no heavy machining of cast iron
>> or stainless stsel) 5axes simultainus milling in research and
>> development and education. Since I'm on a short budged I start thinking
>> about getting a cheep 5axes machine, not capable of 5aces milling by
>> default, but equipped with strong enough servos and good encodes on the
>> aces rotary axes and then replace the 3+2 axes controller by EMC
>> (capable of 5 axes interpolation).
>>
>> One of the machines that might be used for that conversion the the DMU
>> DMG eco 50 (haven't verified it the rotary aces hardware is strong
>> enough, yet) : http://www.dmgecoline.com/de-DE/30-dmu-50-eco
>>
>> So, what do you think, would EMC be able to keep up with the Siemens
>> 810D controller?
>>
>>  
>
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Re: [Emc-users] EMC as an alternative to Heidenhain iTNC 530, Siemens 840D, etc.

2010-09-08 Thread Peter C. Wallace

On Wed, 8 Sep 2010, Igor Chudov wrote:


Date: Wed, 8 Sep 2010 13:44:35 -0500
From: Igor Chudov 
Reply-To: "Enhanced Machine Controller (EMC)"

To: "Enhanced Machine Controller (EMC)" 
Subject: Re: [Emc-users] EMC as an alternative to Heidenhain iTNC 530,
    Siemens 840D, etc.

On Wed, Sep 8, 2010 at 1:37 PM, Ulf Dambacher
 wrote:

Hi Flo

If you have money for a dmg machine  of this new age, maybe emc is not
what you need.
The Siemens 810 is fully digital and fitting emc with the other digital
controls would require much rewiring.
It would be better and simpler to upgrade the 810 to 840.


I kind of agree, but wonder, what does it mean "fully digital"?



It means their analog stuff is all buried in the drives, so the motor drive 
interface is digital.



Peter Wallace
Mesa Electronics

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Re: [Emc-users] EMC as an alternative to Heidenhain iTNC 530, Siemens 840D, etc.

2010-09-08 Thread Igor Chudov
On Wed, Sep 8, 2010 at 1:37 PM, Ulf Dambacher
 wrote:
> Hi Flo
>
> If you have money for a dmg machine  of this new age, maybe emc is not
> what you need.
> The Siemens 810 is fully digital and fitting emc with the other digital
> controls would require much rewiring.
> It would be better and simpler to upgrade the 810 to 840.

I kind of agree, but wonder, what does it mean "fully digital"?

i

>
> Maybe you should look for a good old machine on ebay?
>
> Bye
> Ulf
>
> Am 08.09.2010 20:00, schrieb Florian Rist:
>> Hi,
>> I need a new machine for (rather light, no heavy machining of cast iron
>> or stainless stsel) 5axes simultainus milling in research and
>> development and education. Since I'm on a short budged I start thinking
>> about getting a cheep 5axes machine, not capable of 5aces milling by
>> default, but equipped with strong enough servos and good encodes on the
>> aces rotary axes and then replace the 3+2 axes controller by EMC
>> (capable of 5 axes interpolation).
>>
>> One of the machines that might be used for that conversion the the DMU
>> DMG eco 50 (haven't verified it the rotary aces hardware is strong
>> enough, yet) : http://www.dmgecoline.com/de-DE/30-dmu-50-eco
>>
>> So, what do you think, would EMC be able to keep up with the Siemens
>> 810D controller?
>>
>
>
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Re: [Emc-users] EMC as an alternative to Heidenhain iTNC 530, Siemens 840D, etc.

2010-09-08 Thread Ulf Dambacher
Hi Flo

If you have money for a dmg machine  of this new age, maybe emc is not 
what you need.
The Siemens 810 is fully digital and fitting emc with the other digital 
controls would require much rewiring.
It would be better and simpler to upgrade the 810 to 840.

Maybe you should look for a good old machine on ebay?

Bye
Ulf

Am 08.09.2010 20:00, schrieb Florian Rist:
> Hi,
> I need a new machine for (rather light, no heavy machining of cast iron
> or stainless stsel) 5axes simultainus milling in research and
> development and education. Since I'm on a short budged I start thinking
> about getting a cheep 5axes machine, not capable of 5aces milling by
> default, but equipped with strong enough servos and good encodes on the
> aces rotary axes and then replace the 3+2 axes controller by EMC
> (capable of 5 axes interpolation).
>
> One of the machines that might be used for that conversion the the DMU
> DMG eco 50 (haven't verified it the rotary aces hardware is strong
> enough, yet) : http://www.dmgecoline.com/de-DE/30-dmu-50-eco
>
> So, what do you think, would EMC be able to keep up with the Siemens
> 810D controller?
>


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Re: [Emc-users] EMC as an alternative to Heidenhain iTNC 530, Siemens 840D, etc.

2010-09-08 Thread Thomas Powderly
Flo,
that machine is not cheap
and is precision
it uses a Heidenhain controller so it has precision feedback (it will
use Heidenhain scales )
and you can get great information about how rigid it is from
DeckelMahoGuildemeister
the bearing around the whole B axis is impressive, it will take the
cutting forces
Please keep us posted with this projects progress
that is one sweet machine tool
tomp

On Wed, Sep 8, 2010 at 1:00 PM, Florian Rist  wrote:
> Hi,
> I need a new machine for (rather light, no heavy machining of cast iron
> or stainless stsel) 5axes simultainus milling in research and
> development and education. Since I'm on a short budged I start thinking
> about getting a cheep 5axes machine, not capable of 5aces milling by
> default, but equipped with strong enough servos and good encodes on the
> aces rotary axes and then replace the 3+2 axes controller by EMC
> (capable of 5 axes interpolation).
>
> One of the machines that might be used for that conversion the the DMU
> DMG eco 50 (haven't verified it the rotary aces hardware is strong
> enough, yet) : http://www.dmgecoline.com/de-DE/30-dmu-50-eco
>
> So, what do you think, would EMC be able to keep up with the Siemens
> 810D controller? In terms of features, especially on-line programming,
> it certainly doesn't, but I don't need these features. All the
> programming, simulation, collision checking etc, is done off-line using
> CATIA, HyperMill, SprutCAM or self made CAD-to-CAM scripts (no collision
> checking her, hu...). Is anyone using EMC on a new 5axes machine?
>
> The basic question I guess is would EMC be able to provice the same tool
> path quality as the (lower end) Siemens or Heidenhain controllers?
>
> See you
> Flo
>
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[Emc-users] EMC as an alternative to Heidenhain iTNC 530, Siemens 840D, etc.

2010-09-08 Thread Florian Rist
Hi,
I need a new machine for (rather light, no heavy machining of cast iron 
or stainless stsel) 5axes simultainus milling in research and 
development and education. Since I'm on a short budged I start thinking 
about getting a cheep 5axes machine, not capable of 5aces milling by 
default, but equipped with strong enough servos and good encodes on the 
aces rotary axes and then replace the 3+2 axes controller by EMC 
(capable of 5 axes interpolation).

One of the machines that might be used for that conversion the the DMU 
DMG eco 50 (haven't verified it the rotary aces hardware is strong 
enough, yet) : http://www.dmgecoline.com/de-DE/30-dmu-50-eco

So, what do you think, would EMC be able to keep up with the Siemens 
810D controller? In terms of features, especially on-line programming, 
it certainly doesn't, but I don't need these features. All the 
programming, simulation, collision checking etc, is done off-line using 
CATIA, HyperMill, SprutCAM or self made CAD-to-CAM scripts (no collision 
checking her, hu...). Is anyone using EMC on a new 5axes machine?

The basic question I guess is would EMC be able to provice the same tool 
path quality as the (lower end) Siemens or Heidenhain controllers?

See you
Flo

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Enter the Intel(R) Threading Challenge 2010.
http://p.sf.net/sfu/intel-thread-sfd
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