AcuCam Laser Control Software User Guide v1!00!00 9-25-02

AcuCam LaserControl Software

User Guide

User Guide

AcuCam LaserControl Software

Software Version: 1.00.00

By Preco Laser Systems, LLC

Document PolicyCOPYRIGHT

The contents of this manual are the property of Preco Laser Systems, LLC, Somerset, Wisconsin.Any reproduction of this information without the express written permission of Preco Laser Systems isprohibited.

NON DISCLOSURE

The contents of this manual and all referred or associated documents marked PLS Confidential, areprovided to the original purchaser of the system for internal use only. Any disclosure of documentsmarked PLS Confidential to outside parties without the express written permission of PLS is strictlyprohibited.

POLICY

This manual is based upon the data available at the time of publication. While sincere effort has beenmade to make the manual accurate, the information contained herein does not claim to cover all thedetails or variations in hardware or software, nor to provide for every possible contingency in connectionwith installation, operation, maintenance, repair or replacement.

The Preco Laser Systems policy is one of continuous improvement. Therefore, the information in thismanual is subject to change without notice and should not be construed as a commitment by PrecoLaser Systems. PLS also assumes no obligation to notify manual holders of subsequent revisions.

Preco Laser Systems makes no representation of warranty, expressed or implied, nor assumes anyresponsibility for accuracy, completeness, sufficiency or usefulness or any problems that may arise fromthe use of the information contained herein.

MADE IN THE USA

PLS® products are designed and manufactured in the USA.

Trademark AcknowledgmentsAcuCam is a trademark of Preco Laser Systems, LLC.CIMPLICITY is a registered trademark of General Electric Company.PLS is a registered trademark of Preco Laser Systems, LLC.Microsoft is a registered trademark of Microsoft Corporation.Windows is a trademark of Microsoft Corporation.Windows 2000 is a registered trademark of Microsoft Corporation.

All other product names mentioned herein are used for identification purposes only, and may be thetrademarks or registered trademarks of their respective companies.

Copyright © 2002 Preco Laser Systems, LLC. All rights reserved.

500 Laser DriveSomerset, WI 54025Phone: 715.247.3285

FAX: 715.247.5650Sales Toll Free: 1.800.77.LASER

Service Toll Free: 1.800.799.2583Email: [email protected]

Website: www.precolaser.com

mailto:[email protected]

www.lasermachining.com

User GuideAcuCam Laser Control Software

v

Issued: 09/25/02 © 2002 Preco Laser Systems, LLC. All Rights Reserved Product No.: 01007-100

ContentsINTRODUCTION .................................................................................1

PURPOSE ........................................................................................1OVERVIEW.......................................................................................1GUIDE COMMENTS...........................................................................1HOW TO USE THIS GUIDE.................................................................2HOW THIS GUIDE IS ORGANIZED.......................................................2NOTATIONS AND CONVENTIONS .......................................................3

STANDARD CONVENTIONS..........................................................3MOUSE CONVENTIONS ...............................................................4RESISTIVE TOUCH SCREEN CONVENTIONS .................................4

SOFTWARE DESCRIPTION...............................................................5

PURPOSE ........................................................................................5OVERVIEW.......................................................................................5OPERATION .....................................................................................6OPERATING SYSTEM........................................................................6DISTRIBUTION..................................................................................6HARDWARE ARCHITECTURE .............................................................7

OPERATING INTERFACE ..................................................................9

PURPOSE ........................................................................................9OVERVIEW.......................................................................................9ACUCAM MAIN SCREEN LAYOUT ....................................................10

MAIN SCREEN REGIONS - OPERATOR LEVEL.............................10RECIPE SELECT REGION – OPERATOR LEVEL .....................11RECIPE REGION – OPERATOR LEVEL..................................11DIAGNOSTICS REGION – OPERATOR LEVEL ........................12SYSTEM REGION - OPERATOR LEVEL .................................13PARAMETER REGION – OPERATOR LEVEL ..........................14SYSTEM INFORMATION REGION – OPERATOR LEVEL ...........15MODE CONTROL BUTTONS REGION – OPERATOR LEVEL.....15PROGRAM CYCLE CONTROL BUTTONS REGION –OPERATOR LEVEL..............................................................16

LEVEL REGION – OPERATOR LEVEL..........................................17MAIN SCREEN REGIONS - SUPERVISOR LEVEL..........................18

RECIPE SELECT REGION (AUTO MODE) –SUPERVISOR LEVEL ...........................................................19

User GuideAcuCam Laser Control Software vi

Product No.: 01007-100 © 2002 Preco Laser Systems, LLC All Rights Reserved Issued: 09/25/02

RECIPE REGION (AUTO MODE) – SUPERVISOR LEVEL......... 19RECIPE SELECT REGION (PROGRAM MODE) –SUPERVISOR LEVEL ........................................................... 20CONFIG REGION (PROGRAM MODE) –SUPERVISOR LEVEL ........................................................... 20RECIPE SELECT REGION (MANUAL MODE) –SUPERVISOR LEVEL ........................................................... 20CONFIG REGION (MANUAL MODE) – SUPERVISOR LEVEL .... 21DIAGNOSTICS REGION – SUPERVISOR LEVEL...................... 21SYSTEM REGION - SUPERVISOR LEVEL............................... 22PARAMETER REGION – SUPERVISOR LEVEL........................ 23SYSTEM INFORMATION REGION – SUPERVISOR LEVEL ........ 24MODE CONTROL BUTTONS REGION – SUPERVISOR LEVEL ..25PROGRAM CYCLE CONTROL BUTTONS REGION –SUPERVISOR LEVEL ........................................................... 26LEVEL REGION – SUPERVISOR LEVEL................................. 27

ALARMS WINDOW .......................................................................... 28ALARM MESSAGES................................................................... 29

INPUTS AND OUTPUTS WINDOW ..................................................... 30

OPERATING PROCEDURES ........................................................... 31

STARTING ACUCAM ....................................................................... 31SELECTING A RECIPE..................................................................... 32CHANGING PARAMETER VALUES .................................................... 33

PROGRAMMING REFERENCE........................................................ 35

PURPOSE ...................................................................................... 35OVERVIEW..................................................................................... 35MANUAL GALVO CONTROLS WINDOW............................................. 36PART PARAMETERS WINDOWS....................................................... 39

PART PARAMETERS WINDOW – ONE ........................................ 39PART PARAMETERS WINDOW – TWO........................................ 46

SUPERVISOR PARAMETERS AND CONFIGURATION WINDOWS .......... 47SUPERVISOR: PARAMETERS WINDOW ...................................... 47SUPERVISOR: SINGLE MIRROR GRID CAL WINDOW................... 51SUPERVISOR: DUAL MIRROR GRID CAL WINDOW...................... 54

CALIBRATING THE GALVONOMETER................................................ 58MEASURING THE SCAN RADIUS ................................................ 58MEASURING AND CUTTING THE GRID PATTERN......................... 60WHEN TO KNOW ITS TIME TO STOP CALIBRATING....................... 63

INDEX................................................................................................ 65


Introduction 1


INTRODUCTION

PURPOSEThis guide was designed to provide operating and programming informationfor the AcuCam Laser Control Software designed by Preco Laser Systems.

OVERVIEWThe ACUCAM LASER CONTROL SOFTWARE USER GUIDE assumes the reader isfamiliar with Microsoft Windows® 2000 operating system.

GUIDE COMMENTSAt Preco Laser Systems, our policy is one of continuous improvement. Weappreciate your comments regarding the information in this guide. Afterreading this guide, if there is any information you feel to be incorrect, missingor difficult to understand, please contact us by using one of the followingmethods:

Preco Laser Systems, LLCService Department

500 Laser DriveSomerset, Wisconsin 54025

Voice: 715-247-3285Facsimile: 715-247-5650Sales: 1-800-77.LASERService: 1-800-799-2583Email: [email protected]: www.lasermachining.com

Please be as specific as possible when you submit a correction orsuggestion. Information such as guide title, revision date, section titles, pagenumbers and figure numbers make it easier for us to reference the materialwhen reading your comments. Preco Laser Systems makes the finaldecision as to what information, if any, is incorporated into a guide. PrecoLaser Systems appreciates the time you take to offer comments and willconsider all comments received.

mailto:[email protected]

www.lasermachining.com

User GuideAcuCam Laser Control SoftwareIntroduction 2

Product No.: 01007-100 © 2002 Preco Laser Systems, LLC. All Rights Reserved Issued: 09/25/02

HOW TO USE THIS GUIDEThe ACUCAM LASER CONTROL SOFTWARE USER GUIDE contains detailedinformation about using the AcuCam Laser Control Software. Read thisguide in its entirety before using the system. Information given in a previoussection may be needed to understand or complete a step in a subsequentsection.

HOW THIS GUIDE IS ORGANIZEDThe ACUCAM LASER CONTROL SOFTWARE USER GUIDE is designed to provideinformation on how to use and program AcuCam Laser Control Software.This guide is organized as follows:

• INTRODUCTION – This section provides a description of how this guideis designed, conventions used in the guide, reference informationand so on.

• SOFTWARE DESCRIPTION – This section provides an overview of theAcuCam Laser Control Software and its components.

• OPERATING INTERFACE – This section provides a description of theAcuCam Laser Control Software operating interface. It describes theAcuCam main screen regions and operator functions.

• OPERATING PROCEDURES – This section provides procedures for useractivities.

• PROGRAMMING REFERENCE – This section provides referenceinformation for laser processing modes and AcuCam Laser ControlSoftware programming functions.


Introduction 3


NOTATIONS AND CONVENTIONSSeveral different notations are used throughout this guide. For example, allreference to buttons, switches or indicators on the system will be indicated inthe text in BOLD INITIAL CAPITAL small capital letters.

Example:

The COOLANT interlock light will illuminate if….

STANDARD CONVENTIONSThe following table lists the text standard conventions used in this guide.

Convention Information

Bold Type Text we ask you to type appears inbold.

BOLD INITIAL CAPITAL SMALLCAPITAL LETTERS

All reference to buttons, switches orindicators on the system.

Initial Capital Letters All reference to the titles of screens andfields.

ITALIC INITIAL CAPITAL SMALLCAPITAL LETTERS

All reference to the titles of sections andguides.

Italic lower case letters Indicates a sample name or file name,for example, test.cfg.

MENU > PATH The greater-than sign (>) is used to givethe path for a drop down menu option,for example, FILE > SAVE AS.

User GuideAcuCam Laser Control SoftwareIntroduction 4

Product No.: 01007-100 © 2002 Preco Laser Systems, LLC. All Rights Reserved Issued: 09/25/02

MOUSE CONVENTIONSThe left mouse button is the one to use most of the time (unless you havethe mouse configured differently). The following terms are used in this guideto describe mouse pointer directives.

• Point means to position the mouse pointer so the tip of the pointerrests on whatever you want to point at on the screen.

• Click means to press and then immediately release the mousebutton without moving the mouse.

• Double-click means to press and immediately release the mousebutton twice without moving the mouse.

• Drag means to select and hold down the mouse button while movingthe pointer across the screen.

• Select means to highlight a word, line or paragraph by placing thepointer on the desired item and double-clicking or dragging.

RESISTIVE TOUCH SCREEN CONVENTIONSResistive touch displays provide excellent and accurate touch input throughtouching specific areas within the screen regions. The following terms areused in this guide to describe resistive touch directives.

• Press means to touch or press lightly on a specific item within aregion of an active matrix resistive touch screen.

• Select means to highlight a word or line by pressing on the desireditem.


Software Description 5


SOFTWARE DESCRIPTION

PURPOSEThis section provides an overview of the AcuCam Laser Control Softwaredesigned and developed at Preco Laser Systems.

For more information regarding the operating interface or programming, referto the OPERATING INTERFACE and PROGRAMMING REFERENCE sections in thisguide.

OVERVIEWAcuCam Laser Control Software provides a method for laser processingmaterial on a moving web. It simultaneously steers a laser beam(s) andcontrols laser power to score or cut patterns on a material. It is primarily for,but not limited to, cross-web processing applications (pattern is a straight orcurved line) and contour processing applications (beam is on continuously,processing a geometric shape on the material).

The AcuCam Control System is comprised of four main parts:

• Application software package operating on a PC in a Windows2000 environment, which acts as the user interface forprogramming and selecting the part processing parameters.

• PLS’s MPLC, which acts as the real time laser controller.

• Laser with Beam Delivery for processing.

• Steered beam (galvo) motion system

The AcuCam Laser Control Software includes the following main features :

• Operator interface for controlling the system.

• Usage of recipes for loading and saving part parameters.

• Usage of Set-Up parameters to define the operating characteristicsof the system.

• Scoring and cutting capability.

• Laser power control based on web velocity.

• I/O diagnostic capability.

• Alarming diagnostic capability

• Ability to run two galvo modules (running the same pattern) withindependent grid calibration.

User GuideAcuCam Laser Control SoftwareSoftware Description 6

Product No.: 01007-100 © 2002 Preco Laser Systems, LLC. All Rights Reserved. Issued: 09/25/02

OPERATIONAcuCam Laser Control Software can be configured to be operated in eithermaster or slave mode. Slave mode is defined as being controlled from alocal controller, such as a roll handler, using digital inputs and outputs toessentially start and stop the laser processing. In master mode, AcuCamhas control buttons built into the user interface that the operator uses tostart/stop the laser processing and, if desired, also the web.

OPERATING SYSTEMAcuCam Laser Control Software is designed to be utilized on Windows2000 operating systems. .

DISTRIBUTIONAcuCam Laser Control Software is distributed on a CD-Rom. Files must bemoved manually from the CD-Rom to the required directories for installation..


Software Description 7


HARDWARE ARCHITECTUREThe typical hardware layout for the AcuCam Laser Control System is shownin Figure 1 for a system with a single laser. The AcuCam Laser ControlSoftware, running on the Windows 2000 based computer, interfaces to theGalvo Controller through a USB connection. The Galvo Controller interfacesto the entire system. It has two functions,

• Controls the motion of the galvos

• Conducts the PLC logic for system operation through Digital I/O.

A RS232 Serial communication port is used to communicate to the MPLCfrom the Galvo Controller. The MPLC provides the laser control functionsthat are configured by the operator as part of the recipes. A laser isinterfaced directly to the MPLC. Web speed and distance are detected by theweb encoder and monitored by the MPLC and Galvo Controller to coordinatethe motion and laser power with the web.

A Roll Handler is optional for systems that are not integrated into thefactory’s web handling systems.

USB

DIGITAL I/O

DIGITAL I/OWEB

ENCODERROLL HANDLER

(OPTIONAL)

RS232

COMPUTERWINDOWS 2000

GALVOCONTROLLER

GALVO MOTION SYSTEM

LASER

MPLC

R

Figure 1. AcuCam Laser Control System – Hardware Architecture


Operating Interface 9


OPERATING INTERFACE

PURPOSEThis section describes the operating interface of the AcuCam Laser ControlSoftware in the Windows environment.

For more information about the AcuCam Laser Control Software, refer to theSOFTWARE DESCRIPTION section of this guide.

OVERVIEWThe AcuCam Laser Control Software provides operator and control interfaceto the system for programming and selecting the part parameters. .

The AcuCam Laser Control System operator interface includes the followingmain features:

• Provides an interface for controlling the system.

• Provides the use of recipe files for loading and saving partparameters.

• Provides I/O Diagnostics and System Status Capability.

• Provides Alarm Diagnostics.

• Provides a method to set the system configuration.

There are two levels of authority for the Operating Interface: Operator leveland Supervisor level.

Operator Level – This level does not require an access password. Thefollowing operations are available:

• Allows selection of previously programmed part recipe files.

• Allows execution of previously programmed part recipe files.

• Allows modification of parameter values within the previouslyprogrammed limits.

Supervisor Level – The following operations are available: .

• Allows selection of previously programmed part recipe files.

• Allows execution of previously programmed part recipe files.

• Allows part program recipe programming.

• Allows manual manipulation of the galvonometer.

For more programming information, refer to the PROGRAMMING REFERENCEsection of this guide.

User GuideAcuCam Laser Control SoftwareOperating Interface 10


ACUCAM MAIN SCREEN LAYOUTWhen the system starts, the initial screen displayed is main operator controlinterface. When AcuCam is loaded, the system defaults to Auto modeoperation.

MAIN SCREEN REGIONS - OPERATOR LEVELThe Operator level AcuCam main screen is shown in the following figure withthe Alarms window open. See ACUCAM MAIN SCREEN REGIONS later in thissection for a description of each field. .

Figure 2. AcuCam Main Screen with Alarms Window Open – Operator Level

SystemInformationRegion




RECIPE SELECT REGION – OPERATOR LEVEL

The RECIPE SELECT region for level OPER (operator), in AUTO mode,contains the RECIPE SELECT drop-down selection menu. This region is usedto select program recipes for execution.

Press the RECIPE SELECT down arrow and select the recipe to bedownloaded.

RECIPE REGION – OPERATOR LEVEL

The RECIPE region for level OPER (operator), in AUTO mode, contains theRECIPE DOWNLOAD button.

Press the RECIPE DOWNLOAD button to download the selected part recipe.



DIAGNOSTICS REGION – OPERATOR LEVEL

The DIAGNOSTICS region contains the ALARMS button and the I/O button.

Press the ALARMS button to display the alarm messages in the InformationDisplay region of the AcuCam main screen. See ALARMS WINDOW later inthis section.

Press the CLOSE ALARM button to close the alarms message and resolutionarea and return to the Main Screen. See ALARMS WINDOW later in thissection.

Press the I/O button to display the Input and Output diagnostics window.See INPUTS AND OUTPUTS WINDOW later in this section.




SYSTEM REGION - OPERATOR LEVEL

The SYSTEM region contains the EXIT button.

Press the EXIT button to close AcuCam.

When the EXIT button is pressed, the Confirm Action window is displayed.

Press the OK button to confirm your exit request.



PARAMETER REGION – OPERATOR LEVEL

The Parameter region contains data fields for Laser power adjustment, nameof the active recipe, number of patterns processed and the amount (distanceon the web/roll) of material processed.

Displays the percentage (%) of desired variation of the current powersetting programmed in the recipe. If enabled, press this field to display aSetpoint window. This Setpoint window allows the value to be changed to avalue within the laser power limit, which was set up by the Supervisor. SeeCHANGING PARAMETER VALUES in the OPERATING PROCEDURES section. SeePART PARAMETERS WINDOW in the PROGRAMMING REFERENCE section.

NOTE: Supervisor level is required to access the Part Parameterssetup window.

Displays the active part recipe name in the Galvo controller.

NOTE: If the RECIPE SELECT field displays a different recipe namethan the recipe name shown in this field, you must press theRECIPE DOWNLOAD button to activate your selection.

Displays the number of patterns (or parts) processed since the last time theRESET button was pressed.

Display the distance or amount of material processed in meters since thelast time the RESET button was pressed.




Press the RESET button to clear the count back to zero (0) for the NUMBEROF PATTERNS PROCESSED and the MATERIAL DISTANCE PROCESSED datafields.

SYSTEM INFORMATION REGION – OPERATOR LEVEL

The System Information region displays the alarms messages when theALARM button is pressed; otherwise, it is not displayed. See ALARMS WINDOWlater in this section for a description of the alarms.

MODE CONTROL BUTTONS REGION – OPERATOR LEVEL

The MODE control buttons region contains three buttons. These buttons areused in conjunction with the level of authority (Operator or Supervisor)currently logged into the system. See the following button descriptions fortheir functionality in the Operator level.

AUTO Mode is default mode when the system is powered up.

AUTO Mode allows the system to process parts. Additionally, when in thismode, selecting part recipes is allowed.

PROGRAM mode is not available for Operator level operations.

MANUAL mode is not available for Operator level operations.



PROGRAM CYCLE CONTROL BUTTONS REGION –OPERATOR LEVEL

The program CYCLE control buttons region contains three buttons. TheSTART and STOP buttons are used in Master Mode and are not enabled inSlave Mode. See the following button descriptions for functionality.

START Button

Master Mode:

• Button is enabled.

• When the START button is pressed, it turns green and initializes theprocessing. Depending on system configuration, it may also startthe roll handler.

Slave Mode:

• Button is disabled.

• The Start button is an indicator light. It turns green reflecting that thesystem is processing.

STOP Button

Master Mode:

• Button is active.

• When the STOP button is pressed, it turns red. The system willcontinue to process parts until the web has come to a stop.

Slave Mode:

• Button is not active.

• The STOP button is an indicator light. It turns red reflecting that thesystem is in a stop condition. When an external Stop is applied, thesystem will continue to process parts until the web has come to astop.

DRY RUN Button

DRY RUN button is not available for Operator level operations.




LEVEL REGION – OPERATOR LEVELThe LEVEL region contains one button. The label on this button indicates thelevel of authority currently logged into the system.

NOTE: In the Operator level of authority, the following functions aredisabled:

Cycle control button region: DRY RUN button.Mode region: PROGRAM mode and MANUAL mode.

When the button under the LEVEL region is pressed, the password dialogwindow is displayed.

Type in OPER, no password is necessary, and press the Ok button.



MAIN SCREEN REGIONS - SUPERVISOR LEVELThe Supervisor level AcuCam main screen is shown in the following figurewhen in PROGRAM mode. For AUTO mode, refer to Figure 2 to reference themain screen. See ACUCAM MAIN SCREEN REGIONS later in this section for adescription of each field. .

Figure 3. AcuCam Main Screen in Program Mode – Supervisor Level

SystemInformationRegion




RECIPE SELECT REGION (AUTO MODE) – SUPERVISORLEVEL

The RECIPE SELECT region for level SUPER (supervisor), in AUTO mode,contains the RECIPE SELECT drop-down selection menu. This region is usedto select program recipes for execution.

Press the RECIPE SELECT down arrow and select the recipe to bedownloaded.

RECIPE REGION (AUTO MODE) – SUPERVISOR LEVEL

The RECIPE region for level SUPER (supervisor), in AUTO mode, contains theRECIPE DOWNLOAD button.

Press the RECIPE DOWNLOAD button to download the selected recipe.



RECIPE SELECT REGION (PROGRAM MODE) – SUPERVISORLEVEL

The RECIPE SELECT region for level SUPER (supervisor), in PROGRAM mode,contains one (1) button, VIEW AND MODIFY PART PARAMETERS.

Press the RECIPE SELECT VIEW AND MODIFY PART PARAMETERS button todisplay the Part Parameters windows, which allows the Supervisor toprogram the part. See PART PARAMETERS WINDOWS in the PROGRAMMINGREFERENCE section of this guide.

CONFIG REGION (PROGRAM MODE) – SUPERVISOR LEVEL

The CONFIG region for level SUPER (supervisor), in PROGRAM mode,contains one (1) button, SETUP.

Press the SETUP button to display the supervisor Part Parameters windows,which allows the supervisor to change the system setup parameters. SeeSUPERVISOR PARAMETERS AND CONFIGURATION WINDOWS in the PROGRAMMINGREFERENCE section of this guide.

RECIPE SELECT REGION (MANUAL MODE) – SUPERVISORLEVEL

The RECIPE SELECT region for level SUPER (supervisor), in MANUAL mode isnot available.




CONFIG REGION (MANUAL MODE) – SUPERVISOR LEVEL

The CONFIG region for level SUPER (supervisor), in MANUAL mode is notavailable.

DIAGNOSTICS REGION – SUPERVISOR LEVEL

The DIAGNOSTICS region contains the ALARMS button and the I/O button.These buttons are accessible when in AUTO, PROGRAM and MANUAL modes.

Press the ALARMS button to display the alarm messages in the InformationDisplay region of the AcuCam main screen. See ALARMS WINDOW later inthis section.

Press the CLOSE ALARM button to close the alarms message and resolutionarea and return to the Main Screen. See ALARMS WINDOW later in thissection.

Press the I/O button to display the Input and Output diagnostics window.See INPUTS AND OUTPUTS WINDOW later in this section.



SYSTEM REGION - SUPERVISOR LEVEL

The SYSTEM region contains the EXIT button. This button is accessible whenin AUTO, PROGRAM and MANUAL modes.

Press the EXIT button to close AcuCam.

When the EXIT button is pressed, the Confirm Action window is displayed.

Press the OK button to confirm your exit request.




PARAMETER REGION – SUPERVISOR LEVEL

The Parameter region contains data fields for Laser power adjustment, nameof the active recipe, number of patterns processed and the amount (distanceon the web/roll) of material processed.

Displays the percentage (%) of desired variation of the current powersetting programmed in the recipe. If enabled, press on this field to display aSetpoint window. This Setpoint window allows the value to be changed to avalue within the laser power limit, which was setup by the Supervisor. SeeCHANGING PARAMETER VALUES in the OPERATING PROCEDURES section. SeePART PARAMETERS WINDOW in the PROGRAMMING REFERENCE section.


Displays the active part recipe name in the Galvo Controller.

NOTE: If the RECIPE SELECT field displays a different recipe namethan the recipe name shown in this field, you must press theRECIPE DOWNLOAD button to activate your selection.

Displays the number of patterns (or parts) processed since the last time theRESET button was pressed.

Display the distance or amount of material processed in meters since thelast time the RESET button was pressed.



Press the RESET button to clear the count back to zero (0) for the NUMBEROF PATTERNS PROCESSED and the MATERIAL DISTANCE PROCESSED datafields.

SYSTEM INFORMATION REGION – SUPERVISOR LEVEL

The System Information region displays the alarms messages when theALARM button is pressed; otherwise, it is not displayed. See ALARMS WINDOWlater in this section for a description of the alarms.




MODE CONTROL BUTTONS REGION – SUPERVISOR LEVEL

The MODE control buttons region contains three buttons. These buttons areused in conjunction with the level of authority (Operator or Supervisor)currently logged into the system. See the following button descriptions forfunctionality.

AUTO mode is default mode when the system is powered up.

When the AUTO button is pressed, selecting program recipes (Laser andPart) is allowed.

PROGRAM mode is used to program recipe files. Cycle Start is disabledwhile in PROGRAM mode.

When the PROGRAM button is pressed two (2) buttons are shown in theRecipe Select region of the main AcuCam screen:

• RECIPE SELECT VIEW and MODIFY PART PARAMETERS button. Whenpressed, the Part Parameters windows are displayed. See PartParameters Window in the Programming Reference section.

• CONFIG SETUP button. When pressed, the Supervisor: Parameterswindows are displayed. See Supervisor Parameters andConfiguration Windows in the Programming Reference section ofthis guide.

MANUAL mode is used to manually move the galvonometer to differentlocations.

When the MANUAL button is pressed, Manual galvonometer controls windowis displayed. See the MANUAL GALVO CONTROL WINDOWS in thePROGRAMMING REFERENCE section of this guide.



PROGRAM CYCLE CONTROL BUTTONS REGION –SUPERVISOR LEVEL

The program CYCLE control buttons region contains three buttons. TheSTART and STOP buttons are enabled and disabled as shown in the tablebelow. See the following button descriptions for functionality.

Cycle Start/Stop Buttons Master Mode Slave Mode

AUTO Enabled Disabled

PROGRAM Disabled Disabled

MANUAL Enabled Enabled

START Button

Master Mode:

• Button is enabled

• When the START button is pressed, it turns green and initializes theprocessing. Depending on system configuration, it may also startthe roll handler.

Slave Mode:

• Button is disabled.

• The START button is an indicator light. It turns green reflecting thatthe system is processing.

STOP Button

Master Mode:

• Button is active.

• When the STOP button is pressed, it turns red. The system willcontinue to process parts until the web has come to a stop.

Slave Mode:

• Button is not active.

• The STOP button is an indicator light. It turns red reflecting that thesystem is in a stop condition. When an external STOP is applied thesystem will continue to process parts until the web has come to astop.




DRY RUN Button

When the DRY RUN button is pressed, the LASER READY and MPLC READYalarms are ignored. This function allows the system to be tested and runwithout the laser operational. Additionally, the laser trigger and laser shutterare disabled.

LEVEL REGION – SUPERVISOR LEVEL

The LEVEL region contains one button. The label on this button indicates thelevel of authority currently logged into the system.

When the button under the LEVEL region is pressed, the password dialogwindow is displayed.

Type in SUPER in the User ID field, and type in your site assigned passwordin the Password field, then press the Ok button. The level button will displaythe level of authority currently logged into the system.



ALARMS WINDOWWhen the ALARM button is pressed, alarm messages are listed in theInformation Display region of the AcuCam main screen.In any mode (AUTO, PROGRAM or MANUAL) or level (OPERATOR orSUPERVISOR), press the ALARM button to display the alarm message andresolution area.

Figure 4. Alarms Window

DATE Displays the date of the alarm message.

TIME Displays the time of the alarm message.

CLASS Displays the type of alarm.

MESSAGE Displays the text of the alarm message.

This button is used to acknowledge all of the current alarms. It must bepressed before any alarms can be reset, with the RESET button.

When pressed, an attempt is made to reset all current alarms. If the alarmcondition associated with each alarm no longer exists, that alarm is cleared.Otherwise, if the condition still exists, the alarm remains.

Press the CLOSE ALARM button to close the alarm message and resolutionarea and return to the main screen.




ALARM MESSAGESThe following table describes alarms that are common to AcuCam systemsand other alarms that are dependent on your system configuration.

Alarm Message Description Resolution

Fatal: Emergency Stop System is in an emergency stopcondition.

Check for a depressed EmergencyStop (E-Stop) button.

Stop: Galvo Controller FlashMemory Error

Flash memory error in the GalvoController.

Power must be cycled to reset theGalvo Controller.

Stop: Galvo Controller DPRAMError

DPRAM error in the GalvoController.


Stop: Galvo Controller FirmwareChecksum Error

Checksum error in the GalvoController Firmware.


Stop: Galvo Controller MemoryChecksum Error

Checksum error in the GalvoController memory.


Stop: Galvo Controller Servo Error Servo error in the Galvo Controllerdue to an insufficient calculationtime to complete servo loops.


Stop: Galvo Controller Run-TimeError

Run-Time error in the GalvoController due to an insufficientcalculation time to complete amove in the recipe.

Depending on the Cut Timemethod programmed, eitherincrease the Time for the move ordecrease the Velocity of the move.

Stop: Roller Handler Not Ready Roll Handler is not ready. Check if the Roll Handler ispowered ON, or if the system is inemergency stop.

Stop: Laser Not Ready Laser is not ready. Check if the laser is powered ON,or if the system is in emergencystop.

NOTE: This alarm is ignored inDry Run mode.

Stop: AcuPower Not Ready Laser controller is not ready. Power must be cycled to reset theLaser Controller.

NOTE: This alarm is ignored inDry Run mode.

Stop: Web Speed Too High ToComplete Part

Web Speed is too fast to completethe part with the current recipe.

Either decrease the web speed orreprogram the recipe to completethe part in the time allotted.

Warn: AcuPower Download TimeOut

Timeout in the downloadingparameters to the Laser Controller.

Reset the alarm and trydownloading again.



INPUTS AND OUTPUTS WINDOWThis window displays the status of the Inputs and Outputs.

NOTE: The status cannot be changed from this window.

Figure 5. Inputs and Outputs Window

INPUTS This section displays the input status indicators. ON is displayed as green,and OFF is displayed as red.

OUTPUTS This section displays the output status indicators. ON is displayed as green,and OFF is displayed as red.

Press the DONE button to close this window and return to the Main Screen.


Operating Procedures 31


OPERATING PROCEDURESThis section describes the operating procedures and activities for theAcuCam Laser Control Software system.

STARTING ACUCAMWhen the system is powered ON, the system computer monitor powers upand Windows 2000® is loaded into the system. To start AcuCam,

1. Press the AcuCam Icon

2. The Select Cimplicity® Project window is displayed, press the STARTbutton.

The router window is displayed after starting AcuCam. This windowlists connections and then displays the AcuCam Main screen.

At this point, you may be required to login. If required to login,

a) Press the button below the LEVEL region to display theCimplicity® Login window.

b) Type in OPER.

c) Press the OK button, no password is required for operator levelsystem activities.

NOTE: There is a slight delay while AcuCam initiates communicationbefore the AcuCam main screen becomes active.

The system is now ready to start processing.

User GuideAcuCam Laser Control SoftwareOperating Procedures 32


SELECTING A RECIPETo select a recipe to process,

1. Press the down arrow in the RECIPE SELECT drop-down box todisplay the list of available recipes.

2. Highlight the desired recipe.

3. Press the DOWNLOAD button, to load the recipe into the system.

4. When the selected recipe name is displayed in the ACTIVE PARTRECIPE NAME field, the system is ready to process.

5. Press the START button (Master Mode), or the remote START button(Slave Mode) – to begin processing.


Operating Procedures 33


CHANGING PARAMETER VALUESOperator level of authority only allows modifying the Power Adjustmentparameter field.

To change the parameter value,

1. Press the POWER ADJUSTMENT field.

2. A Setpoint window will be displayed, this Setpoint window allows thisparameter to be changed to a value within the laser power limit thatwas set in the Part Parameters setup window. See PARTPARAMETERS WINDOW in the PROGRAMMING REFERENCE section.


3. Select the NEW VALUE field.

4. Type in the desired power level, or press the Up and Down arrows(Default or Alternate) to adjust the power level displayed in the NEWVALUE field.

5. Press the OK button to accept the change.


Programming Reference 35


PROGRAMMING REFERENCE

PURPOSEThis section provides programming reference information for the AcuCamLaser Control Software in a Windows 2000® environment.

OVERVIEWThe AcuCam Laser Control Software provides an operating interface to thesystem for programming laser operation modes, laser parameters settings,and system diagnostics.

The screens, windows and procedures described in this section requireSupervisor (SUPER) level of authority.

See MAIN SCREEN REGIONS – SUPERVISOR LEVEL in the OPERATING INTERFACEsection of this guide for a description of the fields displayed on this screen.

For more information about the operating interface, refer to the OPERATINGINTERFACE section of this guide.

Supervisor(SUPER) Levelof Authority

User GuideAcuCam Laser Control SoftwareProgramming Reference 36


For more information about the AcuCam Laser Control Software, refer to theSOFTWARE DESCRIPTION section of this guide.

MANUAL GALVO CONTROLS WINDOWThe Manual Galvo Controls window mode is used to manually move thegalvonometer to different locations. The supervisor (SUPER) level ofauthority and MANUAL mode must be selected to access this window. Thereis one (1) Manual Galvo Controls window.

The Manual Galvo Controls window is accessed by pressing the MANUALmode button.

Figure 6. AcuCam Manual Galvo Controls Window

ManualGalvoControlsRegion




The GO TO USER INPUT GALVO FIELD POSITION option lets you movethe galvo to any position in the galvo field. To execute the move,select this option and press the CYCLE START button. The CYCLESTART button momentarily illuminates green while the galvo ismoving to the position programmed.

The PROGRAM RECIPE option lets you cut a part recipe on a non-moving web for test purposes. Select this option and a part recipeand press the CYCLE START button. The part recipe is processedon the work surface. The CYCLE START button momentarilyilluminates green while the galvo is cutting the part recipe.

NOTE: The shutter opens automatically, the laser beam willtrigger while cutting the part recipe, and the shuttersubsequently closes after the part recipe is completed.

The NINE POINT GRID option lets you execute a nine point gridpattern for calibration of the galvo. Select this option and press theCYCLE START button The galvo will cut a nine point grid pattern onthe work surface. The CYCLE START button momentarily illuminatesgreen while the galvo is cutting the grid pattern.

NOTE: The shutter opens automatically, the laser beam willtrigger while cutting the nine point grid, and the shuttersubsequently closes after the part recipe is completed.

The CENTER option is a pre-programmed position for the galvo fieldcenter. Select this option and press CYCLE START button. Thegalvo will move to the center of the galvo field. The CYCLE STARTbutton momentarily illuminates green while the galvo is moving tothe center of the field.



IMPORTANT:If the system is a dual galvo system, frequently the rightgalvo is mirrored with respect to the left galvo. As a result,the right galvo positions will be mirrored with respect tothe left galvo. For example, the Top Left Position willphysically be the Top Right Position for right galvo and viceversa.

The TOP LEFT option is a pre-programmed position for theTop Left position of the galvo field. Select this option andpress CYCLE START button. The galvo will move to the TopLeft Corner of the galvo field. The CYCLE START buttonmomentarily illuminates green while the galvo is moving tothe top left of the field.

The TOP RIGHT option is a pre-programmed position for theTop Right position of the galvo field. Select this option andpress CYCLE START button. The galvo will move to the TopRight Corner of the galvo field. The CYCLE START buttonmomentarily illuminates green while the galvo is moving tothe top right of the field.

The BOTTOM LEFT option is a pre-programmed position forthe Bottom Left position of the galvo field. Select thisoption and press CYCLE START button. The galvo will moveto the Bottom Left Corner of the galvo field. The CYCLESTART button momentarily illuminates green while the galvois moving to the bottom left of the field.

The BOTTOM RIGHT option is a pre-programmed position forthe Bottom Right position of the galvo field. Select thisoption and press CYCLE START button. The galvo will moveto the Bottom Right Corner of the galvo field. The CYCLESTART button momentarily illuminates green while the galvois moving to the bottom right of the field.




PART PARAMETERS WINDOWSThe Part Parameters windows are used for programming part parametersvalues. The supervisor (SUPER) level of authority and PROGRAM mode mustbe selected to access these windows. There are two (2) Part Parameterswindows.

The Part Parameters windows are accessed by pressing the RECIPE SELECTVIEW AND MODIFY PART PARAMETERS button to display the Part Parameterswindows.

PART PARAMETERS WINDOW – ONE

Figure 7. AcuCam Part Parameters (Window 1)



The SELECT/SAVE TO PART NAME field displays the partname. Press the down arrow and select the recipe toview or modify.

The DISPLAYED/CHANGE PART NAME field displays the partname and allows part name changes. To change thecurrent Part Name, select the displayed name and type-inthe new name (up to 20 characters).

The WEB SPEED field displays the web speed reference thatis associated with the CUT TIME field (described later in thissection). When VARIABLE (as opposed to CONSTANT) isselected in the Cut Time Field, all of the programmedpoints use a time parameter (msec) instead of a velocityparameter for determining how much time the move for theassociated point is desired for processing. The time isbased on this WEB SPEED Field.

Normally, this parameter is set for the web speed at whichthe part is desired to be processed.




The SENSOR OFFSET field displays the sensor offset that isassociated with the TRIGGER field (described later in thissection).

When EYE-SPOT is selected for the TRIGGER field, thisparameter dictates the distance, or offset, from the sensorto the start of the cut pattern.

When DISTANCE is selected for the TRIGGER field, thisparameter dictates the distance between parts (or patterns)for when to repeat the cut pattern.

A minimum offset is desired since the minimum distance, oroffset, is used to anticipate the response of the galvo as theweb changes speed. For example, ramping up or rampingdown. To illustrate this point, on ramp up, once the eye-spot is sensed, and the web has moved the amountspecified in the sensor offset parameter, the galvo istriggered to cut a pattern. Since the response of the galvois fixed, at different web speeds the amount of web materialthat passes during the amount of fixed time it takes for thegalvo to respond varies, which would cause the start of thecut pattern to shift on web.

AcuCam compensates for this variance by triggering thegalvo sooner at higher web speed (anticipation) in order toaccount for the fixed response time of the galvo.

The minimum offset desired uses the WEB SPEED COMP(compensation) field in Set-Up and the maximum webspeed to calculate the minimum offset. It is up to you tocalculate the minimum value.

For most systems, the offset is large enough where theminimum is not an issue. If the pattern starts to driftupward of the web as the speed of the web increases(ramps up), then this parameter might be set to low.

Press the OK or CANCEL button to complete the operation.

• OK – Press the OK button to display the new value window.

• CANCEL – Closes the window and ceases the operation. .



Type-in the new value and press the OK button, or press the CANCEL buttonto close the window without changes. The SKIP button is not used.

The TRIGGER field is used to select the type of trigger touse to process a part. There are three (3) selectionsavailable, click on the drop-down box:

EYE-SPOT: An eye-spot is used as a trigger to startprocessing the part. One part is processed pereye-spot trigger.

DISTANCE: A distance increment is used to trigger thestart of a part. Each time the web moves thedistance programmed in the Sensor Offset field, apart is processed.

CONTINUOUS: The part is processed continuously.Once a part is completed, the next part is startedimmediately. If the CUT TIME field (describedlater in this section) is programmed for Constant,processing does not depend upon webmovement to process a part. If the CUT TIMEparameter (described later in this section) isprogrammed for Variable, web movement isrequired for part processing.

The X-OFFSET field offsets the pattern in the X-directionfrom the Bottom Left location of the galvo field. It isprogrammed in mm.

The Y-OFFSET field offsets the pattern in the Y-directionfrom the Bottom Left location of the galvo field. It isprogrammed in mm.




The CUT TIME field is used to select the type of CutMethod. There are two (2) selections available, click onthe drop-down box:

CONSTANT: With this parameter selected, the part cuttime is always constant regardless of web speed.Once the part program is commanded to execute,the cut time remains constant with only the in-linegalvo axis synchronized with the web position. Ifthe web is stopped, and the part program istriggered, the part program will still cut in the sametime amount of time.

VARIABLE: With this parameter selected, the part cuttime is indirectly synchronized (proportional) to theweb speed. As the web speed increases, the cuttime decreases. If the web is stopped, and thepart program is triggered, no cutting takes place,essentially the cut time is infinity. If the web startsmoving, the part will start to be processed, but willnot finish until the web moved the entire distancerequired to complete the part. Both galvo axesare synchronized to the web movement.

POINT The POINT field is read-only. This field lets you see whichpoint you are programming. There are a total of 20 pointsavailable on two the Part Parameters screens.

BEAM ON/OFF The BEAM ON/OFF field is used for laser beam control (Onor Off) for the associated point. Programming a 1 meansthe beam is on, while programming a 0 means the beam isoff.

∆ X (MM) The ∆X field is used to program the incremental x-distancemove for the associated point. This parameter isprogrammed in mm.

∆ Y (MM) The ∆Y field is used to program the incremental y-distancemove for the associated point. This parameter isprogrammed in mm.

ON DIST (MM) The ON DIST field is used for perforating. The ON DISTparameter is the distance that the laser beam will be ONduring a perforating cycle. This parameter is programmedin mm.

OFF DIST (MM) The OFF DIST field is used for perforating. The OFF DISTfield is the distance that the laser beam will be OFF during



a perforating cycle. This parameter is programmed in mm.

ON DELAY (MSEC) The ON DELAY field is used to set the delay in turning onthe laser beam, after the request for the beam has beencommanded. This value is used to compensate for thefollowing error (difference in commanded position versusactual position) in the galvos. The commanded positionleads the actual position. This delay is used tocompensate for following error by delaying the firing of thelaser beam so it more closely matches the position youprogrammed.

OFF DELAY (MSEC) The OFF DELAY field is used to set the delay at theassociated point for two (2) cases:

• Delay in turning off the laser beam at the end of apoint

• Delay in changing the laser parameters for the nextpoint

This delay is used to compensate for the following error(difference in commanded position vs. actual position) inthe galvos. The commanded position leads the actualposition. This delay is used to compensate for followingerror by delaying the turning off of the laser beam, ordelaying the change in laser parameters, so it moreclosely matches the position you programmed.

VEL (CONST) (M/S) The VEL (CONST) field is available only when CONSTANT isselected in the Cut Time Field (described earlier in thissection). This field is used to program the surface velocityof the cut for the associated point. This parameter isprogrammed in m/sec.

TIME (VAR) (MSEC) The TIME (VAR) field is available only when VARIABLE isselected in the Cut Time Field (described earlier in thissection). This field is used to program the time to performa cut for the associated point, at the web speedprogrammed in the WEB SPEED field. This parameter isprogrammed in msec.

LASER POWER (WATTS) The LASER POWER field is used to program the LaserPower to be used for the associated point. This parameteris programmed in watts.




Press the MORE button to display the second PartParameters window.

Press the SAVE & DOWNLOAD button to save the changesto the table as shown for the displayed part name, andthen it downloads the changes into the galvo controller.

Press the SAVE TABLE button to save the changes to thetable for the displayed part name, without downloading itinto the galvo controller.

Press the CLOSE button to close this window and return tothe main screen.



PART PARAMETERS WINDOW – TWO

Figure 8. AcuCam Part Parameters (Window 2)

The DISPLAYED PART NAME field displays the current partname for the displayed parameters.

Press the BACK button to return to the first parameterswindow.




SUPERVISOR PARAMETERS ANDCONFIGURATION WINDOWSThe Parameter and Configuration windows are used for programmingsystem parameter values and calibrating the galvonometer. The supervisor(SUPER) level of authority and Program mode must be selected to accessthese windows.

Press the Config Setup button to display these windows. There are three (3)Supervisor Parameters and Configuration windows.

SUPERVISOR: PARAMETERS WINDOWThe Supervisor Parameters window allows a supervisor to vary some to thesystem parameters to fine tune the system and to access the screens toperform grid calibration(s) for the galvos.



Figure 9. Supervisor: Parameters Window

The WEB SPEED GALVO COMP field is used as anadjustment to compensate for the response of the galvo. Itis essentially equal to the response time of the galvo.Since the response of the galvo is fixed, at different webspeeds the amount of web material that passes during theamount of fixed time it takes for the galvo to respondvaries, which would cause the start of the cut pattern toshift. AcuCam uses this parameter to adjust for thissituation.

The GALVO ORIENTATION (SINGLE MOVING MIRROR) field isonly used for single moving mirror systems. It is used toprogram the angle that the galvo is at with respect to the




web. This parameter is provided since this angle is systemdependent.

The MEASURE LASER POWER field is used to set theactual power of the laser, usually measured with apower puck. This field is particularly useful whensealed lasers are employed. Typically, over the life ofa sealed laser, the power output decreases. In order tomaintain the integrity of laser power parameters in thepart recipes, this parameter is used in conjunction withrated laser power and automatically adjusts the dutycycle of the laser to maintain the programmed settingsin the part recipe files. However, the maximumadjustment that can be achieved is the currentmaximum measured laser output power. Therefore, itis generally good practice to program the part recipelaser power to be less than the rated laser power inorder to allow for the degradation of laser over time.

NOTE: This option applies primarily to sealedlasers.

The WEB ENCODER RESOLUTION field is used to inputthe resolution of the encoder that is attached to one ofthe passive rollers on the web. If this parameter is notset correctly, cutting a straight line across the web(using only an x-direction move) with the CUT TIME fieldset at CONSTANT will cause the line to be cut at anangle.

The KEYING FREQUENCY field sets the frequency atwhich the laser is operated. Power control of the laseris accomplished by controlling the Duty Cycle of thelaser. This value is the frequency on which the DutyCycle is operating.



The POWER ADJUSTMENT TOLERANCE field, lets theSupervisor set the percentage (%) range of adjustmentallowable for the Power Adjustment % parameter onthe main screen. The value here is bi-directional, thatis, a value of 1% means a range of +/-1%.

Press the MORE button to display the Single Mirror GridCal window.

Press the SAVE button to save the changes to the tablefor the displayed part name, and then it downloads thechanges into the PMAC system.

Press the CLOSE button to close this window and returnto the main screen.




SUPERVISOR: SINGLE MIRROR GRID CAL WINDOWThe Supervisor: Single Mirror Grid Cal window is used for single mirror gridcalibration of the scan head field. .

Figure 10. Supervisor: Single Mirror Grid Cal Window

The SIDE field is used for a system with dual galvos toselect which galvo to conduct the grid calibration Thereare two (2) selections for a dual galvo system, Left andRight. If there is only one galvo in the system, then theLeft Side is normally used.

GridCalibrationRegion



The SCAN RADIUS field is used to set the working distance,which is the measurement (mm) of the distance from thebottom mirror of the Scan Head to the top of the worksurface.

The LASER POWER field is used to set the current laserpower (watts) when cutting the nine point grid calibrationpattern in MANUAL mode.

The D (distance) fields are used to enter in values aftermeasuring the cut grid and after generating a nine pointgrid pattern cut. These values can be entered either asnegative or positive values.

The Z-AXIS OFFSET field is used to adjust the focus of theZ-translator. For most galvo systems, adjustment is donemechanically since the Z-translator is mounted on amovable slide. For systems where the Z-translator is notmounted on a movable slide, this parameter is used toadjust the focus.

The RIGHT SIDE OFFSET field is used to aid in thealignment of the right galvo to the left galvo. The left andright galvos should physically be aligned as close aspossible. This parameter is used to fine tune thatalignment. Since it shifts the zero point of the entire field,it reduces the margin of the galvo field; therefore, it shouldonly be used for fine tuning the alignment, not adjustingfor gross misalignment.

Press the BACK button to display the Supervisor:Parameters window.

Press the MORE button to display the Supervisor: DualMirror Grid Cal window.

The TABLE button is used to generate the initial calibrationtable for the galvos based on the Scan Radius. The tableis generated by pressing this button. After the button isdepressed, the button momentarily turns yellow and theDistance fields (above) are filled in automaticallydisplaying the theoretical values expected for the field




size.

NOTE: Pressing the 9PT COR button erases anypreviously saved calibration.

The 9PT COR button is used to perform the nine pointcorrection. Once the initial calibration table is generated(see the TABLE button), a nine point grid pattern is cut andmeasured. Type-in the values into the Distance Fields,replacing the theoretical values. When pressed, thisbutton momentarily turns yellow, a nine point correction isperformed, and the Distance fields (above) are replacedautomatically with the theoretical values expected for thefield size based on the Scan Radius.

This process is iterative. Once a nine point correction isperformed, another nine point grid pattern is cut,measured and the values re-entered into the DistanceFields. This process continues until the field size is withindesired tolerance.




SUPERVISOR: DUAL MIRROR GRID CAL WINDOWThe Supervisor: Dual Mirror Grid Cal window is used for dual mirror gridcalibration of the scan head field.

Figure 11. Supervisor: Dual Mirror Grid Cal Window

The 9-Point Grid Calibration region displays the current values for the 9-Pointgrid. See CALIBRATING THE GALVONOMETER later in this section for moreinformation.

The SIDE field is used for a system with dual galvos toselect which galvo to conduct the grid calibration. Thereare two (2) selections for a dual galvo system, Left andRight. If there is only one galvo in the system, then theLeft Side is normally used.

9-PointGridCalibrationRegion




The SCAN RADIUS field is used to set the working distance,which is the measurement (mm) of the distance from thebottom mirror of the Scan Head to the top of the worksurface.

The LASER POWER field is used to set the current laserpower (watts) when cutting the nine point grid calibrationpattern in manual mode.

The X and Y Fields are used to enter in values aftermeasuring the cut grid after performing a nine point gridpattern cut. These values can be entered either asnegative or positive values.

The Z-AXIS OFFSET field is used to adjust the focus of theZ-translator. For most galvo systems, adjustment is donemechanically since the Z-translator is mounted on amovable slide. For systems where the Z-translator is notmounted on a movable slide, this parameter is used toadjust the focus.



The RIGHT SIDE X-OFFSET field is used to aid in alignment ofthe right galvo to the left galvo. The left and right galvosshould physically be aligned as close as possible. Thisparameter is used to fine tune that alignment in the x-axis.Since it shifts the zero point of the entire field, it reducesthe margin of the galvo field; therefore, it should only beused for fine tuning the alignment, not adjusting for grossmisalignment.

The RIGHT SIDE Y-OFFSET field is used to aid in alignment ofthe right galvo to the left galvo. The left and right galvosshould physically be aligned as close as possible. Thisparameter is used to fine tune that alignment in the y-axis.Since it shifts the zero point of the entire field, it reducesthe margin of the galvo field; therefore, it should only beused for fine tuning the alignment, not adjusting for grossmisalignment.

Press the BACK button to display the Supervisor: SingleMirror Grid Cal window.

The TABLE button is used to generate the initial calibrationtable for the galvos based on the Scan Radius. The tableis generated by pressing this button. After the button isdepressed, the button momentarily turns yellow and theDistance fields (above) are filled in automatically displayingthe theoretical values expected for the field size.

NOTE: Pressing the 9PT COR button erases anypreviously saved calibration.

The 9PT COR button is used to perform the nine pointcorrection. Once the initial calibration table is generated(see the TABLE button), a nine point grid pattern is cut andmeasured. Type-in the values into the Distance Fields,replacing the theoretical values. When pressed, this buttonmomentarily turns yellow, a nine point correction isperformed, and the Distance fields (above) are replacedautomatically with the theoretical values expected for thefield size based on the Scan Radius.

This process is iterative. Once a nine point correction isperformed, another nine point grid pattern is cut, measuredand the values re-entered into the Distance Fields. Thisprocess continues until the field size is within desiredtolerance.







CALIBRATING THE GALVONOMETERThe Supervisor Grid Cal windows and the Manual Galvo Controls windowsare used to calibrate the galvonometer. Supervisor level of authority isrequired to do this procedure.

MEASURING THE SCAN RADIUSThe measurement from the scan head to the work surface is the ScanRadius.

1. Press the PROGRAM mode button.

2. Press the CONFIG SETUP button to display the Supervisor setupwindows.

3. Press the button two times to display the Supervisor: DualMirror Grid Cal window.

4. Using a square ruler or tape measure, measure the perpendiculardistance from the center of the bottom mirror motor of the ScanHead to the top of the work surface.

NOTE: The scan head protective cover assembly may need to beremoved for this procedure. Re-install the cover assembly whenfinished.

5. Type in the distance measurement into the Scan Radius field.

6. Press the TABLE button to insert theoretical X and Y 9-Point gridvalues and generate a theoretical correction table.

7. Press the button to close the Supervisor: Dual Mirror Grid Calwindow.

8. Place a target sheet on the work surface.

9. Press the MANUAL mode button to display the Manual Galvo Controlswindow.




10. Select the NINE POINT GRID function by pressing the radio button nextto it.

11. Press the CYCLE START button to cut the grid.

12. Examine the grid cut. If cut is consistent, proceed to the MEASURINGAND CUTTING THE GRID PATTERN procedure. If the cut is notconsistent, it may be necessary to adjust the Laser Power.

a) Press the PROGRAM mode button.

b) Press the CONFIG SETUP button to display the Supervisor setupwindows.

c) Press the button two times to display the Supervisor: DualMirror Grid Cal window.

d) Adjust the Laser Power setting as per the inconsistency of thecut, lower setting if cut too deep or raise setting if not cutthrough.

NOTE: You may need to adjust the Scan Radius and generate a newtheoretical table if the measured field size does not closely match thecalculated field size.

e) Recut the grid – repeat Steps 7 through 11 until the grid isconsistent.



MEASURING AND CUTTING THE GRID PATTERNCalibration is accomplished by cutting a known grid pattern onto a cuttingfield and measuring nine test points from the center reference point (P5) onthe grid pattern. Figure 12 is an example of a 9-point grid (web direction isalways in the Y+ direction).

P4

P1 P2 P3

P6P5

P7 P9P8

X+

Y+ Y+

X+

Web

Dire

ctio

n

Left Side Right Side

Figure 12. 9-Point Grid Example




Measuring the grid pattern must be done as accurately as possible.Measurement equipment accuracy should be plus or minus .001 inches.Measurement errors directly affect the performance of grid calibrationsoftware. In this procedure, sample information is used to help explain theprocess of cutting and measuring the grid. Figure 13 illustrates an exampleof a measured plate.

Figure 13. Measured 9-Point Grid Example

Several methods of evaluating errors are possible using measuringequipment such as optical comparators or precision comparators.

The following method for error evaluation is recommended.

NOTE: More complex methods, including the use of digitizers torecord point-to-point spacing, are acceptable. However, if digitizersare used, they must be calibrated to ensure accurate measurement.

1. Align a measurement axis along a line that includes twomeasurement points, preferably along the longest distance ifmeasuring a shortened grid (that is, grid points P2 and P8 as shownin Figure 13).

2. Select the center reference point (P5) to be the origin and the zero ofyour measurement equipment.



3. Record all X and Y positions (reference points) on the 9-point grid.

4. Once all X and Y reference points have been measured andrecorded, type in the measurements into the appropriate fields onthe Supervisor: Dual Mirror Grid Cal window as shown in Figure 14.

NOTE: The values can be entered as either positive or negative(internally the absolute value is used).

Figure 14. Measured Dual Mirror Grid Cal Window Example

5. Check the grid values entered on the Supervisor: Dual Mirror GridCal window. If all values were entered correctly, press the 9PT CORbutton.

6. Press the button to close the Supervisor: Dual Mirror Grid Calwindow.

7. Place a target sheet on the work surface.

8. Press the MANUAL mode button to display the Manual Galvo Controlswindow.




9. Select the NINE POINT GRID function by pressing the radio button nextto it.

10. Press the CYCLE START button to cut the grid.

11. Examine the grid cut. If the grid was cut within acceptable limits, gridcalibration is complete. If not, repeat Steps 4 through 10 until grid iscut within acceptable limits.

WHEN TO KNOW ITS TIME TO STOP CALIBRATINGDepending on the accuracy needed and the field of view of thegalvanometer, the rule of thumb is to stop when the measurements arewithin 0.05% of the Field of View (FOV) or smaller.

Examples:

4 inches F.O.V. = 0.002 inches




NOTE: If a higher accuracy is needed, calibrating to within 0.001inches is possible, but internal/external influences will affect itsstability. The galvanometer motors, beam alignment stability andworksupport stability are all factors that may and will influence thefinal accuracy and repeatability of the system, better than the 0.05%of the field of view.


Index 65


INDEX

AAcuCam

Calibrating, 58Distribution, 6Levels of Authority, 9main features, 5Main Screen Layout, 10Operating Interface, 9Operating System, 6Operation, 4, 6Overview, 5typical hardware layout, 7

AcuCam Calibrating. SeeCalibrating

AcuCam Main ScreenLayout, 10, 18Operator Level, 10Regions, 10, 18Supervisor Level, 18

AcuCam Main Screen RegionsConfig, 20, 21Diagnostics, 12, 21Level, 17, 27Mode Control Buttons, 15, 25Parameter, 14, 23Program Cycle Control, 16, 26Recipe Select, 11, 19, 20System, 13, 22System Information, 15, 24

AcuCam Screens. See AcuCamWindows

AcuCam WindowsConfiguration Window, 47Manual Galvo Controls

Window, 36Part Parameters Window, 39,

46Part Parameters Window 1, 39Part Parameters Window 2, 46Supervisor Dual Mirror Grid Cal

Window, 54Supervisor Parameters

Window, 47Supervisor Single Mirror Grid

Cal Window, 51

CCalibrating

AcuCam windows, 58Cut grid pattern, 60Cutting the grid, 59Distance fields, 52Dual Mirror Grid Cal window, 54Error evaluation, 61Measure grid pattern, 61Measure the scan radius, 58Measured Grid example, 61Nine point grid button, 53, 56Nine Single Mirror Grid Cal

window, 51Scan Radius field, 58Select the Nine point grid, 59X and Y fields, 55

Calibrating:, 60Config Region

Manual Mode, 21Program Mode, 20Setup Button, 20, 21Supervisor Level, 20, 21

DDiagnostics

Alarm Button, 12, 21Close Alarm Button, 12, 21I/O Button, 12, 21

Diagnostics RegionButtons, 12, 21Operator Level, 12Supervisor Level, 21

LLevel Region

Buttons, 17, 27Level Region

Level Button, 17, 27OPER Login, 17Operator Level, 17Operator Login, 17SUPER Login, 27Supervisor Level, 27Supervisor Login, 27

Levels of AuthorityOperator Level, 9Supervisor Level, 9

Levels of AuthoritySUPER, 35Supervisor, 35

MManual Galvo Controls Window,

36Field descriptions, 37, 38Screen layout, 36

Manual Galvo Controls WindowHow to access, 36

Mode Control Buttons RegionAuto Button, 15, 25Buttons, 15, 25Manual Button, 15, 25Operator Level, 15Program Button, 15, 25Supervisor Level, 25

Mouse Conventions, 4

OOperator Level of Authority, 9

PParameters Region

Active Part Recipe Name, 14,23

Material Distance Processsed,14, 23

Number of Patterns Processed,14, 23

Operator Level, 14Parameters, 14, 23Power Adjustment, 14, 23Reset Button, 15, 24Supervisor Level, 23

Part Parameters Window, 39, 46Part Parameters Window

How to access, 39Part Parameters Window 1

Beam On/Off, 43Button descriptions, 44Cut Time, 43Field descriptions, 40, 43How to access, 46Laser Power, 44Off Delay, 44Off Dist, 43On Delay, 44On Dist, 43

User GuideAcuCam Laser Control SoftwareIndex 66


Point, 43Sensor Offset, 41Time for cut, 44Trigger, 42Velocity, 44Web Speed, 40X-Offset, 42Y-Offset, 42

Part Parameters Window 2Button descriptions, 46Field descriptions, 46

Part Parameters Window 2How to access, 44

Program Cycle Control RegionButtons, 16, 26Dry Run Button, 16, 27Operator Level, 16Start Button, 16, 26Stop Button, 26Supervisor Level, 26

RRecipe Region

Auto Mode, 19Download button, 11, 19Operator Level, 11Supervisor Level, 19

Recipe Select RegionAuto Mode, 19Manual Mode, 20Operator Level, 11Program Mode, 20Supervisor Level, 19, 20

Resistive Touch Screen, 4conventions, 4

SSupervisor Dual Mirror Grid Cal

Window, 54Button descriptions, 56Field descriptions, 54, 55Grid Calibration region, 54How to access, 52laser Power, 55Right Side X Offset, 56Right side Y Offset, 56Scan Radius, 55X and Y fields, 55Z-Axis Offset, 55

Supervisor Level of Authority, 9Supervisor Parameters Window

Button descriptions, 50Field descriptions, 48, 49, 50Galvo Orientation, 48

How to access, 47Keying Frequency, 49Measured Laser Power, 49Power Adjustment Tolerance,

50Web Encoder Resolution, 49Web Speed Galvo Comp, 48

Supervisor Single Mirror Grid CalWindow, 519-Point Grid Button, 53, 56Button descriptions, 52, 53, 56Distance, 52Field descriptions, 51, 52How to access, 50, 56Laser Power, 52Right Side Offset, 52Scan Radius, 52Side, 51Z-Axis Offset, 52

System Information RegionOperator Level, 15Supervisor Level, 24

System RegionExit Button, 13, 22Operator Level, 13Supervisor Level, 22

AcuCam Laser Control Software User Guide v1!00!00 9-25-02

Documents

express written

previously

shutter subsequently

shutter opens

9pt cor button

insufficient

initial calibration

saving part