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NCPLUS 2000

Version 6.11

Copyright © 1988, 2007 by Gil Hagiz
Last updated Jan-17-2007

Introduction

NCPLUS is an 8-axis Computerized Numerical Control software package, for high speed, high accuracy, machine tools.
NCPLUS platform is Pentium 300 MHz or better PC, running Dos or Win98.

The design goal has been to develop a modular and flexible control that will not be obsolete the moment it leaves the factory.
That goal is achieved by providing the machine builder with all the necessary tools for tailoring his exclusive suit.

Why NCPLUS?

• NCPLUS is hardware independent.
  Various servo controllers (e.g. Delta Tau®), displays, digital and analog I/O's and third party boards can be used without software modification, since they are controlled by device drivers. NCPLUS can also run on a desktop, for offline programming.
• NCPLUS handles huge files.
  NC files: up to 3,000,000 lines.
  Programs can chain other programs, indefinitely.
• NCPLUS is Fast.
  Compilation of part-program produces a lightning fast code, instead of a slow interpretation.
  With a 300 MHz Pentium, block processing time is 0.025 msec (40,000 block per second). Feedrate is up to 32000 mm/sec (1250 ipm).
  Positioning is up to 64000 mm/sec (2500 ipm)
• NCPLUS does Networking.
  Current networks are 1000 times faster (and counting) than RS-232, so that no data starvation or machine hesitation occurs.
• NCPLUS is Simple.
  English is used in place of obscure, vendor-specific, G-codes. (The good old ones are still in use). A part-program can include BASIC statements, mixed with NC data.
• NCPLUS is a Computer language.
  While it excels at high speed machining, it can also be used for any computing task:
  Math, data collection, testing, simulations, and more.
• NCPLUS is configurable.
  The machine builder is in full control of:
  Machine specific data.
  Programmable G and M codes.
  Internal PLC, programmable keys, switches and timers.
  Screen layout - what and where is displayed.
  Multi level and logged user access, by name and password.
  Dialogs, help screens and error messages.
• NCPLUS is an Integrated Development Environment.
  All in one: Editor, Compiler, PLC, Testing and Debugging aids, everything required for writing applications. Screen dumps can be used for the operator's manual. (They are used in this website).

Description

General

NCPLUS is a versatile CNC software based on CNC development experience since 1975.
The language is an extended NC letter-address standard RS-274-D, (N, G, M, etc.) which includes additional commands in BASIC, such as IF, THEN, ELSE, GOTO, and other words such as ON, OFF, BLUE, PITCH, REPEAT (more than 280 words in plain English).

Features

In addition to conventional CNC functions it performs:

• High speed, high accuracy machining - 80 smart look ahead buffers (about 80 mm).
• Eight axis linear, circular and helical simultaneous interpolation.
• Polar and spherical coordinates, azimuth-elevation / pitch-yaw and roll.
• Look-ahead cutter radius compensation, chamfering and automatic rounding of any corner.
• User defined canned cycles, G and M codes.
• Subroutines, functions, loops, chaining and calling programs.
• Built-in menu generator and data entry to create conversational programs.
• Color graphic display, powerful multi-window editor.
• Common computer chores: number crunching, text and file processing, screen manipulation.
• PLC, implemented in software, runs in the background.

Compiler

NCPLUS compiles a user program and produces a machine code file, instead of interpreting each block while cutting. That means that all syntax and typing errors are detected before the actual cutting begins.
In addition, it takes less than 25 micro-second to process a block, while other high speed control builder are proud with 1 milli-second for the same.
(Test conditions: 300 MHz Pentium, sequence of blocks with N and X,Y,Z)
The time is saved because the compiler translates decimal numbers into binary format and replaces all Goto line numbers with absolute memory addresses.

High Speed

Processing speed of 40,000 block/sec doesn't ensure high speed machining.
A few factors affect high speed machining, all of them are handled by NCPLUS.

• Data starvation (hesitation)
  This occurs when, in the middle of a high speed motion, the control needs more processing time for one or more blocks. If the current motion ends before new data is available the servos stop for a split second, then continue. Just by reading this you can feel how the machine vibrates. NCPLUS avoids this condition by buffering. Operations that may be slow are buffered so their average time affects the speed rather than their worst time. Now even with buffering, what if the next move is delayed for a few seconds, such in the case of a network? The answer is that in addition to buffering the network, the feedrate is reduced gradually when the buffer is not full and deceleration is never greater than a preset value.
• Corners
  In sharp corners the feed should decelerate to zero. In dull corners, like those in contouring, deceleration is undesired. In the good old days the servo gain took care of corners, but that couldn't work for feed greater than 1250 mm/sec (50 ipm). In some current controls this is done for two axis contouring by special codes. NCPLUS does that automatically for up to eight axes. The control looks ahead and calculates the best feed according to feed changes in any one of the axes.
• Reduced speed ahead
  This warning is seen on the road, not in CNC, but NCPLUS looks ahead and when reduced feed is programmed it decelerates ahead of time.
• Feed override
  Feed override action is immediate. What if the operator sets the override to 200% while the look ahead has already decided to decelerate? Most controls just won't let you go over 100%.
  This is a very complex problem but NCPLUS solves it by temporarily overriding the feed override itself when necessary.

Nanometer Technology

All internal motion calculations are performed in 1 nanometer resolution (ultra-high-precision nano interpolation). Nano interpolation generates smoother path and better surface finish.

5-axis RTCP

For RTCP (Rotary Tool Center Point) additional driver files are provided.
The following geometries are currently supported:
Gimbal head: CA, CB
Tilting head: BA
Nutating head: CA, CB (programmable nutator angle)
Rotary: AB, AC, BC
Combo: B-tilting head and A or C rotary

• Tool Center Point is programmed (position and orientation) rather than the mechanical axes.
• Feed is given in ipm or mm/min, same as with a regular 3-axis program.
• Real time display of TCP (tool coordinates, Absolute/Distance-to-go).
• Manual jogging and MPG in tool coordinates.
• Programming in tool coordinates, mainly for moving in tool direction.
• Standard drilling canned cycles work for any tool orientation.

Jerk

Jerk is the rate at which the acceleration changes. Jerk factor is the time it takes the acceleration to rise and fall, and it converts step acceleration into trapezoidal or triangular one.
Two linear Jerk factors can be set up to 250 msec- one for positioning and another for interpolation.
The Jerk factor generates bell-shaped feed profile and is essential for high-speed contouring.

Spindle/Axis

If the spindle motor has an encoder it can be programmed both as an axis in degrees or as a spindle in RPM. This is used for some tool changers and for rigid tapping.
The mode can be switched anytime without losing position.

Endless rotary axis

When set, such an axis behaves as a linear axis for interpolation but its limits are set internally for thousands of revolutions.
Unwinding is performed automatically in the following cases:

• Jogging to zero or positioning command: The axis moves at the shortest path (180 deg or less).
• Incremental programming of zero move: There is no motion but the current position is reduced by multiples of 360 to the range +-180 deg.
• Spindle operation: When the axis is used as a spindle it is constantly kept in the +-180 deg range.

Follower/Axis

Any axis can be switched to Follower mode.
In this mode the axis is moved by a feed command rather than position.
A follower axis can follow feedback signal (force, position), pushbuttons, another axis, etc.
The mode can be switched anytime without losing position.

Differential pair

Two axes can be setup as a differential pair, with the ratio between them.
This is required for some CA heads in which the A-axis is driven through the C-axis.

Gantry

Up to 2 gantry axes, each driven by 2 independent servos, are supported.
If necessary, the Reference routine can align the 2 servos to ensure squareness.

Ball and Bull nose cutter radius comp

This compensation is used for 3D contouring. It requires a post-processor that can generate IJK vector in addition to XYZ.
It also works with 5-axis profiling.

Drilling cycles

N Display

Three different displays can show where the part-program is. They can be switched any time:

• Block number (N), as appears in the program.
• Sequential line count, regardless of N.
• Percentage of the program in 4 digits.

Mid-Program Start

A simple 4 step Start from the Middle sequence, no access to the program is needed. The computer picks-up the required data from the program automatically.
The operator can seek a line in the program or the current position of the tool.
The position and spindle are resumed simply by pressing Cycle Start, following on-screen instructions.

On-the-Fly offset

If this feature is used the offset is displayed in a window. The offset can be changed, by the handwheel and the jogging pushbuttons, before or while the program is running.
This feature can be set for all axes but it is mostly used for Z.

Virtual W

For 3-axis machine, virtual W looks like a 4th axis. Using it moves Z of course.
This lets you raise or lower the tool manually the same as with actual W, at rest and on the fly.

PLC

The Plc is implemented in software and runs constantly in the background.
It is used for background operations like preparing next tool, spindle control, display, alarm, watchdog, etc.
The Plc reads and writes I/O's from an I/O board with a supplied driver. The I/O ports are numbered by the retrofitter so there is no need to use absolute addresses. The Plc copies the I/O's to/from Plc designated registers. In addition, it intercepts all keyboard keys; these key-codes can be modified, used as inputs, or pass-thru.

700 registers are available, about 200 of them are associated with NCPlus variables that can be read and/or written, like mode, feed, position, leadscrew-comp, trace-error, etc.
Plc programs are written and compiled using the NCPlus editor, no tools are needed.
Arithmetic/Logic statements are used like:

#101= #2 * #123 / 10000 + 1
if #400&$20<>0 and (#300>=12 or #300<-12) then
 ...... 
else
 ......
end
#56=red #57=white sound(1000)
#333=encoder(#2,#377)

Plc registers can be displayed on the screen in real time in different formats. In addition to numerical values they can point to text messages with variable colors.

Tool Changer

All kinds of tool changers can be programmed in the internal PLC.
There are four basic types of tool changer:

• The tool is picked up solely by axis motion.
• The tool is taken directly from the magazine, with or without axis motion.
• The tool is exchanged with a new tool from the magazine by a Tool-Changer-Arm (TCA).
  This is also called Random ATC because tools are not returned to the pots from which they were taken.
• The TCA exchanges tools with an Intermediate Arm, which is loaded ahead of time from the magazine.

For M6, T represents actual tool number. For a random ATC the computer finds and updates the pot number in the tool table. For non-random ATC the pot number is set to the tool number.
M6 also sets the tool offset according to the entry in the tool table.

Setup Tool Length

A pop up window lets the operator enter tool length either as a number (if known) or as measured on the machine.
The operator can use or ignore tool radius (for ball nose) and enter the current Z, if not zero, which is saved for the next tool.
In addition, tool length can be incremented.

Sequence

Any automatic sequence that may require operator intervention, e.g. tool changer, can be displayed in real time. The full sequence is displayed while a moving color bar highlights the current operation. If an error occurs the erroneous operation stops and blinks. The operator can go backward and forward by the arrow keys. Once the problem is solved the program can be resumed.

Editor

Powerful word-processor for interactive program editing:

• Up to 250 MB or 3,000,000 lines file size.
• Up to 5 simultaneous open windows, with zoom.
• Automatic generation of backup file.
• Automatic program save before exiting the editor.
• Moving and copying text inside a window or between windows.
• Search, search and replace, compare two files.
• Merging or splitting of programs.
• Syntax check for the program; if error is detected the cursor points to the erroneous data.
• Point and shoot directory and file selection.
• 10 bookmarks can be set and recalled.
• Undo changes to a line, undelete lines.
• Print to a printer.

Security

If security is a factor, the NC program source code can be deleted from the control (the compiled file is unreadable and useless for competitors).
For greater security, up to 9 levels of access are provided via user name and password.
Any access is logged to a file.

Technical Specification

Total controlled position axes	8
Follower/axis			8
Gantry pairs                    2
Spindle/axis			1
Differential pair 		1

Feed Range 			1 to 32,000 mm/min (0.04 to 1250 ipm)
Positioning			Up to 64,000 mm/min (2500 ipm)
Max encoder counts		16,000,000 count/sec
Min resolution                  0.001 micron (1 nano-meter)

Acceleration 			0.01 to 10g
Programmable max feed		per axis: positioning, jog, dryrun, feed
Programmable max acceleration	per axis: positioning and interpolation
Programmable Jerk factor	For all axes: Positioning and interpolation
 
Feedrate override 		up to 31 programmable steps, 0.0 to 199.9%
G0 override                     Programmable steps 1 to 100%, usually 25-50-75-100%
Linear axis travel 		About 2,000,000,000 encoder counts
Rotary axis travel		Same, with optional 'electronic-unwind'
Rotary axis programming	unit	Degree, regardless of inch/metric mode
 
Control accuracy 		15 digit floating point
Max value of any dimension 	1,000,000,000,000.000 mm
Dwell 				0.01 sec to 300,000 years
 
Max program size 		250 MB or 3,000,000 lines
Disk storage per 1 MB 		Equivalent to 2.5 km of tape (1.5 mile)
Tool data storage 		up to 253 tools per table
Settable fixture offsets        9 (g54 to g59.3) extendable to 99 
Lead screw compensation		1 table per axis, dynamically interpolated

Digital I/O			up to 320 inputs, 320 outputs
Analog and odd I/O's		up to 40 addresses
 
Look Ahead			80 Buffers
 
User Parameters			100 
System Parameters		100
Extra parameters or arrays      up to 8200
 
PLC Registers			700 (16 bit)
 
CNC Compiler			Virtual (Byte) code
PLC Compiler			Native intel® code

Basic Features

Note: the terms 'unlimited' and 'indefinitely' are used when a quantity is limited by memory size or when the limit is in the quadrillions and beyond any need.

• 8 axis positioning.
• 8 axis linear interpolation.
• 3 axis circular interpolation.
• 2 or 3 axis circular and all other axes linear, simultaneous (helical) interpolation.
• Up to 250 MB program size.
• Up to 1,000,000 miles dimension for any axis or radius. (That's one trillion mm).
• 80 look-ahead buffers for high speed cutting of cad/cam output.
• 6 digit Spindle RPM.
• 7 digit block number. Line count can be used instead of block number.
• Cartesian, polar, toroidal and spherical coordinates.
• Rotation and elevation to any program, including cutter comp.
• Inclined polar coordinates. (Tilt and swivel).
• Automatic rounding for 3D corner.
• 3 point 3D arc.
• 3 point 3D full circle.
• Feed input (for more info see: Feed Modes)
  g93 inverse time- Feed[unit/min]= Length[unit] * Inverse_time[1/min]
  g94 unit/min
  g95 unit/rev
• Feed in ipm or mm/min for a rotary table (for more info see: Rollerdie)
• Programmable scale for Feedrate, ipm or mm/min independent of scale or inch/metric switching.
• Feed profile: Bell-shape (S curve), programmable Jerk.
• Programmable automatic deceleration in corners.
• Programmable feed override, up to 31 steps 0% to 199%.
• Programmable G0 override 1% to 100%.
• 9 settable fixture offsets, extendable to 99 (for more info see: Fixture Offset)
• Mixed absolute and incremental input.
• Programmable inch/metric, mixed in the same block.
• Programmable zero offset and local coordinates.
• Programmable scale-factor, independent for each axis.
• Programmable mirror image for all axes in any combination.
• Programmable plane for circular interpolation and radius-comp: g17 to g19 for XYZ,
  g16 for user defined axes, selected by 'Plane(axis1,axis2,axis3)' command.
• Dwell up to 300,000 years. (If a longer dwell is required, use two or more blocks).
• 15 digit data, written with floating decimal point. No leading or trailing zeros are necessary.
• Follow the leader - any axis can lead any number of other axes, in any combination. (For all kinds of coordinates and motions).
• Gearbox - any axis command can be multiplied by a gear ratio.
• Arithmetic: Direct programming of arithmetic expressions with any level of complexity, written in a subset of BASIC language, e.g.:
  

  n10 #1=SIN(#2 + LOG(15.37/2)) + sqrt(1+2)*3
  n20 g1 If #2>=1.25 Then x1.25 Else x#2 end
  n30 WHILE #14<10 G81 x#14 y-1.7 #14+=2.25 WEND
  n40 FOR #1=1 TO 10 GOSUB 1000; NEXT #1

• NC addresses can be used on the right side of an equation, e.g.:
  

  n100 g1 x10 y20 z=x+y
  n200 if s>3000 then s3000 end

• File handling - text and random-access, open, close, read, print, seek, put, get, eof, lof.
• DOS programs can be called from within a CNC program.
• Text processing: input, modify, append, compare, examine, print, e.g.:
  

  n10 A$='abcd' B$=input$(B$) #1=asc('Y')
  n20 if A$==B$+'.CNC' then ...... endif
  n30 print 'par #1= ',#1;
  n40 print "That's all folks!" M2

• Date and Time functions for scheduling maintenance.
• Unlimited number of sub-programs.
• Loops:
  

  For ... To ... Next
  While... Wend
  Repeat ... Until

• Loops may be nested indefinitely.
• Unlimited number of repetitions of any loop.
• Chain - a program can load and run another program.
• Call - a program can call another program as a subroutine, up to 16 levels of nesting.
• 100 general-purpose parameters, 15 digits each.
• 100 special purpose parameters, for programmable canned cycles.
• 8200 parameters, can be used as general purpose or arranged in user-defined vectors and matrices.
• 700 PLC's 16 bit variables.
• Support for Mouse, Touch-screen, RS-232.
• Tool radius and length compensation.
• Ball and bull nose 3D compensation.
• Up to 253 tool data storage, arranged in a pop up table.
• Tool data given in mixed inch/mm, independent of the program.
• Mixed tool radius and tool diameter.
• Tool data is called by tool number.
• Tool data can be checked and modified by the program.
• No-excuses, look-ahead cutter radius compensation, covers all transitions: line to line, arc to line, line to arc and arc to arc, external and internal corners.
• Look ahead search goes as deep as necessary. Up to 10 Z-blocks and M-functions can be properly handled by the look ahead.
• Z motion inside corners is handled automatically.
• Automatic rounding of corners by a programmed radius. All corners are covered: line to line, arc to line, line to arc and arc to arc. All cases of external and internal corners are handled automatically.
• Automatic chamfering for any corner between two lines. Chamfer may have rounded corners. Internal chamfer is automatically ignored if the tool does not fit in.
• Center-line programming for slots.
• Meander milling with tool compensation.
• Semi-automatic recovery from power loss.
• Skip function enables interrupting a motion or dwell upon a programmable input condition.
• Leadscrew compensation, dynamically interpolated.
• Stored end-of-travel limits.

Program debugging facilities:

• Graphic
• Dry-run
• Test
• Single
• Break-points
• Messages

CRT displays the following: (user arranged)

• Current mode.
• Program name.
• Current & buffered program lines.
• Axis position.
• Block and tool number, actual feedrate and spindle-speed.
• Time of day.
• Error messages.
• INCH/MM, Dry-run, Single, Home #, Feed-override.
• Bottom line instant help.
• Graphic projection and isometric view of tool path.
• Diagnostic tests.

Pop-ups

• Main menu.
• Tool table.
• Parameter table.
• I/O status.
• Help screens.
• File directories.
• Context sensitive help screens can be displayed any time.
  These help-screens include all G-codes, the Letter-addresses, MDI commands, editing commands and more.
• Help text can be included in any CNC file.

Miscellaneous

• Transformations (for 5 axis machines).
  World coordinates.
  Wrist coordinates.
  TCP.
  Electronic roll.
• Calculator mode may be used in MDI.
• Graphic display: projection and isometric, make-BMP command.
• Program may be started regardless of current axis position.
• Dialogue windows, enable programming of menus and instructions to the operator.
  Operator can enter data on line.
• Programmable standard drilling, boring and tapping canned-cycles.
• Tool radius compensation may be used with any selected plane.
• With radius compensation, few programming chores can be performed automatically:
  Avoiding deceleration when possible.
  Chamfering.
  Rounding of corners.
  Finding intersections between a line and an arc.
  Finding intersections between two arcs.
  Centerline programming for slots.
• Built-in diagnostic and calibration.
  Trace error and time-constant.
  Reference test (without jogging to the reference point).
  I/O status for all inputs and outputs.
  Boot-log file for tracing boot sequence.

List of Functions

List of addresses

Note: the addresses X,Y,Z,U,V,W,A,B,C can be assigned to the 8 axes in any combination.
Unused addresses can be used as parameters to sub-programs.

G codes

Cartesian coordinates

Polar coordinates

Spherical and Toroidal coordinates

Plane select for circular interpolation and tool compensation

Tool compensation (length & radius)

Misc.

• Pocket and hole milling canned cycles:
  Circular pocket
  Rectangular pocket
  Deep hole milling (for more info see: Pocket Milling)
• Drilling canned cycles:
  G72 to G89 can be programmed as stand alone codes or as classic canned cycles.
  Work with polar coordinate as well.
  G-codes for hole patterns.
  For 5-axis machines- work in any orientation.(for more info see: Drilling Canned Cycles)

BASIC - Partial list of functions

CNC commands

Functions and procedures

Constants

Colors

Variables

Parameters

Data structures

Operators

Arithmetic functions

File operations

String and Screen Control (colors: fg=foreground, bg=background)

Mouse Control

Other functions and procedures

Program control

PLC commands - 16 bit integer arithmetic and logic

Registers #1 to #699 (16 bit)