WORKING ZONE

MANAGEMENT
USER’S MANUAL

October 2007
Document UWZ-01-V1.00-07EN
Table of contents
INTRODUCTION........................................................................................................................... 3
Hardware solution.................................................................................................................. 3
Input signals.....................................................................................................................................3
Output signals..................................................................................................................................4
Working zones....................................................................................................................... 4
Parking zone.......................................................................................................................... 4

OPERATION ................................................................................................................................. 4
Functions of the buttons ........................................................................................................ 7
Parking ......................................................................................................................................... 7
Preparation of cutting ................................................................................................................. 7
Selection of applied technology............................................................................................. 8
Selection of parameter group ................................................................................................ 8
Selection of tool parameters.................................................................................................. 9
Selection of cutting program................................................................................................ 10
Selection of starting point .................................................................................................... 11
Plate detection setting ......................................................................................................... 12
Automatic mode ........................................................................................................................ 14
Manual interventions in automatic mode ............................................................................... 17
Servicing mode.......................................................................................................................... 18
Error messages ......................................................................................................................... 18
Status information..................................................................................................................... 19

FULL AREA OPERATION.......................................................................................................... 19

Metal sheet detection ................................................................................................................ 20
Plate detection function buttons ............................................................................................. 23
Error messages of plate alignment ......................................................................................... 23

LIST OF FIGURES...................................................................................................................... 24
Introduction
This manual is a supplement to MSNC500 User’s Manual and describes features and
usage of working zone management panel.
Special extension of MSNC500 software implements functions preventing collision of
machine gantry and loading crane. It performs synchronization of the cutting machine
and external crane employed for handling metal sheets. Machine control system
evaluates actual position and operating mode of the machine and checks for the
signals indicating actual location of the crane. Based on this information, the control
system appropriately interlocks cutting machine or crane.
An example of a machine layout that uses the extension is given in Fig. 1.
Zone B Zone A
Parking zone

x 0
y

Fig. 1. Example of machine layout with illustration of working zones

Working area of the machine is in X-direction logically divided into three sections
referred to as “Zone A”, “Zone B”, and “parking zone”. Main idea of the system is to
prevent crane entering the zone when the cutting machine is in operation.
Working zone manager can be used in several modes:

Automatic mode (default mode, interlocking of machine and crane, crane
access can be modified manually)

Servicing mode (interlocking function by-passed)

Hardware solution
From a hardware point of view, the corresponding signals are evaluated and processed
by a dedicated I/O module 33COMMIX. The module uses two input and two output
channels:

Input signals

Crane present in “Zone A”

Crane present in “Zone B”

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Output signals

Enable crane in “Zone A”

Enable crane in “Zone B”
The module is physically located in the machine control box.

Working zones
The machine co-ordinate system is absolute with respect to co-ordinate system origin.
The zones define limits of permitted working area. Necessary a-priori condition for the
correct system function is that the machine must be initialized. Initialization is
necessary because the control system starts to use co-ordinate system only after
machine zero (co-ordinate system origin) is detected and set.

Parking zone
Parking zone is a short zone between “Zone A” and “Zone B” and is used for parking
the machine gantry. When the gantry is in the parking zone, the control system
disables both working zones for machine and thus releases machine working area for
any manipulation works.

Operation
Working zone management screen is accessible from MSNC500 (“F3 Cutting machine
→ F6 Status window and desktop setting”) as illustrated in Fig. 2.

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Fig. 2. Screen layout of status window and desktop setting menu
In the menu, <F4> button displays working area layout and window on the left side
screen indicates status of working zone manager and provides function buttons for
operator intervention (Fig. 3). The window is vertically divided into three sections, the
first two sections are used for working zones, bottom section includes the button for
parking and buttons for switching between servicing mode and normal operation mode.
Items appearing in the zone management window are explained in Fig. 4.

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 Working zones A and B

Move to parking zone

Enter servicing mode

Normal mode

Mode status information

Fig. 3. Default screen of the working zone manager after start-up

Start program button

Zone access information Change crane access

Actual zone status Actual technology

Cutting program path Parameter group

Starting point Actual tool

Start. point co-ordinates Plate alignment options

Fig. 4. Explanation of control panel elements

Meaning of actual zone status (Fig. 4) is as follows:
Machine is cutting in the zone, in the automatic mode the zone is locked
for the crane
Zone is ready for cutting, prepared cutting program can be run
immediately after currently running program is completed
Zone is free for any operation e.g. loading

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Functions of the buttons
Functions of the individual buttons are explained in Fig. 3 and Fig. 4. The function
button in Fig. 4 referred to as “Start program button” has meaning “set task to ready-to-
run CNC program” status.

Parking
Machine gantry is moved to the parking zone using “Move to parking zone” button (see
Fig. 3). An example given in Fig. 5 illustrates the situation when the machine gantry is
in the parking zone. As mentioned above “Zone A” and “Zone B” are now locked for the
machine gantry.

Fig. 5. Machine in the parking zone

Preparation of cutting
In order to save time, the system supports simultaneous cutting or marking in one zone
and preparation of cutting for another zone. Preparation procedure normally includes:
1. Selection of applied technology (Fig. 6)
2. Selection of parameter group (Fig. 7)
3. Selection of tool parameters (Fig. 8)
4. Selection of cutting plan (Fig. 10)
5. Selection of starting point (Fig. 11)
6. Plate detection setting (Fig. 13)

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Selection of applied technology
In case when the machine includes several technologies, it is possible to define the
technology that will be applied in subsequent cutting or other way of sheet processing.
The machine supports usage of more technologies within single CNC program. In such
cases, for each technology an appropriate parameter group and tool parameter should
be separately set prior starting a CNC program. An example in Fig. 6 illustrates the
case when the machine includes high-definition plasma and writing tool.

Fig. 6. Technology selection

Selection of parameter group

Provided that the machine supports usage of different parameters groups, it is possible
to select one of available groups. For example, for a machine with plasma bevel cutting
head it is possible to select parameter group for straight cutting, bevel cutting, marking,
or punching (Fig. 7).

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Fig. 7. Tool parameter group selection

Selection of tool parameters

For particular type of sheet material, thickness, quality, plasma current settings, and
other criteria, it is possible to select corresponding tool parameters from existing tool
parameters database. For editing line a filter is applied so when some characters from
tool parameter identification name are entered, only limited list of available parameters
is displayed. Displayed list contains only parameter names that contain entered
characters. Parameter names that do contain entered string of characters are not
displayed. For example, when cutting a metal sheet with 10 mm thickness, characters
“10.0” are entered and the situation looks like in Fig. 8.

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Fig. 8. Tool parameter name selection
In case when entered string of characters is not found in any parameter name in
corresponding tool database, the panel looks like in Fig. 9.

Fig. 9. No tool found that matches entered string of characters

Selection of cutting program

Cutting program is selected in usual way as described in machine User’s Manual.
Program selection screen is displayed in Fig. 10. When the CNC program is selected, it

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is first compiled and provided it does not contain any errors detectable by the compiler,
it is loaded into the job queue.

Fig. 10. Program selection

Selection of starting point

There are several options how to select a starting point of the program. Co-ordinates of
the starting point are set according to following methods (Fig. 11):

Start from current position

Start from reference point No. 1

Start from reference point No. 2

Start from reference point No. 3

Start from reference point No. 4

Start from co-ordinates
Start from current position is obvious. It is possible to use one of four user-defined
reference points (menu “F3 Cutting machine → S2 Reference points”). For X-co-
ordinates of the starting point for direct entering of the starting point co-ordinates it is
important to respect the fact that work in the zones is given by absolute machine co-
ordinates and thus specification of the starting point outside of the current zone results
in corresponding error message.

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Fig. 11. Selection of future starting point

Plate detection setting

Another useful tool for increasing the efficiency of preparation of a cutting task is a
plate detection function. Plate detection is started in the neighbourhood of the starting
point of cutting program.
There are four options of plate alignment based on results achieved by sheet detection
module:
1. No plate alignment
2. Plate alignment – corner only
3. Plate alignment – corner, angle
4. Plate alignment – corner, angle, size
The first option means no sheet detection at all. The second option defines the
detection of sheet corner only and serves for automatic adjustment of program starting
point. This option does not perform rotation of the cutting plan. The third option besides
adjustment of starting point also computes rotation angle of cutting plan and aligns the
plan according to edges of the sheet. The last option also checks for sheet dimensions,
reference dimensions are defined in cutting program according to settings in Asper
CAM software. Sheet dimensions are automatically identified form “SHEET_DIM …”
item in the program source code (see example listing of CNC program in Fig. 12).
Permitted tolerance of sheet dimensions is set in machine parameters (ParamCNC
servicing tool, “Find plate → Plate size tolerance” item).

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Fig. 12. CNC program listing with sheet dimension information
When sheet dimensions are not present in the program source code, it is possible to
set them independently in “Plate detection” screen (“F3 Cutting machine → F6
Automatic mode settings → S10 Plate alignment parameters”).

Fig. 13. Plate detection options

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Automatic mode
Automatic mode is a default operating mode of the machine. After machine start-up,
the system enters automatic mode.
After loading a plate to the corresponding zone, operator selects CNC program and a
set of parameters. To activate the job, “Start program” button should be pressed. The
job becomes active, corresponding zone is locked for crane operation and when the
machine is ready, the CNC program is started. If there is a cutting job running in
another working zone, “Start program” button just sets the current job into “Ready-to-
cut” status. After cutting job in another zone is finished, crane operation in another
zone is enabled, and current job is automatically started.
Note: After cutting job has been prepared and “Start program” button has been already
pressed, it is still possible to cancel (deactivate) the job by pressing “Start program”
button again.
Attached pictures present several typical situations. The first screenshot of the control
panel (Fig. 14) represents situation when cutting machine gantry works in “Zone A”. In
this case “Zone A” is locked for the crane. “Zone B” is prepared for cutting and cutting
can start immediately after cutting in “Zone A” is completed. Crane operation in “Zone
B” is enabled.

Fig. 14. Cutting in progress in “Zone A”, “Zone B” is ready for cutting
The second screenshot (Fig. 15) represents another situation. The cutting machine
gantry works in “Zone A”, the zone is locked for the crane. “Zone B” is free for any
manipulation. Crane operation in “Zone B” is enabled.

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Fig. 15. Cutting in progress in “Zone A”, “Zone B” is free for any manipulation
The third example illustrates the situation when the machine is cutting in “Zone B” and
“Zone A” is free for any manipulation using the crane that is present in “Zone A”

Fig. 16. Cutting in progress in “Zone B”, “Zone A” is free for any manipulation
The last situation is when no cutting in the zones is in progress and the machine gantry
or the crane is present in any zone. For example, the machine gantry is in “Zone A”.
Both zones are free for manipulation but locked for crane entry. The situation depicted
in Fig. 17 corresponds to a situation after system start-up or when the machine is not
initialized.

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Fig. 17. Machine in “Zone A”, no cutting task is running
An example sequence of cutting first in the “Zone A” and then in “Zone B” is depicted in
Fig. 18. Displayed screenshots include initial state, cutting in “Zone A”, cutting in “Zone
A” with cutting job prepared for “Zone B”, and cutting in “Zone B”. The example does
not contain pictures of intermediate steps related to preparation of both cutting jobs.

Fig. 18. Example of typical task sequence (excludes steps of cutting task preparation)
Situation when the crane is present in “Zone A” is illustrated in Fig. 19. In this case,
“Zone B” is free for the machine.

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Fig. 19. Crane present in “Zone A”, “Zone B” is free for the machine

Manual interventions in automatic mode

After initialization the machine enters automatic mode and check positions of the
machine gantry and the crane with respect to working zones. Then it is possible to
modify access permissions for the crane “manually”, i.e. release or lock the zone for
crane operation by pressing a button on the control system screen.
The zone can be released for crane operation only when the machine gantry is
positioned out of the zone. Releasing zone for crane operation means that “Crane
enable” signal is activated and software limits for the machine motion are modified so
that the gantry cannot enter the corresponding zone. Locking the zone for crane
operation means that “Crane enable” signal is deactivated and software limits are
modified to enable the machine to enter the zone. The zone can be locked for crane
operation only if the “Crane present” signal is off. When the zone is locked for crane
operation and “Crane present” signal is active, the machine stops and issues an error
message.
Control panel screenshot in Fig. 20 depicts a situation when crane operation in “Zone
A” is manually enabled, “Zone B” remains locked for the crane.

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Fig. 20. Manual enabling of crane

Servicing mode
Servicing mode is used when operating personnel performs any operation on the
machine. In this mode, complete status information is displayed on the computer
screen but no interlocking functions are applied.
Note: Crane presence in the zone is not evaluated by the system and thus operating
personnel is fully responsible for meeting necessary safety requirements.

Error messages
Possible error messages generated by working zone manager are summarised bellow

Area is locked for machine by crane

Crane inside machine area MACHINE COLLISION!

Area is locked for crane by machine position

Machine is not initialized

Crane inside machine area
Meaning of the messages is obvious.

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Fig. 21. Service mode

Status information
Actual situation is evaluated by the control system and status information is displayed
for either working zone. Status messages are summarised bellow:

Area is locked for machine by crane

Crane inside machine area MACHINE COLLISION!

Area is locked for crane by machine position

Machine is not initialized

Crane inside machine area

Full area operation

The system enables to utilise also complete working area of the machine for cutting
metal sheets that exceed the dimensions of the zones. This feature can be used by
selecting and starting CNC program in standard way, i. e. via “F3 Cutting machine →
F3 Load, compile and transfer NC program” and “F3 Cutting machine → F5 Run NC
program” menu items.
Note: After system start-up, crane operation in both working zones is disabled by
default. Later, it is strongly recommended to disable crane in both zones manually from
the working zones control panel.

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Metal sheet detection can be used also in this mode. Parameters and settings for metal
sheet detection system are accessible in MSNC500 (“F3 Cutting machine → F6
Automatic mode settings → S10 Plate alignment parameters”).
Note: Plate detection described in this section is used only for full working area
operation. For cutting in the working zones (NC program loaded and run as described
in section “Preparation of cutting”) plate detection settings are accessible in the control
panel for working zones management.

Metal sheet detection

Metal sheet detection is a tool that detects actual position of metal sheet and the result
is automatic setting of program starting point. The system is applicable only for
rectangular sheets.
There are four options of plate alignment based on results achieved by sheet detection
module:
1. No plate alignment
2. Plate alignment – corner only
3. Plate alignment – corner, angle
4. Plate alignment – corner, angle, size
The first option means no sheet detection at all. The second option defines the
detection of sheet corner only and serves for automatic adjustment of program starting
point. The third option besides adjustment of starting point also computes rotation
angle of cutting plan and aligns the plan according to edges of the sheet. The last
option also checks for sheet dimensions, reference dimensions are defined in cutting
program according to settings in Asper CAM software.

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Fig. 22. Main menu of plate detection
Following examples illustrate case for two cases: the first case (Fig. 22) defines starting
point for sheet detection given by user reference point No. 4 and results in offset of the
cutting program starting point on basis of sheet corner detection results. The second
example (Fig. 24) performs no detection and therefore no alignment.

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Fig. 23. Editing plate detection

Fig. 24. No detection

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Plate detection function buttons
Button Function
F2 Move up in detection mode options
F3 Move up in starting point definition options
F4 Edit X-co-ordinate of user defined starting point
F5 Edit X-dimension of metal sheet
F9 Reset to default settings
F10 Apply settings
F12 Quit menu to upper level
S2 Move down in detection mode options
S3 Move down in starting point definition options
S4 Edit Y-co-ordinate of user defined starting point
S5 Edit Y-dimension of metal sheet
S12 Clear error message

Error messages of plate alignment

The list of error messages of plate alignment contain messages that can be generated
during plate detection procedure:

Cannot do measuring movement

Cannot move to ref. measuring point

Sensor cannot detect plate

Sensor cannot find edge of plate

Math error

Error plate length

Error plate width

Error plate dimensions

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List of figures
Fig. 1. Example of machine layout with illustration of working zones............................. 3
Fig. 2. Screen layout of status window and desktop setting menu................................. 5
Fig. 3. Default screen of the working zone manager after start-up ................................ 6
Fig. 4. Explanation of control panel elements................................................................ 6
Fig. 5. Machine in the parking zone .............................................................................. 7
Fig. 6. Technology selection ......................................................................................... 8
Fig. 7. Tool parameter group selection.......................................................................... 9
Fig. 8. Tool parameter name selection........................................................................ 10
Fig. 9. No tool found that matches entered string of characters .................................. 10
Fig. 10. Program selection .......................................................................................... 11
Fig. 11. Selection of future starting point ..................................................................... 12
Fig. 12. CNC program listing with sheet dimension information .................................. 13
Fig. 13. Plate detection options................................................................................... 13
Fig. 14. Cutting in progress in “Zone A”, “Zone B” is ready for cutting ......................... 14
Fig. 15. Cutting in progress in “Zone A”, “Zone B” is free for any manipulation ........... 15
Fig. 16. Cutting in progress in “Zone B”, “Zone A” is free for any manipulation ........... 15
Fig. 17. Machine in “Zone A”, no cutting task is running.............................................. 16
Fig. 18. Example of typical task sequence (excludes steps of cutting task preparation)
................................................................................................................................... 16
Fig. 19. Crane present in “Zone A”, “Zone B” is free for the machine .......................... 17
Fig. 20. Manual enabling of crane............................................................................... 18
Fig. 21. Service mode ................................................................................................. 19
Fig. 22. Main menu of plate detection ......................................................................... 21
Fig. 23. Editing plate detection.................................................................................... 22
Fig. 24. No detection................................................................................................... 22

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