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Southwestern Industries, Inc.

TRAK



KMX Knee Mill, Bed Mill & ProtoTRAK



KMX CNC Retrofit Safety, Programming, Operating & Care Manual

2.3

Safety Precautions

Do not operate this machine before the

ProtoTRAK KMX CNC Safety,

Installation, Maintenance, Service and Parts List Manual

, and the

Safety,

Programming, Operating & Care Manual

have been studied and understood.

Do not run this machine without knowing the function of every control key, button,

knob, or handle. Ask your supervisor or a qualified instructor for help when needed.

Protect your eyes. Wear approved safety glasses (with side shields) at all times.

Don't get caught in moving parts. Before operating this machine remove all jewelry

including watches and rings, neckties, and any loose-fitting clothing.

Keep your hair away from moving parts. Wear adequate safety headgear.

Protect your feet. Wear safety shoes with oil-resistant, anti-skid soles, and steel
toes.

Take off gloves before you start the machine. Gloves are easily caught in moving
parts.

Remove all tools (wrenches, check keys, etc.) from the machine before you start.

Loose items can become dangerous flying projectiles.

Never operate a milling machine after consuming alcoholic beverages, or taking
strong medication, or while using non-prescription drugs.

10.

Protect your hands. Stop the machine spindle and ensure that the CNC control is in
the stop mode:

•

Before changing tools

•

Before changing parts

•

Before you clear away the chips, oil or coolant. Always use a chip scraper or

brush

•

Before you make an adjustment to the part, fixture, coolant nozzle or take
measurements

•

Before you open safeguards (protective shields, etc.). Never reach for the part,
tool, or fixture around a safeguard.

11.

Protect your eyes and the machine as well. Don't use a compressed air hose to
remove the chips or clean the machine (oil, coolant, etc.).

12.

Stop and disconnect the machine before you change belts, pulley, gears.

13.

Keep work area well lighted. Ask for additional light if needed.

14.

Do not lean on the machine while it is running.

15.

Prevent slippage. Keep the work area dry and clean. Remove the chips, oil, coolant
and obstacles of any kind around the machine.

Содержание ProtoTRAK KMX K3

Страница 1: ...MX3 Upgrade o MX3 To KMX3 Upgrade o M2 To KMX2 Upgrade o M2 To KMX3 Upgrade o M3 To KMX3 Upgrade o AGE2 To KMX2 Upgrade o AGE2 To KMX3 Upgrade o AGE3 To KMX3 Upgrade o EDGE2 To KMX2 Upgrade o EMX To K...

Страница 2: ...n made to include all the information required for the purposes of this guide Southwestern Industries Inc assumes no responsibility for inaccuracies or omission and accepts no liability for damages re...

Страница 3: ...s 14 3 3 1 Manual Lubrication System K3KMX 17 3 3 2 Auto Lube System K3KMX Option 17 3 3 3 Electrical Cabinet TRAK Knee Mills Only 18 3 4 Optional Equipment 19 3 4 1 Power Draw Bar 19 3 4 2 Remote Sto...

Страница 4: ...hanges to the Head 27 4 4 Coolant Pump Spray Coolant 27 5 0 Definitions Terms Concepts 28 5 1 ProtoTRAK KMX Axis Conventions 28 5 2 Part Geometry and Tool Path Programming 28 5 3 Planes and Vertical P...

Страница 5: ...7 4 7 Finishing Teach Events 49 7 5 Prompts Used to Define the Events 49 7 6 Assumed Tool Offset Feedrate and Tool 51 7 7 Incremental Reference Position 52 7 8 Finish Cuts 52 7 9 Look 52 8 0 Program M...

Страница 6: ...dwheel Option 68 11 7 1 TRAKing in Two Axis CNC 69 11 8 Data Errors 69 11 9 Fault Messages 69 12 0 Program Memory Storage 70 12 1 Cautions About Opening and Deleting Programs 70 12 2 Program Formats a...

Страница 7: ...that is typically done on knee mills or bed mills The operation of the ProtoTRAK KMX CNC has been painstakingly refined to bring you the most useful CNC technology while retaining the ease of use that...

Страница 8: ...e retrofit TRAK Knee Mill and Upgrade products that use the ProtoTRAK KMX CNC Some Sections do not apply to all users For example if you own a ProtoTRAK retrofit you should skip the sections that cove...

Страница 9: ...tudy the following publications for assistance in enhancing the safe use of this machine Safety Requirements For The Construction Care And Use of Drilling Milling and Boring Machines ANSI B11 8 2001 A...

Страница 10: ...ng Operating Care Manual Safety Information Labels Used On The TRAK Knee or Bed Mills It is forbidden by OSHA regulations and by law to deface destroy or remove any of these labels Retrofit customers...

Страница 11: ...ill Bed Mill ProtoTRAK KMX CNC Retrofit Safety Programming Operating Care Manual 220 440 VOLTS Safety Information Labels Used On The ProtoTRAK KMX CNC It is forbidden by OSHA regulations and by law to...

Страница 12: ...easily caught in moving parts 8 Remove all tools wrenches check keys etc from the machine before you start Loose items can become dangerous flying projectiles 9 Never operate a milling machine after c...

Страница 13: ...start the machine including the rotation of the spindle if the tool is in contact with the part 21 Check the direction or of movement of the table when using the jog or power feed 22 Don t use dull or...

Страница 14: ...s service and maximized uptime 115V 60HZ 10 amps Feedrate Override of programmed feedrate and rapid Polycarbonate Sealed Membrane Keypad to lock out contamination 9 0 Color LCD USB port for interface...

Страница 15: ...r minute Selectable 2 or 3 axis operation AGE Auto Geometry Engine Programmed Canned Cycles Posn Drill single point Bolt Hole series of points evenly spaced around a circle Mill straight line in any d...

Страница 16: ...ncremental dimensions and general data ABS SET loads absolute dimensions and general data X Y Z selects axis for subsequent commands 0 9 inputs numeric data with floating point format Data is automati...

Страница 17: ...p switch kills all power to the ProtoTRAK s servomotors and the spindle motor when pressed on a TRAK machine The computer and pendant remain powered The Liquid Crystal Display LCD The display of the P...

Страница 18: ...ale cable Table Guard For plugging in the interlock switch that is part of the optional table guard Not available with retrofits The USB Ports There are two USB ports use only one at a time for an opt...

Страница 19: ...hines only RSG Remote Stop and Go switch Mach ID Machine ID key to customize parameters to each machine type UMB1 and UMB2 Logic connections to the Cable Breakout Box Network Network connection to you...

Страница 20: ...TRAK Knee Mill Specifications This section describes the TRAK Knee Mill machine it does not apply to ProtoTRAK KMX retrofits Item Part Number Description 1 20819 Spindle Motor 2 29751 1 KMX Pendant 3...

Страница 21: ...15 Southwestern Industries Inc TRAK KMX Knee Mill Bed Mill ProtoTRAK KMX CNC Retrofit Safety Programming Operating Care Manual FIGURE 3 3 2 The TRAK Knee Mill back view...

Страница 22: ...RPM Head Tilt 45 forward and back 90 left and right Quill Feeds per Rev 0 0015 0 003 0 006 Spindle Motor Power Vari speed 3HP Power Requirement Control 110V 1P 10A Power requirements machine 220 440V...

Страница 23: ...he lower left area of the head with SAE 30 or 30W oil 2 Extend the quill fully and apply a coating of SAE 30 or 30W oil to the outside diameter of the quill Twice a Month 1 Apply 2 drops of oil in upp...

Страница 24: ...time by one second FEED this button is used to manually feed the ways and ballscrews RST this button tells the pump to discharge for the time programmed Factory Default Values Interval Time 60 min Di...

Страница 25: ...ant TRAK Knee Mills Only The Fog Buster spray coolant option consists of a one gallon holding tank nozzle air lines and an air regulator for attaching compressed air Coolant flow is adjusted by a need...

Страница 26: ...when the Select a Mode message appears on the screen Handwheel resolution is determined by the F C key on the display Fine feed moves 200 inches per revolution Course feed moves 800 inches per revolut...

Страница 27: ...m is not used either by a keystroke or by counting for 20 continuous minutes the LCD will turn itself off Press any key to bring the screen back to its previous display The key you press will be ignor...

Страница 28: ...Power is also shut off to the spindle motor for TRAK Mills Rotate the switch to release 4 2 Machine Operation This section covers the operation of the TRAK Mills If you purchased your ProtoTRAK KMX C...

Страница 29: ...hwestern Industries Inc TRAK KMX Knee Mill Bed Mill ProtoTRAK KMX CNC Retrofit Safety Programming Operating Care Manual Figure 4 2 1 TRAK K3 Mill head front view Shown without the standard quill glass...

Страница 30: ...es the knee up while counterclockwise rotation moves the knee down Be sure the knee is unclamped before raising or lowering 4 2 4 Spindle Brake The mechanical spindle break is activated pulling it dow...

Страница 31: ...eed may be varied by rotating the variable speed crank CAUTION Do not rotate the variable speed crank when the spindle is stationary 4 2 8 Operating the Quill The quill may be moved up and down throug...

Страница 32: ...dle RPM is over 3000 Always leave the selector in the disengaged position unless the feed function is being used 4 2 11 Fine Feed Direction Shaft The direction of the fine feed is set by the position...

Страница 33: ...e 3 axis TRAK K3 KMX 3 and on 3 axis retrofits is modified with a kit to drive the quill up and down The kit is comprised of 1 A fork bracket is substituted for the quill stop knob 2 A bracket encompa...

Страница 34: ...TRAK KMX CNC has the job of figuring out the tool path from the part dimensions and the tool set up information This is a great benefit compared to regular CNC because it doesn t force the programmer...

Страница 35: ...vertical plane rather than just XZ or YZ 5 4 Absolute Incremental Reference The ProtoTRAK KMX may be programmed and operated in either or in a combination of absolute or incremental dimensions An abso...

Страница 36: ...POCKET or PROFILE then an incremental move is from the X CENTER Y CENTER programmed in that event RECTANGLE POCKET or PROFILE then an incremental move is from the first or X1 Y1 corner programmed in t...

Страница 37: ...rammed instead of the radius of the center of the cutter Rc Tool cutter compensation is always specified as the tool either right or left of the workpiece while looking in the direction of the tool mo...

Страница 38: ...of tool is perpendicular to BC Note how the tool at the beginning point point B starts below in the Z direction point B so that it can actually touch this point If this were not true a cusp would rema...

Страница 39: ...t the tool cutter to move continuously from X1 Y1 through T1 r k T2 to X3 Y3 For this figure you program an Arc event from X1 Y1 to X2 Y2 with tool offset left and another Arc event from X2 Y2 to X3 Y...

Страница 40: ...uter with a firewall An anti virus program is not necessary since the virus risk is low and is not recommended because the background tasks may cause damage by interfering with ProtoTRAK real time ope...

Страница 41: ...r all keys Reset One Axis Press X or Y or Z INC SET This zeros the incremental position in the selected axis Preset Press X or Y or Z numeric data INC SET to preset selected axis Reset Absolute Refere...

Страница 42: ...The feedrate and override boxes will show these adjustments Press the up arrow key to increase the speed The range is between 10 and 150 5 Press and hold X or Y to jog that axis Release the key to st...

Страница 43: ...ram If there is not already a program in current memory Teaching will start a new program For example if you already had a program in current memory that had 10 events when you press Teach the event c...

Страница 44: ...on will stop at the entered dimension even if you continue to crank the handwheel 6 7 Tool The Tool softkey is used in 3 axis mode when you want to change the tool you have in the spindle The Z DRO pr...

Страница 45: ...es Inc TRAK KMX Knee Mill Bed Mill ProtoTRAK KMX CNC Retrofit Safety Programming Operating Care Manual 7 Repeat the process beginning at 3 above as often as you wish 8 Press RETURN soft key to return...

Страница 46: ...Program names consist of one to eight numbers Note It is not necessary to enter a program name If none is entered and the INC SET or ABS SET button is pushed the system will assume the program name is...

Страница 47: ...5 3 for a definition of planes For this reason the ProtoTRAK KMX CNC gives you the option of entering your own tool path If you wish to program the part by defining tool path yourself you may choose t...

Страница 48: ...X END Options 0 None No Auxiliary functions will turn off at the end of this event 1 Coolant Air Off Turns the coolant or air solenoid off at the end of this event 3 Indexer Activates an electronic si...

Страница 49: ...area and the next prompt will be shown in the conversation line From the event data screen you may press the up arrow key to the upper right of the LCD screen to go back to edit any data within an eve...

Страница 50: ...rcle When the program is run at a Posn Drill Event the ProtoTRAK KMX will servo at rapid or as modified by you to each location defined and will wait for you to finish the operation e g drill the hole...

Страница 51: ...the pocket and prompt SET Z After you have set the cutter and pressed GO it will machine outward to the final shape minus the finish pass and then then make the finish pass When the program is run as...

Страница 52: ...ated mirrored or rotated without changing the original events Connect so that the quill will not move up to the Z Rapid position and back down unnecessarily However to be connective you must be certai...

Страница 53: ...ents are rotated through a 45 degree angle about a point offset from absolute zero by X Center and Y Center dimensions A is rotated 3 times to produce shape B C and D MIRROR is used for parts that hav...

Страница 54: ...e of these different types TEACH POSN DRILL See Section 7 3 1 for a description of Position Drill event prompts TEACH MILL a straight line that specifies the beginning and the end When TEACH MILL even...

Страница 55: ...t you must program the Z information 7 4 6 Subroutine Events These events are the same as in 2 axis mode except you can offset the Z rapid and Z depth 7 4 7 Finishing Teach Events The TEACH event is t...

Страница 56: ...dius of the bolt hole pattern arc or circle Tool the number you assign to identify the tool Tool Diameter the diameter of the tool See the note on finish cuts later in this section Tool offset the sel...

Страница 57: ...riable fixed or chip break Z Feedrate this is the feedrate the Z axis will move down at Z Rapid Offset this is the Z rapid offset you want to apply to your repeat event If you program 0 INC the Z rapi...

Страница 58: ...was repeated Note For 3 axis programs the Z rapid Z end or depth and taken from the previous event 7 8 Finish Cuts The Pocket and Profile events are designed with built in finish cut routines because...

Страница 59: ...l ProtoTRAK KMX CNC Retrofit Safety Programming Operating Care Manual The part graphics are useful for checking what you have programmed so far Certain kinds of programming mistakes are not caught by...

Страница 60: ...Enter the data you know and skip the prompts you don t Use different types of data like angles that may be available from the print Enter guesses for the X and Y ends and centers not available on the...

Страница 61: ...ents is lost 8 2 A G E Mill Prompts Press the A G E Mill key Prompts in A G E Mill programming Tangent this refers to the tangency of the mill to the previous event See Section 8 10 for a discussion o...

Страница 62: ...of the arc cut incremental is from Y Begin X CENTER is the X dimension to the center of the arc incremental is from X End Y CENTER is the Y dimension to the center of the arc incremental is from Y End...

Страница 63: ...the A G E is ended the Irregular Pocket or Irregular Profile event is complete and you may then choose from all the programming canned cycles from the Select an Event screen To reopen the A G E Profi...

Страница 64: ...g a lot of data it may be desirable to program arcs as separate events where possible This gives the system more information to work with 8 10 Tangency Tangency can occur between a mill and arc or an...

Страница 65: ...pts by pressing an arrow key that need to be entered to complete an event 9 3 Editing Previously Programmed Events From the Select Event screen you may press the arrow up key to the right of the LCD s...

Страница 66: ...rograms in current memory may be changed and run with the changes but unless they are saved again the changes made will be lost when the program is cleared from current memory If you intend to keep th...

Страница 67: ...10 0 SET UP RUN Mode The Set Up Mode contains the tool table tool path home Verify and service codes 10 1 TOOL TABLE The tool table is where you set your Z retract set the lengths of your tools and al...

Страница 68: ...ode on the KMX you can also set Z offsets if you choose These offsets will be applied when you press GO after loading a new tool The Z readout will update to the new value Most people just zero out ea...

Страница 69: ...the Z End should not be higher than the Z Rapid The displayed graphic is automatically sized to fit the screen and an icon that represents the X Y and Z orientation is placed at the program s absolute...

Страница 70: ...oms in to see more detail Return returns to tool path screen 10 3 Setting Home Home is the X Y location relative to the program absolute zero that you want the table to move to just before a tool chan...

Страница 71: ...he stock is a cubic piece of material slightly larger than your part If you choose to define your stock press DEFINE STOCK and input the X Y and Z absolute dimensions relative to your program absolute...

Страница 72: ...n the spindle is the tool that the control thinks is in the spindle The tool the control thinks is in the spindle can be found in the status line 11 2 Starting After setting up in the DRO Mode go into...

Страница 73: ...formation area The SHOW ABS soft key which is automatically assumed if one of the other 3 show keys are not selected will show the absolute X Y Z positions as the part is run The SHOW INC soft key wil...

Страница 74: ...of Z zero is not applicable in 3 axis mode Run Over Means that the program run is complete If you are running a second part that will be fixtured clamped in the exact same position as the first part...

Страница 75: ...t in position when the messages Set Z or Check Z appear When TRAKing through an XY move the Z axis handwheel is not active 11 8 Data Errors A program must make sense geometrically For example you can...

Страница 76: ...rom internal storage into the current memory does not remove it from the internal storage Only deleting the program will remove it 12 1 Cautions About Opening and Deleting Programs Care must be taken...

Страница 77: ...will open programs with PT4 extensions but error out if they contain Tap Events from the ProtoTRAK SMX or any programs written on our legacy controls with MX2 or MX3 extensions All MX2 and MX3 will au...

Страница 78: ...implement turn on the PrototTRAK KMX go to Prog I O and press Open Temp 12 4 Saving a Program Onto the ProtoTRAK KMX Thumb Drive Press MODE PROG I O and SAVE keys The display will show Use Column Forw...

Страница 79: ...n SAVE TEMP During the time the KMX is off be sure nothing has moved the table or adjusted the tools If uncertain reset your absolute zero and or tool offsets 12 5 Deleting a Program on Your ProtoTRAK...

Страница 80: ...mplicity of editing in the KMX format instead of editing G Codes It is not useful for large complex G Code programs These programs must have a CAM extension Both GCD and CAM programs will only operate...

Страница 81: ...lant off M12 X Indexer pulse at beginning of event M20 X Indexer pulse at end of event M21 X Indexer pulse M30 X End of program rewind stop M333 X Enable low pass filter M334 X Disable low pass filter...

Страница 82: ...drive or the network LOCATION shows the folder that it will open under PROG I O Note that on a USB flash drive only the KMX Programs folder is able to be accessed It will also be automatically created...

Страница 83: ...in the network path of the shared folder that you want to open files from The path can be typed in by using the Data Left and Right Keys and the Up and Down Arrow keys to scroll through the letters an...

Страница 84: ...e path specified and to help troubleshoot if you find that you are having connectivity issues When this softkey is used the ProtoTRAK KMX control will attempt to write a temp file to the defined netwo...

Страница 85: ...ions and devices This includes Ethernet cables routers switches etc 3 Make sure that location specified is properly being shared and is accessible by this device Network Setup Our ProtoTRAK KMX contro...

Страница 86: ...is recommended to use a wireless media bridge in order to successfully communicate with your network The wireless bridge can be setup to fit the requirements of your network where you can define a us...

Страница 87: ...amming Operating Care Manual hooking it up to a desktop pc first logging into the device following the setup procedure and then connecting it to the device of your choice Companies such as Linksys D L...

Страница 88: ...ally calculate points of intersection centers of arcs trig functions square roots etc 13 1 Procedure To enter the Math Help Mode press MODE and select the MATH HELP soft key The screen will show Selec...

Страница 89: ...than one will be shown on the left side of the information area Use the Up and Down arrow keys to move the highlight There are often multiple solutions for geometry problems For example in the Type 13...

Страница 90: ...a line tangent to two arcs line does not cross arc centers center of each arc radius of each arc 17 Intersection of a line tangent to an arc one point on the line center of the arc radius of the arc...

Страница 91: ...from a USB thumb drive device to the ProtoTRAK system Use this routine to install new ProtoTRAK software Press B for Machine Codes Input code number and press SET 11 Hysterisis Measures the backlash b...

Страница 92: ...s includes the users program configuration files message log fault log etc This is meant to be used to help us solve problems that may pertain to our software This file can then be emailed to our serv...

Страница 93: ...K open up in inch measurement 79 Turn On Beeper Turn the beeper on when pressing keys on either of the front panels 80 Turn Off Beeper Turns the beeper off when pressing keys 140 Step Over for Pockets...

Страница 94: ...ny implied warranty of merchantability or fitness for a particular purpose and of any other obligations or liability on the part of SWI or any producing entity if different Warranty repairs exchanges...

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