Advanced Control System (ACS)

Description
Features
Technology Packages
Servo Motors
Touch Panel

FlexiCAM’s Advanced Control System (ACS) offers CNC functions for numerous cutting technologies: From 3 to 5-axis routers, plasma and oxyfuel through laser and waterjet cutting. Plotter with oscillating or ultrasonic knife, creasing wheels or dispensers are supported as well.

With FlexiCAM’s control technology through customized adjustments almost any application scenarios are conceivable. Both, cutting and non-cutting methods, can be used.

The FlexiCAM Advanced Control System (ACS) is based on optimized components for drives, CNC, PLC and Motion Control tasks.
These components can be configured to demand for almost any CNC solution. This can be the most demanding multi-channel CNC applications with up to 32 CNC axes, 64 motion axes and cycle times <1ms. The PLC functionality is of course also already integrated.

If required by the task, the FlexiCAM Advanced Control System (ACS) can be adapted to specific applications and technologies.
Integrated Ethernet-based real-time communication between controls, drives and I/O peripherals keeps cabling costs low and significantly less error prone.

RISC processor for high performance computing
Large CNC instruction set
CNC programming according to DIN 66025
Motion function library according to PLCopen®
Extremely short cycle times for highly dynamic applications
Communication: EtherCAT®, Sercos III, CANopen®
Interfaces: Ethernet, USB, RS-232
32 CNC axis with a large instruction set
64 motion axis with extensive motion function library according PLCopen®
Motion can be seamlessly combined with CNC functions
Extremely fast, robust and easy to wire the realtime I/O system
Open architecture, vendor independent and IEC compliant
Use of industry standards in programming (CoDeSys, IEC 61131-3, PLCopen®) and interfaces (EtherCAT®, CANopen®, Sercos III) for future-proof automation solutions
PLC programming according to IEC 61131-3 (CoDeSys)
Look-Ahead to optimize machining speeds
Block preparation for processing extremely short NC blocks
Feed-forward for compensating following errors
Reverse travel and restart on contour
Spatial rounding for fast and smooth movements
Variable acceleration profiles for changing load conditions
Block search for random start in long-running operations
Teach-in of axis positions with subsequent data reduction and generating of polynomials
Tangential following C-axis for tool orientation at contouring
Synchronous axes / gantry axes for saving mechanical drive components
Tool management and technology charts
Graphical CNC user interface (HMI) for Microsoft Windows
Formula interpreter to create mathematically sophisticated part programs
Path velocity-dependent output signals for power control, dosing etc.
Fast inputs and outputs for immediate response in the NC program
Lead pitch correction / backlash compensation to compensate mechanical errors
PLC positioning axes (motion axis) in parallel with contour machining (CNC axis)
Touch-trigger input for fast data acquisition
Multi-channel, simultaneous running of multiple NC programs
3D online spline for processing teach-in contour points in space
Coordinate transformation for easy programming
5-axis-transformation (RTCP)
Tool slaving in space (6 axes) with consideration of the machine geometry
Fast Z-axis following to focus on the workpiece surface
3D axis compensation to compensate for mechanical tolerances
Geometry filter to reduce the point density
Path velocity-dependent output power control; Depending on requirements as a voltage or PWM signal (e.g. for laser power control, abrasive dosing etc.). The frequency and the relationship between pulse and pause are dynamically adjusted depending on the cuttingspeed.
Measurement and compensation of the surface of the cutting table or the material surface
Automatic workpiece position detection and correction
Automatic Z-height adjustment, for example, automatic measuring and correction on the Z-axis, depending on the plate thickness
Tool radius compensation
Intuitive user interface (HMI)
Shop floor programming under Microsoft Windows
All major import formats are available
Connection to virtually all major CAD / CAM systems possible
Tool management: The integrated automatic tool management is designed for 255 tools. The function “Sistertool” ensures that the system changes automatically to an alternate tool once a tool is considered defective or missing.
Automatic tool breakage detection after each tool change for unmanned machining
All system parameters can be stored on SD card for a quick and easy hardware replacement
Robust, long-term available components
Numerous cutting- and technology-specific special functions

CNC Technology Package Laser and Waterjet

Support of various laser manufacturers and models, for example, fiber lasers, CO2 lasers etc.
Speed-dependent laser power control, analogue and pulse width modulated (PWM)
Control of laser cutting heads of various manufacturers such as Precitec, LaserMech, American Laser Enterprises etc.
Control of waterjet high pressure pumps such as KMT, BHDT, Hammelmann etc.
Configurable abrasive dosing
Various height sensing procedures and interfaces

CNC Technology Package Plasma and Oxyfuel

Connection to plasma sources and gas consoles of Kjellberg, Hypertherm, Victor (Thermadyne), other power sources on request
CNC-integrated dynamic torch Z-height control (THC)
Alternatively, control of external height controls, e.g. IHT
Control of bevel aggregates of different kinematics, also oxyfuel bevel cutting with lateral adjustment
Full 3D machining, e.g. bevel cutting of profiles such as rectangular tubes, I-beams etc.
Combination with other technologies such as drilling, tapping, marking or labeling
Programmable head and technology change

General Control Functions

Automatic work piece position detection and correction
Forward and backward on the contour, any restart of the processing
Memory of last position, e.g. during power failure
Programmable position / spacing of multiple cutting heads by using belt/clamps or individual servo drives

FlexiCAM’s Advanced Control System (ACS) features a large range of digital AC servo systems consisting of compact, high-torque servo motors and servo amplifiers.

Features:

Digital AC servo drives and motors for highly dynamic machine axes with high control quality in a wide capacity range
High resolution 17bit absolute encoder for excellent surface quality
EtherCAT interface for extremely fast communication, minimal cabling and low failure rate
Safety function STO (Safe Torque Off)

FlexiCAM’s Advanced Control System (ACS) features an intuitive touch screen interface. Just as easily, the machine functions can be managed and monitored.

CNC user interface with complete machine operation via touchscreen
Special screens for operation and technology
Interactive graphical user interface
Extensive help functions
Customizable
Optional machine control panel (MCP), handwheel, keyboard with touchpad, jogbox

The FlexiCAM Advanced Control System (ACS) features a workstation-level industrial touch panel computer with 17-inch SXGA TFT LCD display and is perfect for factory automation and more industrial applications. This ruggedized system offers an industrial-grade resistive touch panel PC with IP65/NEMA 4 sealing.