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AcuCam Laser Control Software

User Guide

User Guide

AcuCam Laser Control Software


Software Version: 1.00.00 By Preco Laser Systems, LLC

Document Policy
COPYRIGHT 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 is prohibited. NON DISCLOSURE The contents of this manual and all referred or associated documents marked PLS Confidential, are provided to the original purchaser of the system for internal use only. Any disclosure of documents marked PLS Confidential to outside parties without the express written permission of PLS is strictly prohibited. POLICY This manual is based upon the data available at the time of publication. While sincere effort has been made to make the manual accurate, the information contained herein does not claim to cover all the details or variations in hardware or software, nor to provide for every possible contingency in connection with installation, operation, maintenance, repair or replacement. The Preco Laser Systems policy is one of continuous improvement. Therefore, the information in this manual is subject to change without notice and should not be construed as a commitment by Preco Laser 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 any responsibility for accuracy, completeness, sufficiency or usefulness or any problems that may arise from the use of the information contained herein. MADE IN THE USA PLS products are designed and manufactured in the USA. Trademark Acknowledgments AcuCam 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 the trademarks or registered trademarks of their respective companies. Copyright 2002 Preco Laser Systems, LLC. All rights reserved.

500 Laser Drive Somerset, WI 54025 Phone: 715.247.3285


FAX: 715.247.5650 Sales Toll Free: 1.800.77.LASER Service Toll Free: 1.800.799.2583 Email: publications@precolaser.com Website: www.precolaser.com

User Guide AcuCam Laser Control Software v

Contents
INTRODUCTION .................................................................................1 PURPOSE ........................................................................................1 OVERVIEW .......................................................................................1 GUIDE COMMENTS ...........................................................................1 HOW TO USE THIS GUIDE .................................................................2 HOW THIS GUIDE IS ORGANIZED .......................................................2 NOTATIONS AND CONVENTIONS .......................................................3 STANDARD CONVENTIONS ..........................................................3 MOUSE CONVENTIONS ...............................................................4 RESISTIVE TOUCH SCREEN CONVENTIONS .................................4 SOFTWARE DESCRIPTION ...............................................................5 PURPOSE ........................................................................................5 OVERVIEW .......................................................................................5 OPERATION .....................................................................................6 OPERATING SYSTEM ........................................................................6 DISTRIBUTION ..................................................................................6 HARDWARE ARCHITECTURE .............................................................7 OPERATING INTERFACE ..................................................................9 PURPOSE ........................................................................................9 OVERVIEW .......................................................................................9 ACUCAM MAIN SCREEN LAYOUT ....................................................10 MAIN SCREEN REGIONS - OPERATOR LEVEL.............................10 RECIPE SELECT REGION OPERATOR LEVEL .....................11 RECIPE REGION OPERATOR LEVEL ..................................11 DIAGNOSTICS REGION OPERATOR LEVEL ........................12 SYSTEM REGION - OPERATOR LEVEL .................................13 PARAMETER REGION OPERATOR LEVEL ..........................14 SYSTEM INFORMATION REGION OPERATOR LEVEL ...........15 MODE CONTROL BUTTONS REGION OPERATOR LEVEL .....15 PROGRAM CYCLE CONTROL BUTTONS REGION OPERATOR LEVEL ..............................................................16 LEVEL REGION OPERATOR LEVEL..........................................17 MAIN SCREEN REGIONS - SUPERVISOR LEVEL ..........................18 RECIPE SELECT REGION (AUTO MODE) SUPERVISOR LEVEL ...........................................................19

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User Guide AcuCam Laser Control Software vi


RECIPE REGION (AUTO MODE) SUPERVISOR LEVEL ......... 19 RECIPE SELECT REGION (PROGRAM MODE) SUPERVISOR LEVEL ........................................................... 20 CONFIG REGION (PROGRAM MODE) SUPERVISOR LEVEL ........................................................... 20 RECIPE SELECT REGION (MANUAL MODE) SUPERVISOR LEVEL ........................................................... 20 CONFIG REGION (MANUAL MODE) SUPERVISOR LEVEL .... 21 DIAGNOSTICS REGION SUPERVISOR LEVEL ...................... 21 SYSTEM REGION - SUPERVISOR LEVEL ............................... 22 PARAMETER REGION SUPERVISOR LEVEL ........................ 23 SYSTEM INFORMATION REGION SUPERVISOR LEVEL ........ 24 MODE CONTROL BUTTONS REGION SUPERVISOR LEVEL .. 25 PROGRAM CYCLE CONTROL BUTTONS REGION SUPERVISOR LEVEL ........................................................... 26 LEVEL REGION SUPERVISOR LEVEL ................................. 27 ALARMS WINDOW .......................................................................... 28 ALARM MESSAGES ................................................................... 29 INPUTS AND OUTPUTS WINDOW ..................................................... 30 OPERATING PROCEDURES ........................................................... 31 STARTING ACUCAM ....................................................................... 31 SELECTING A RECIPE ..................................................................... 32 CHANGING PARAMETER VALUES .................................................... 33 PROGRAMMING REFERENCE........................................................ 35 PURPOSE ...................................................................................... 35 OVERVIEW..................................................................................... 35 MANUAL GALVO CONTROLS WINDOW ............................................. 36 PART PARAMETERS WINDOWS ....................................................... 39 PART PARAMETERS WINDOW ONE ........................................ 39 PART PARAMETERS WINDOW TWO ........................................ 46 SUPERVISOR PARAMETERS AND CONFIGURATION WINDOWS .......... 47 SUPERVISOR: PARAMETERS WINDOW ...................................... 47 SUPERVISOR: SINGLE MIRROR GRID CAL WINDOW ................... 51 SUPERVISOR: DUAL MIRROR GRID CAL WINDOW ...................... 54 CALIBRATING THE GALVONOMETER ................................................ 58 MEASURING THE SCAN RADIUS ................................................ 58 MEASURING AND CUTTING THE GRID PATTERN ......................... 60 WHEN TO KNOW ITS TIME TO STOP CALIBRATING ....................... 63 INDEX................................................................................................ 65

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User Guide AcuCam Laser Control Software Introduction 1

INTRODUCTION
PURPOSE
This guide was designed to provide operating and programming information for the AcuCam Laser Control Software designed by Preco Laser Systems.

OVERVIEW
The ACUCAM LASER CONTROL SOFTWARE USER GUIDE assumes the reader is familiar with Microsoft Windows 2000 operating system.

GUIDE COMMENTS
At Preco Laser Systems, our policy is one of continuous improvement. We appreciate your comments regarding the information in this guide. After reading this guide, if there is any information you feel to be incorrect, missing or difficult to understand, please contact us by using one of the following methods:

Preco Laser Systems, LLC


Service Department 500 Laser Drive Somerset, Wisconsin 54025 Voice: Facsimile: Sales: Service: Email: Website: 715-247-3285 715-247-5650 1-800-77.LASER 1-800-799-2583 service@lasermachining.com www.lasermachining.com

Please be as specific as possible when you submit a correction or suggestion. Information such as guide title, revision date, section titles, page numbers and figure numbers make it easier for us to reference the material when reading your comments. Preco Laser Systems makes the final decision as to what information, if any, is incorporated into a guide. Preco Laser Systems appreciates the time you take to offer comments and will consider all comments received.

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User Guide AcuCam Laser Control Software Introduction 2

HOW TO USE THIS GUIDE


The ACUCAM LASER CONTROL SOFTWARE USER GUIDE contains detailed information about using the AcuCam Laser Control Software. Read this guide in its entirety before using the system. Information given in a previous section may be needed to understand or complete a step in a subsequent section.

HOW THIS GUIDE IS ORGANIZED


The ACUCAM LASER CONTROL SOFTWARE USER GUIDE is designed to provide information 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 guide is designed, conventions used in the guide, reference information and so on. SOFTWARE DESCRIPTION This section provides an overview of the AcuCam Laser Control Software and its components. OPERATING INTERFACE This section provides a description of the AcuCam Laser Control Software operating interface. It describes the AcuCam main screen regions and operator functions. OPERATING PROCEDURES This section provides procedures for user activities. PROGRAMMING REFERENCE This section provides reference information for laser processing modes and AcuCam Laser Control Software programming functions.

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2002 Preco Laser Systems, LLC. All Rights Reserved

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User Guide AcuCam Laser Control Software Introduction 3

NOTATIONS AND CONVENTIONS


Several different notations are used throughout this guide. For example, all reference to buttons, switches or indicators on the system will be indicated in the text in BOLD INITIAL CAPITAL small capital letters. Example: The COOLANT interlock light will illuminate if.

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

Convention
Bold Type BOLD INITIAL CAPITAL SMALL CAPITAL LETTERS Initial Capital Letters ITALIC INITIAL CAPITAL SMALL CAPITAL LETTERS Italic lower case letters MENU > PATH

Information
Text we ask you to type appears in bold. All reference to buttons, switches or indicators on the system. All reference to the titles of screens and fields. All reference to the titles of sections and guides. Indicates a sample name or file name, for example, test.cfg. The greater-than sign (>) is used to give the path for a drop down menu option, for example, FILE > SAVE AS.

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2002 Preco Laser Systems, LLC. All Rights Reserved

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User Guide AcuCam Laser Control Software Introduction 4

MOUSE CONVENTIONS
The left mouse button is the one to use most of the time (unless you have the mouse configured differently). The following terms are used in this guide to describe mouse pointer directives. Point means to position the mouse pointer so the tip of the pointer rests on whatever you want to point at on the screen. Click means to press and then immediately release the mouse button without moving the mouse. Double-click means to press and immediately release the mouse button twice without moving the mouse. Drag means to select and hold down the mouse button while moving the pointer across the screen. Select means to highlight a word, line or paragraph by placing the pointer on the desired item and double-clicking or dragging.

RESISTIVE TOUCH SCREEN CONVENTIONS


Resistive touch displays provide excellent and accurate touch input through touching specific areas within the screen regions. The following terms are used in this guide to describe resistive touch directives. Press means to touch or press lightly on a specific item within a region of an active matrix resistive touch screen. Select means to highlight a word or line by pressing on the desired item.

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2002 Preco Laser Systems, LLC. All Rights Reserved

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User Guide AcuCam Laser Control Software Software Description 5

SOFTWARE DESCRIPTION
PURPOSE
This section provides an overview of the AcuCam Laser Control Software designed and developed at Preco Laser Systems. For more information regarding the operating interface or programming, refer to the OPERATING INTERFACE and PROGRAMMING REFERENCE sections in this guide.

OVERVIEW
AcuCam Laser Control Software provides a method for laser processing material on a moving web. It simultaneously steers a laser beam(s) and controls 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 or curved 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 Windows 2000 environment, which acts as the user interface for programming and selecting the part processing parameters. PLSs MPLC, which acts as the real time laser controller. Laser with Beam Delivery for processing. Steered beam (galvo) motion system Operator interface for controlling the system. Usage of recipes for loading and saving part parameters. Usage of Set-Up parameters to define the operating characteristics of 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) with independent grid calibration.

The AcuCam Laser Control Software includes the following main features :

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2002 Preco Laser Systems, LLC. All Rights Reserved

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User Guide AcuCam Laser Control Software Software Description 6

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

OPERATING SYSTEM
AcuCam Laser Control Software is designed to be utilized on Windows 2000 operating systems. .

DISTRIBUTION
AcuCam Laser Control Software is distributed on a CD-Rom. Files must be moved manually from the CD-Rom to the required directories for installation. .

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2002 Preco Laser Systems, LLC. All Rights Reserved.

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User Guide AcuCam Laser Control Software Software Description 7

HARDWARE ARCHITECTURE
The typical hardware layout for the AcuCam Laser Control System is shown in Figure 1 for a system with a single laser. The AcuCam Laser Control Software, running on the Windows 2000 based computer, interfaces to the Galvo Controller through a USB connection. The Galvo Controller interfaces to 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 MPLC from the Galvo Controller. The MPLC provides the laser control functions that are configured by the operator as part of the recipes. A laser is interfaced directly to the MPLC. Web speed and distance are detected by the web encoder and monitored by the MPLC and Galvo Controller to coordinate the motion and laser power with the web. A Roll Handler is optional for systems that are not integrated into the factorys web handling systems.

COMPUTER WINDOWS 2000 R

USB

GALVO CONTROLLER

GALVO MOTION SYSTEM

LASER

DIGITAL I/O

RS232

MPLC

ROLL HANDLER (OPTIONAL)

DIGITAL I/O

WEB ENCODER

Figure 1. AcuCam Laser Control System Hardware Architecture

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User Guide AcuCam Laser Control Software Operating Interface 9

OPERATING INTERFACE
PURPOSE
This section describes the operating interface of the AcuCam Laser Control Software in the Windows environment. For more information about the AcuCam Laser Control Software, refer to the SOFTWARE DESCRIPTION section of this guide.

OVERVIEW
The AcuCam Laser Control Software provides operator and control interface to the system for programming and selecting the part parameters. . The AcuCam Laser Control System operator interface includes the following main features: Provides an interface for controlling the system. Provides the use of recipe files for loading and saving part parameters. 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 level and Supervisor level. Operator Level This level does not require an access password. The following 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 previously programmed limits. 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.

Supervisor Level The following operations are available: .

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

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User Guide AcuCam Laser Control Software Operating Interface 10

ACUCAM MAIN SCREEN LAYOUT


When the system starts, the initial screen displayed is main operator control interface. When AcuCam is loaded, the system defaults to Auto mode operation.

MAIN SCREEN REGIONS - OPERATOR LEVEL


The Operator level AcuCam main screen is shown in the following figure with the Alarms window open. See ACUCAM MAIN SCREEN REGIONS later in this section for a description of each field. .

System Information Region

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

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User Guide AcuCam Laser Control Software Operating Interface 11

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 used to select program recipes for execution.

Press the RECIPE SELECT down arrow and select the recipe to be downloaded.

RECIPE REGION OPERATOR LEVEL


The RECIPE region for level OPER (operator), in AUTO mode, contains the RECIPE DOWNLOAD button. Press the RECIPE DOWNLOAD button to download the selected part recipe.

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User Guide AcuCam Laser Control Software Operating Interface 12

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 Information Display region of the AcuCam main screen. See ALARMS WINDOW later in this section. Press the CLOSE ALARM button to close the alarms message and resolution area and return to the Main Screen. See ALARMS WINDOW later in this section. Press the I/O button to display the Input and Output diagnostics window. See INPUTS AND OUTPUTS WINDOW later in this section.

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User Guide AcuCam Laser Control Software Operating Interface 13

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.

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User Guide AcuCam Laser Control Software Operating Interface 14

PARAMETER REGION OPERATOR LEVEL


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

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

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

Displays the active part recipe name in the Galvo controller.

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

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

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

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User Guide AcuCam Laser Control Software Operating Interface 15


Press the RESET button to clear the count back to zero (0) for the NUMBER OF PATTERNS PROCESSED and the MATERIAL DISTANCE PROCESSED data fields.

SYSTEM INFORMATION REGION OPERATOR LEVEL


The System Information region displays the alarms messages when the ALARM button is pressed; otherwise, it is not displayed. See ALARMS WINDOW later 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 are used in conjunction with the level of authority (Operator or Supervisor) currently logged into the system. See the following button descriptions for their 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 this mode, selecting part recipes is allowed. PROGRAM mode is not available for Operator level operations.

MANUAL mode is not available for Operator level operations.

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User Guide AcuCam Laser Control Software Operating Interface 16

PROGRAM CYCLE CONTROL BUTTONS REGION OPERATOR LEVEL


The program CYCLE control buttons region contains three buttons. The START and STOP buttons are used in Master Mode and are not enabled in Slave 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 the processing. Depending on system configuration, it may also start the roll handler. Button is disabled. The Start button is an indicator light. It turns green reflecting that the system is processing.

Slave Mode:

STOP Button Master Mode: Button is active. When the STOP button is pressed, it turns red. The system will continue to process parts until the web has come to a stop. Button is not active. The STOP button is an indicator light. It turns red reflecting that the system is in a stop condition. When an external Stop is applied, the system will continue to process parts until the web has come to a stop.

Slave Mode:

DRY RUN Button DRY RUN button is not available for Operator level operations.

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User Guide AcuCam Laser Control Software Operating Interface 17

LEVEL REGION OPERATOR LEVEL


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

NOTE: In the Operator level of authority, the following functions are disabled: 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 dialog window is displayed.

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

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User Guide AcuCam Laser Control Software Operating Interface 18

MAIN SCREEN REGIONS - SUPERVISOR LEVEL


The Supervisor level AcuCam main screen is shown in the following figure when in PROGRAM mode. For AUTO mode, refer to Figure 2 to reference the main screen. See ACUCAM MAIN SCREEN REGIONS later in this section for a description of each field. .

System Information Region

Figure 3. AcuCam Main Screen in Program Mode Supervisor Level

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User Guide AcuCam Laser Control Software Operating Interface 19

RECIPE SELECT REGION (AUTO MODE) SUPERVISOR LEVEL


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

Press the RECIPE SELECT down arrow and select the recipe to be downloaded.

RECIPE REGION (AUTO MODE) SUPERVISOR LEVEL


The RECIPE region for level SUPER (supervisor), in AUTO mode, contains the RECIPE DOWNLOAD button. Press the RECIPE DOWNLOAD button to download the selected recipe.

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User Guide AcuCam Laser Control Software Operating Interface 20

RECIPE SELECT REGION (PROGRAM MODE) SUPERVISOR LEVEL


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 to display the Part Parameters windows, which allows the Supervisor to program the part. See PART PARAMETERS WINDOWS in the PROGRAMMING REFERENCE 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. See SUPERVISOR PARAMETERS AND CONFIGURATION WINDOWS in the PROGRAMMING REFERENCE section of this guide.

RECIPE SELECT REGION (MANUAL MODE) SUPERVISOR LEVEL


The RECIPE SELECT region for level SUPER (supervisor), in MANUAL mode is not available.

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User Guide AcuCam Laser Control Software Operating Interface 21

CONFIG REGION (MANUAL MODE) SUPERVISOR LEVEL


The CONFIG region for level SUPER (supervisor), in MANUAL mode is not available.

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 Information Display region of the AcuCam main screen. See ALARMS WINDOW later in this section. Press the CLOSE ALARM button to close the alarms message and resolution area and return to the Main Screen. See ALARMS WINDOW later in this section. Press the I/O button to display the Input and Output diagnostics window. See INPUTS AND OUTPUTS WINDOW later in this section.

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User Guide AcuCam Laser Control Software Operating Interface 22

SYSTEM REGION - SUPERVISOR LEVEL


The SYSTEM region contains the EXIT button. This button is accessible when in 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.

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2002 Preco Laser Systems, LLC. All Rights Reserved.

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User Guide AcuCam Laser Control Software Operating Interface 23

PARAMETER REGION SUPERVISOR LEVEL


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

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

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

Displays the active part recipe name in the Galvo Controller.

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

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

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

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User Guide AcuCam Laser Control Software Operating Interface 24


Press the RESET button to clear the count back to zero (0) for the NUMBER OF PATTERNS PROCESSED and the MATERIAL DISTANCE PROCESSED data fields.

SYSTEM INFORMATION REGION SUPERVISOR LEVEL


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

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2002 Preco Laser Systems, LLC. All Rights Reserved.

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User Guide AcuCam Laser Control Software Operating Interface 25

MODE CONTROL BUTTONS REGION SUPERVISOR LEVEL


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

AUTO mode is default mode when the system is powered up. When the AUTO button is pressed, selecting program recipes (Laser and Part) is allowed. PROGRAM mode is used to program recipe files. Cycle Start is disabled while in PROGRAM mode. When the PROGRAM button is pressed two (2) buttons are shown in the Recipe Select region of the main AcuCam screen: RECIPE SELECT VIEW and MODIFY PART PARAMETERS button. When pressed, the Part Parameters windows are displayed. See Part Parameters Window in the Programming Reference section. CONFIG SETUP button. When pressed, the Supervisor: Parameters windows are displayed. See Supervisor Parameters and Configuration Windows in the Programming Reference section of this guide.

MANUAL mode is used to manually move the galvonometer to different locations. When the MANUAL button is pressed, Manual galvonometer controls window is displayed. See the MANUAL GALVO CONTROL WINDOWS in the PROGRAMMING REFERENCE section of this guide.

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User Guide AcuCam Laser Control Software Operating Interface 26

PROGRAM CYCLE CONTROL BUTTONS REGION SUPERVISOR LEVEL


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

Cycle Start/Stop Buttons


AUTO PROGRAM MANUAL START Button Master Mode: Button is enabled

Master Mode
Enabled Disabled Enabled

Slave Mode
Disabled Disabled Enabled

When the START button is pressed, it turns green and initializes the processing. Depending on system configuration, it may also start the roll handler. Button is disabled. The START button is an indicator light. It turns green reflecting that the system is processing.

Slave Mode:

STOP Button Master Mode: Button is active. When the STOP button is pressed, it turns red. The system will continue to process parts until the web has come to a stop. Button is not active. The STOP button is an indicator light. It turns red reflecting that the system is in a stop condition. When an external STOP is applied the system will continue to process parts until the web has come to a stop.

Slave Mode:

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User Guide AcuCam Laser Control Software Operating Interface 27


DRY RUN Button When the DRY RUN button is pressed, the LASER READY and MPLC READY alarms are ignored. This function allows the system to be tested and run without the laser operational. Additionally, the laser trigger and laser shutter are disabled.

LEVEL REGION SUPERVISOR LEVEL


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

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

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

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User Guide AcuCam Laser Control Software Operating Interface 28

ALARMS WINDOW
When the ALARM button is pressed, alarm messages are listed in the Information Display region of the AcuCam main screen. In any mode (AUTO, PROGRAM or MANUAL) or level (OPERATOR or SUPERVISOR), press the ALARM button to display the alarm message and resolution area.

Figure 4. Alarms Window


DATE TIME CLASS MESSAGE Displays the date of the alarm message. Displays the time of the alarm message. Displays the type of alarm. Displays the text of the alarm message. This button is used to acknowledge all of the current alarms. It must be pressed before any alarms can be reset, with the RESET button. When pressed, an attempt is made to reset all current alarms. If the alarm condition 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 resolution area and return to the main screen.

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User Guide AcuCam Laser Control Software Operating Interface 29

ALARM MESSAGES
The following table describes alarms that are common to AcuCam systems and other alarms that are dependent on your system configuration.

Alarm Message
Fatal: Emergency Stop Stop: Galvo Controller Flash Memory Error Stop: Galvo Controller DPRAM Error Stop: Galvo Controller Firmware Checksum Error Stop: Galvo Controller Memory Checksum Error Stop: Galvo Controller Servo Error

Description
System is in an emergency stop condition. Flash memory error in the Galvo Controller. DPRAM error in the Galvo Controller. Checksum error in the Galvo Controller Firmware. Checksum error in the Galvo Controller memory. Servo error in the Galvo Controller due to an insufficient calculation time to complete servo loops. Run-Time error in the Galvo Controller due to an insufficient calculation time to complete a move in the recipe. Roll Handler is not ready.

Resolution
Check for a depressed Emergency Stop (E-Stop) button. Power must be cycled to reset the Galvo Controller. Power must be cycled to reset the Galvo Controller. Power must be cycled to reset the Galvo Controller. Power must be cycled to reset the Galvo Controller. Power must be cycled to reset the Galvo Controller. Depending on the Cut Time method programmed, either increase the Time for the move or decrease the Velocity of the move. Check if the Roll Handler is powered ON, or if the system is in emergency stop. Check if the laser is powered ON, or if the system is in emergency stop.

Stop: Galvo Controller Run-Time Error

Stop: Roller Handler Not Ready

Stop: Laser Not Ready

Laser is not ready.

NOTE: This alarm is ignored in Dry Run mode.


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

NOTE: This alarm is ignored in Dry Run mode.


Stop: Web Speed Too High To Complete Part Warn: AcuPower Download Time Out Web Speed is too fast to complete the part with the current recipe. Timeout in the downloading parameters to the Laser Controller. Either decrease the web speed or reprogram the recipe to complete the part in the time allotted. Reset the alarm and try downloading again.

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User Guide AcuCam Laser Control Software Operating Interface 30

INPUTS AND OUTPUTS WINDOW


This 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. 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.

OUTPUTS

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User Guide AcuCam Laser Control Software Operating Procedures 31

OPERATING PROCEDURES
This section describes the operating procedures and activities for the AcuCam Laser Control Software system.

STARTING ACUCAM
When the system is powered ON, the system computer monitor powers up and 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 START button.

The router window is displayed after starting AcuCam. This window lists 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 the Cimplicity Login window. b) Type in OPER. c) Press the OK button, no password is required for operator level system activities.

NOTE: There is a slight delay while AcuCam initiates communication before the AcuCam main screen becomes active.
The system is now ready to start processing.

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SELECTING A RECIPE
To select a recipe to process, 1. Press the down arrow in the RECIPE SELECT drop-down box to display 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 PART RECIPE 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.

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User Guide AcuCam Laser Control Software Operating Procedures 33

CHANGING PARAMETER VALUES


Operator level of authority only allows modifying the Power Adjustment parameter field. To change the parameter value, 1. Press the POWER ADJUSTMENT field.

2. A Setpoint window will be displayed, this Setpoint window allows this parameter to be changed to a value within the laser power limit that was set in the Part Parameters setup window. See PART PARAMETERS WINDOW in the PROGRAMMING REFERENCE section.

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

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 NEW VALUE field. 5. Press the OK button to accept the change.

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User Guide AcuCam Laser Control Software Programming Reference 35

PROGRAMMING REFERENCE
PURPOSE
This section provides programming reference information for the AcuCam Laser Control Software in a Windows 2000 environment.

OVERVIEW
The AcuCam Laser Control Software provides an operating interface to the system for programming laser operation modes, laser parameters settings, and system diagnostics. The screens, windows and procedures described in this section require Supervisor (SUPER) level of authority.

Supervisor (SUPER) Level of Authority

See MAIN SCREEN REGIONS SUPERVISOR LEVEL in the OPERATING INTERFACE section of this guide for a description of the fields displayed on this screen. For more information about the operating interface, refer to the OPERATING INTERFACE section of this guide.

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

MANUAL GALVO CONTROLS WINDOW


The Manual Galvo Controls window mode is used to manually move the galvonometer to different locations. The supervisor (SUPER) level of authority and MANUAL mode must be selected to access this window. There is one (1) Manual Galvo Controls window. The Manual Galvo Controls window is accessed by pressing the MANUAL mode button.

Manual Galvo Controls Region

Figure 6. AcuCam Manual Galvo Controls Window

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The GO TO USER INPUT GALVO FIELD POSITION option lets you move the galvo to any position in the galvo field. To execute the move, select this option and press the CYCLE START button. The CYCLE START button momentarily illuminates green while the galvo is moving to the position programmed. The PROGRAM RECIPE option lets you cut a part recipe on a nonmoving web for test purposes. Select this option and a part recipe and press the CYCLE START button. The part recipe is processed on the work surface. The CYCLE START button momentarily illuminates green while the galvo is cutting the part recipe.

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

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

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

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

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IMPORTANT:
If the system is a dual galvo system, frequently the right galvo is mirrored with respect to the left galvo. As a result, the right galvo positions will be mirrored with respect to the left galvo. For example, the Top Left Position will physically be the Top Right Position for right galvo and vice versa.
The TOP LEFT option is a pre-programmed position for the Top Left position of the galvo field. Select this option and press CYCLE START button. The galvo will move to the Top Left Corner of the galvo field. The CYCLE START button momentarily illuminates green while the galvo is moving to the top left of the field. The TOP RIGHT option is a pre-programmed position for the Top Right position of the galvo field. Select this option and press CYCLE START button. The galvo will move to the Top Right Corner of the galvo field. The CYCLE START button momentarily illuminates green while the galvo is moving to the top right of the field. The BOTTOM LEFT option is a pre-programmed position for the Bottom Left position of the galvo field. Select this option and press CYCLE START button. The galvo will move to the Bottom Left Corner of the galvo field. The CYCLE START button momentarily illuminates green while the galvo is moving to the bottom left of the field. The BOTTOM RIGHT option is a pre-programmed position for the Bottom Right position of the galvo field. Select this option and press CYCLE START button. The galvo will move to the Bottom Right Corner of the galvo field. The CYCLE START button momentarily illuminates green while the galvo is moving to the bottom right of the field.

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User Guide AcuCam Laser Control Software Programming Reference 39

PART PARAMETERS WINDOWS


The Part Parameters windows are used for programming part parameters values. The supervisor (SUPER) level of authority and PROGRAM mode must be selected to access these windows. There are two (2) Part Parameters windows. The Part Parameters windows are accessed by pressing the RECIPE SELECT VIEW AND MODIFY PART PARAMETERS button to display the Part Parameters windows.

PART PARAMETERS WINDOW ONE

Figure 7. AcuCam Part Parameters (Window 1)

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The SELECT/SAVE TO PART NAME field displays the part name. Press the down arrow and select the recipe to view or modify. The DISPLAYED/CHANGE PART NAME field displays the part name and allows part name changes. To change the current Part Name, select the displayed name and type-in the new name (up to 20 characters). The WEB SPEED field displays the web speed reference that is associated with the CUT TIME field (described later in this section). When VARIABLE (as opposed to CONSTANT) is selected in the Cut Time Field, all of the programmed points use a time parameter (msec) instead of a velocity parameter for determining how much time the move for the associated point is desired for processing. The time is based on this WEB SPEED Field. Normally, this parameter is set for the web speed at which the part is desired to be processed.

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User Guide AcuCam Laser Control Software Programming Reference 41


The SENSOR OFFSET field displays the sensor offset that is associated with the TRIGGER field (described later in this section). When EYE-SPOT is selected for the TRIGGER field, this parameter dictates the distance, or offset, from the sensor to the start of the cut pattern. When DISTANCE is selected for the TRIGGER field, this parameter dictates the distance between parts (or patterns) for when to repeat the cut pattern. A minimum offset is desired since the minimum distance, or offset, is used to anticipate the response of the galvo as the web changes speed. For example, ramping up or ramping down. To illustrate this point, on ramp up, once the eyespot is sensed, and the web has moved the amount specified in the sensor offset parameter, the galvo is triggered to cut a pattern. Since the response of the galvo is fixed, at different web speeds the amount of web material that passes during the amount of fixed time it takes for the galvo to respond varies, which would cause the start of the cut pattern to shift on web. AcuCam compensates for this variance by triggering the galvo sooner at higher web speed (anticipation) in order to account 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 web speed to calculate the minimum offset. It is up to you to calculate the minimum value. For most systems, the offset is large enough where the minimum is not an issue. If the pattern starts to drift upward 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. .

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Type-in the new value and press the OK button, or press the CANCEL button to close the window without changes. The SKIP button is not used. The TRIGGER field is used to select the type of trigger to use to process a part. There are three (3) selections available, click on the drop-down box: EYE-SPOT: An eye-spot is used as a trigger to start processing the part. One part is processed per eye-spot trigger. DISTANCE: A distance increment is used to trigger the start of a part. Each time the web moves the distance programmed in the Sensor Offset field, a part is processed. CONTINUOUS: The part is processed continuously. Once a part is completed, the next part is started immediately. If the CUT TIME field (described later in this section) is programmed for Constant, processing does not depend upon web movement to process a part. If the CUT TIME parameter (described later in this section) is programmed for Variable, web movement is required for part processing. The X-OFFSET field offsets the pattern in the X-direction from the Bottom Left location of the galvo field. It is programmed in mm. The Y-OFFSET field offsets the pattern in the Y-direction from the Bottom Left location of the galvo field. It is programmed in mm.

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The CUT TIME field is used to select the type of Cut Method. There are two (2) selections available, click on the drop-down box: CONSTANT: With this parameter selected, the part cut time is always constant regardless of web speed. Once the part program is commanded to execute, the cut time remains constant with only the in-line galvo axis synchronized with the web position. If the web is stopped, and the part program is triggered, the part program will still cut in the same time amount of time. VARIABLE: With this parameter selected, the part cut time is indirectly synchronized (proportional) to the web speed. As the web speed increases, the cut time decreases. If the web is stopped, and the part program is triggered, no cutting takes place, essentially the cut time is infinity. If the web starts moving, the part will start to be processed, but will not finish until the web moved the entire distance required to complete the part. Both galvo axes are synchronized to the web movement.

POINT

The POINT field is read-only. This field lets you see which point you are programming. There are a total of 20 points available on two the Part Parameters screens. The BEAM ON/OFF field is used for laser beam control (On or Off) for the associated point. Programming a 1 means the beam is on, while programming a 0 means the beam is off. The X field is used to program the incremental x-distance move for the associated point. This parameter is programmed in mm. The Y field is used to program the incremental y-distance move for the associated point. This parameter is programmed in mm. The ON DIST field is used for perforating. The ON DIST parameter is the distance that the laser beam will be ON during a perforating cycle. This parameter is programmed in mm. The OFF DIST field is used for perforating. The OFF DIST field is the distance that the laser beam will be OFF during

BEAM ON/OFF

X (MM)

Y (MM)

ON DIST (MM)

OFF DIST (MM)

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a perforating cycle. This parameter is programmed in mm.

ON DELAY (MSEC)

The ON DELAY field is used to set the delay in turning on the laser beam, after the request for the beam has been commanded. This value is used to compensate for the following error (difference in commanded position versus actual position) in the galvos. The commanded position leads the actual position. This delay is used to compensate for following error by delaying the firing of the laser beam so it more closely matches the position you programmed. The OFF DELAY field is used to set the delay at the associated point for two (2) cases: Delay in turning off the laser beam at the end of a point Delay in changing the laser parameters for the next point

OFF DELAY (MSEC)

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

VEL (CONST) (M/S)

The VEL (CONST) field is available only when CONSTANT is selected in the Cut Time Field (described earlier in this section). This field is used to program the surface velocity of the cut for the associated point. This parameter is programmed in m/sec. The TIME (VAR) field is available only when VARIABLE is selected in the Cut Time Field (described earlier in this section). This field is used to program the time to perform a cut for the associated point, at the web speed programmed in the WEB SPEED field. This parameter is programmed in msec. The LASER POWER field is used to program the Laser Power to be used for the associated point. This parameter is programmed in watts.

TIME (VAR) (MSEC)

LASER POWER (WATTS)

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Press the MORE button to display the second Part Parameters window.

Press the SAVE & DOWNLOAD button to save the changes to the table as shown for the displayed part name, and then it downloads the changes into the galvo controller. Press the SAVE TABLE button to save the changes to the table for the displayed part name, without downloading it into the galvo controller. Press the CLOSE button to close this window and return to the main screen.

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PART PARAMETERS WINDOW TWO

Figure 8. AcuCam Part Parameters (Window 2)


The DISPLAYED PART NAME field displays the current part name for the displayed parameters. Press the BACK button to return to the first parameters window.

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SUPERVISOR PARAMETERS AND CONFIGURATION WINDOWS


The Parameter and Configuration windows are used for programming system parameter values and calibrating the galvonometer. The supervisor (SUPER) level of authority and Program mode must be selected to access these windows. Press the Config Setup button to display these windows. There are three (3) Supervisor Parameters and Configuration windows.

SUPERVISOR: PARAMETERS WINDOW


The Supervisor Parameters window allows a supervisor to vary some to the system parameters to fine tune the system and to access the screens to perform grid calibration(s) for the galvos.

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Figure 9. Supervisor: Parameters Window

The WEB SPEED GALVO COMP field is used as an adjustment to compensate for the response of the galvo. It is essentially equal to the response time of the galvo. Since the response of the galvo is fixed, at different web speeds the amount of web material that passes during the amount of fixed time it takes for the galvo to respond varies, which would cause the start of the cut pattern to shift. AcuCam uses this parameter to adjust for this situation.

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

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User Guide AcuCam Laser Control Software Programming Reference 49


web. This parameter is provided since this angle is system dependent.

The MEASURE LASER POWER field is used to set the actual power of the laser, usually measured with a power puck. This field is particularly useful when sealed lasers are employed. Typically, over the life of a sealed laser, the power output decreases. In order to maintain the integrity of laser power parameters in the part recipes, this parameter is used in conjunction with rated laser power and automatically adjusts the duty cycle of the laser to maintain the programmed settings in the part recipe files. However, the maximum adjustment that can be achieved is the current maximum measured laser output power. Therefore, it is generally good practice to program the part recipe laser power to be less than the rated laser power in order to allow for the degradation of laser over time.

NOTE: This option applies primarily to sealed lasers.

The WEB ENCODER RESOLUTION field is used to input the resolution of the encoder that is attached to one of the passive rollers on the web. If this parameter is not set correctly, cutting a straight line across the web (using only an x-direction move) with the CUT TIME field set at CONSTANT will cause the line to be cut at an angle.

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

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The POWER ADJUSTMENT TOLERANCE field, lets the Supervisor set the percentage (%) range of adjustment allowable for the Power Adjustment % parameter on the main screen. The value here is bi-directional, that is, a value of 1% means a range of +/-1%. Press the MORE button to display the Single Mirror Grid Cal window.

Press the SAVE button to save the changes to the table for the displayed part name, and then it downloads the changes into the PMAC system. Press the CLOSE button to close this window and return to the main screen.

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SUPERVISOR: SINGLE MIRROR GRID CAL WINDOW


The Supervisor: Single Mirror Grid Cal window is used for single mirror grid calibration of the scan head field. .

Grid Calibration Region

Figure 10. Supervisor: Single Mirror Grid Cal Window

The SIDE field is used for a system with dual galvos to select which galvo to conduct the grid calibration There are two (2) selections for a dual galvo system, Left and Right. If there is only one galvo in the system, then the Left Side is normally used.

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The SCAN RADIUS field is used to set the working distance, which is the measurement (mm) of the distance from the bottom mirror of the Scan Head to the top of the work surface. The LASER POWER field is used to set the current laser power (watts) when cutting the nine point grid calibration pattern in MANUAL mode.

The D (distance) fields are used to enter in values after measuring the cut grid and after generating a nine point grid pattern cut. These values can be entered either as negative or positive values. The Z-AXIS OFFSET field is used to adjust the focus of the Z-translator. For most galvo systems, adjustment is done mechanically since the Z-translator is mounted on a movable slide. For systems where the Z-translator is not mounted on a movable slide, this parameter is used to adjust the focus. The RIGHT SIDE OFFSET field is used to aid in the alignment of the right galvo to the left galvo. The left and right galvos should physically be aligned as close as possible. This parameter is used to fine tune that alignment. Since it shifts the zero point of the entire field, it reduces the margin of the galvo field; therefore, it should only be used for fine tuning the alignment, not adjusting for gross misalignment. Press the BACK button to display the Supervisor: Parameters window.

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

The TABLE button is used to generate the initial calibration table for the galvos based on the Scan Radius. The table is generated by pressing this button. After the button is depressed, the button momentarily turns yellow and the Distance fields (above) are filled in automatically displaying the theoretical values expected for the field

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User Guide AcuCam Laser Control Software Programming Reference 53


size.

NOTE: Pressing the 9PT COR button erases any previously saved calibration.
The 9PT COR button is used to perform the nine point correction. Once the initial calibration table is generated (see the TABLE button), a nine point grid pattern is cut and measured. Type-in the values into the Distance Fields, replacing the theoretical values. When pressed, this button momentarily turns yellow, a nine point correction is performed, and the Distance fields (above) are replaced automatically with the theoretical values expected for the field size based on the Scan Radius. This process is iterative. Once a nine point correction is performed, another nine point grid pattern is cut, measured and the values re-entered into the Distance Fields. This process continues until the field size is within desired tolerance. Press the CLOSE button to close this window and return to the main screen.

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SUPERVISOR: DUAL MIRROR GRID CAL WINDOW


The Supervisor: Dual Mirror Grid Cal window is used for dual mirror grid calibration of the scan head field.

9-Point Grid Calibration Region

Figure 11. Supervisor: Dual Mirror Grid Cal Window


The 9-Point Grid Calibration region displays the current values for the 9-Point grid. See CALIBRATING THE GALVONOMETER later in this section for more information. The SIDE field is used for a system with dual galvos to select which galvo to conduct the grid calibration. There are two (2) selections for a dual galvo system, Left and Right. If there is only one galvo in the system, then the Left Side is normally used.

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The SCAN RADIUS field is used to set the working distance, which is the measurement (mm) of the distance from the bottom mirror of the Scan Head to the top of the work surface. The LASER POWER field is used to set the current laser power (watts) when cutting the nine point grid calibration pattern in manual mode.

The X and Y Fields are used to enter in values after measuring the cut grid after performing a nine point grid pattern cut. These values can be entered either as negative or positive values. The Z-AXIS OFFSET field is used to adjust the focus of the Z-translator. For most galvo systems, adjustment is done mechanically since the Z-translator is mounted on a movable slide. For systems where the Z-translator is not mounted on a movable slide, this parameter is used to adjust the focus.

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The RIGHT SIDE X-OFFSET field is used to aid in alignment of the right galvo to the left galvo. The left and right galvos should physically be aligned as close as possible. This parameter is used to fine tune that alignment in the x-axis. Since it shifts the zero point of the entire field, it reduces the margin of the galvo field; therefore, it should only be used for fine tuning the alignment, not adjusting for gross misalignment. The RIGHT SIDE Y-OFFSET field is used to aid in alignment of the right galvo to the left galvo. The left and right galvos should physically be aligned as close as possible. This parameter is used to fine tune that alignment in the y-axis. Since it shifts the zero point of the entire field, it reduces the margin of the galvo field; therefore, it should only be used for fine tuning the alignment, not adjusting for gross misalignment. Press the BACK button to display the Supervisor: Single Mirror Grid Cal window.

The TABLE button is used to generate the initial calibration table for the galvos based on the Scan Radius. The table is generated by pressing this button. After the button is depressed, the button momentarily turns yellow and the Distance fields (above) are filled in automatically displaying the theoretical values expected for the field size.

NOTE: Pressing the 9PT COR button erases any previously saved calibration.
The 9PT COR button is used to perform the nine point correction. Once the initial calibration table is generated (see the TABLE button), a nine point grid pattern is cut and measured. Type-in the values into the Distance Fields, replacing the theoretical values. When pressed, this button momentarily turns yellow, a nine point correction is performed, and the Distance fields (above) are replaced automatically with the theoretical values expected for the field size based on the Scan Radius. This process is iterative. Once a nine point correction is performed, another nine point grid pattern is cut, measured and the values re-entered into the Distance Fields. This process continues until the field size is within desired tolerance.

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

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CALIBRATING THE GALVONOMETER


The Supervisor Grid Cal windows and the Manual Galvo Controls windows are used to calibrate the galvonometer. Supervisor level of authority is required to do this procedure.

MEASURING THE SCAN RADIUS


The measurement from the scan head to the work surface is the Scan Radius. 1. Press the PROGRAM mode button. 2. Press the CONFIG SETUP button to display the Supervisor setup windows. 3. Press the button two times to display the Supervisor: Dual Mirror Grid Cal window. 4. Using a square ruler or tape measure, measure the perpendicular distance from the center of the bottom mirror motor of the Scan Head to the top of the work surface.

NOTE: The scan head protective cover assembly may need to be removed for this procedure. Re-install the cover assembly when finished.
5. Type in the distance measurement into the Scan Radius field.

6. Press the TABLE button to insert theoretical X and Y 9-Point grid values and generate a theoretical correction table. 7. Press the window. button to close the Supervisor: Dual Mirror Grid Cal

8. Place a target sheet on the work surface. 9. Press the MANUAL mode button to display the Manual Galvo Controls window.

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User Guide AcuCam Laser Control Software Programming Reference 59


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

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

12. Examine the grid cut. If cut is consistent, proceed to the MEASURING AND CUTTING THE GRID PATTERN procedure. If the cut is not consistent, 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 setup windows. c) Press the button two times to display the Supervisor: Dual Mirror Grid Cal window. d) Adjust the Laser Power setting as per the inconsistency of the cut, lower setting if cut too deep or raise setting if not cut through.

NOTE: You may need to adjust the Scan Radius and generate a new theoretical table if the measured field size does not closely match the calculated field size.
e) Recut the grid repeat Steps 7 through 11 until the grid is consistent.

Issued: 09/25/02

2002 Preco Laser Systems, LLC. All Rights Reserved

Product No.: 01007-100

User Guide AcuCam Laser Control Software Programming Reference 60

MEASURING AND CUTTING THE GRID PATTERN


Calibration is accomplished by cutting a known grid pattern onto a cutting field and measuring nine test points from the center reference point (P5) on the grid pattern. Figure 12 is an example of a 9-point grid (web direction is always in the Y+ direction).

P7

P8

P9

Web Direction

P5 P4 P6

Y+

Y+

P1

P2

P3

X+

X+

Left Side

Right Side

Figure 12. 9-Point Grid Example

Product No.: 01007-100

2002 Preco Laser Systems, LLC. All Rights Reserved.

Issued: 09/25/02

User Guide AcuCam Laser Control Software Programming Reference 61


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 calibration software. In this procedure, sample information is used to help explain the process of cutting and measuring the grid. Figure 13 illustrates an example of a measured plate.

Figure 13. Measured 9-Point Grid Example


Several methods of evaluating errors are possible using measuring equipment such as optical comparators or precision comparators. The following method for error evaluation is recommended.

NOTE: More complex methods, including the use of digitizers to record point-to-point spacing, are acceptable. However, if digitizers are used, they must be calibrated to ensure accurate measurement.
1. Align a measurement axis along a line that includes two measurement points, preferably along the longest distance if measuring a shortened grid (that is, grid points P2 and P8 as shown in Figure 13). 2. Select the center reference point (P5) to be the origin and the zero of your measurement equipment.

Issued: 09/25/02

2002 Preco Laser Systems, LLC. All Rights Reserved

Product No.: 01007-100

User Guide AcuCam Laser Control Software Programming Reference 62


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 and recorded, type in the measurements into the appropriate fields on the 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 Grid Cal window. If all values were entered correctly, press the 9PT COR button. 6. Press the window. button to close the Supervisor: Dual Mirror Grid Cal

7. Place a target sheet on the work surface. 8. Press the MANUAL mode button to display the Manual Galvo Controls window.

Product No.: 01007-100

2002 Preco Laser Systems, LLC. All Rights Reserved.

Issued: 09/25/02

User Guide AcuCam Laser Control Software Programming Reference 63


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

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

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

WHEN TO KNOW ITS TIME TO STOP CALIBRATING


Depending on the accuracy needed and the field of view of the galvanometer, the rule of thumb is to stop when the measurements are within 0.05% of the Field of View (FOV) or smaller. Examples: 4 inches F.O.V. = 0.002 inches 6 inches F.O.V. = 0.003 inches 8 inches F.O.V. = 0.004 inches 12 inches F.O.V. = 0.006 inches

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

Issued: 09/25/02

2002 Preco Laser Systems, LLC. All Rights Reserved

Product No.: 01007-100

User Guide AcuCam Laser Control Software Index 65

INDEX
A
AcuCam Calibrating, 58 Distribution, 6 Levels of Authority, 9 main features, 5 Main Screen Layout, 10 Operating Interface, 9 Operating System, 6 Operation, 4, 6 Overview, 5 typical hardware layout, 7 AcuCam Calibrating. See Calibrating AcuCam Main Screen Layout, 10, 18 Operator Level, 10 Regions, 10, 18 Supervisor Level, 18 AcuCam Main Screen Regions Config, 20, 21 Diagnostics, 12, 21 Level, 17, 27 Mode Control Buttons, 15, 25 Parameter, 14, 23 Program Cycle Control, 16, 26 Recipe Select, 11, 19, 20 System, 13, 22 System Information, 15, 24 AcuCam Screens. See AcuCam Windows AcuCam Windows Configuration Window, 47 Manual Galvo Controls Window, 36 Part Parameters Window, 39, 46 Part Parameters Window 1, 39 Part Parameters Window 2, 46 Supervisor Dual Mirror Grid Cal Window, 54 Supervisor Parameters Window, 47 Supervisor Single Mirror Grid Cal Window, 51 AcuCam windows, 58 Cut grid pattern, 60 Cutting the grid, 59 Distance fields, 52 Dual Mirror Grid Cal window, 54 Error evaluation, 61 Measure grid pattern, 61 Measure the scan radius, 58 Measured Grid example, 61 Nine point grid button, 53, 56 Nine Single Mirror Grid Cal window, 51 Scan Radius field, 58 Select the Nine point grid, 59 X and Y fields, 55 Calibrating:, 60 Config Region Manual Mode, 21 Program Mode, 20 Setup Button, 20, 21 Supervisor Level, 20, 21

M
Manual Galvo Controls Window, 36 Field descriptions, 37, 38 Screen layout, 36 Manual Galvo Controls Window How to access, 36 Mode Control Buttons Region Auto Button, 15, 25 Buttons, 15, 25 Manual Button, 15, 25 Operator Level, 15 Program Button, 15, 25 Supervisor Level, 25 Mouse Conventions, 4

O
Operator Level of Authority, 9

D
Diagnostics Alarm Button, 12, 21 Close Alarm Button, 12, 21 I/O Button, 12, 21 Diagnostics Region Buttons, 12, 21 Operator Level, 12 Supervisor Level, 21

P
Parameters Region Active Part Recipe Name, 14, 23 Material Distance Processsed, 14, 23 Number of Patterns Processed, 14, 23 Operator Level, 14 Parameters, 14, 23 Power Adjustment, 14, 23 Reset Button, 15, 24 Supervisor Level, 23 Part Parameters Window, 39, 46 Part Parameters Window How to access, 39 Part Parameters Window 1 Beam On/Off, 43 Button descriptions, 44 Cut Time, 43 Field descriptions, 40, 43 How to access, 46 Laser Power, 44 Off Delay, 44 Off Dist, 43 On Delay, 44 On Dist, 43

L
Level Region Buttons, 17, 27 Level Region Level Button, 17, 27 OPER Login, 17 Operator Level, 17 Operator Login, 17 SUPER Login, 27 Supervisor Level, 27 Supervisor Login, 27 Levels of Authority Operator Level, 9 Supervisor Level, 9 Levels of Authority SUPER, 35 Supervisor, 35

C
Calibrating

Issued: 09/25/02

2002 Preco Laser Systems, LLC. All Rights Reserved

Product No.: 01007-100

User Guide AcuCam Laser Control Software Index 66


Point, 43 Sensor Offset, 41 Time for cut, 44 Trigger, 42 Velocity, 44 Web Speed, 40 X-Offset, 42 Y-Offset, 42 Part Parameters Window 2 Button descriptions, 46 Field descriptions, 46 Part Parameters Window 2 How to access, 44 Program Cycle Control Region Buttons, 16, 26 Dry Run Button, 16, 27 Operator Level, 16 Start Button, 16, 26 Stop Button, 26 Supervisor Level, 26 Recipe Select Region Auto Mode, 19 Manual Mode, 20 Operator Level, 11 Program Mode, 20 Supervisor Level, 19, 20 Resistive Touch Screen, 4 conventions, 4 How to access, 47 Keying Frequency, 49 Measured Laser Power, 49 Power Adjustment Tolerance, 50 Web Encoder Resolution, 49 Web Speed Galvo Comp, 48 Supervisor Single Mirror Grid Cal Window, 51 9-Point Grid Button, 53, 56 Button descriptions, 52, 53, 56 Distance, 52 Field descriptions, 51, 52 How to access, 50, 56 Laser Power, 52 Right Side Offset, 52 Scan Radius, 52 Side, 51 Z-Axis Offset, 52 System Information Region Operator Level, 15 Supervisor Level, 24 System Region Exit Button, 13, 22 Operator Level, 13 Supervisor Level, 22

S
Supervisor Dual Mirror Grid Cal Window, 54 Button descriptions, 56 Field descriptions, 54, 55 Grid Calibration region, 54 How to access, 52 laser Power, 55 Right Side X Offset, 56 Right side Y Offset, 56 Scan Radius, 55 X and Y fields, 55 Z-Axis Offset, 55 Supervisor Level of Authority, 9 Supervisor Parameters Window Button descriptions, 50 Field descriptions, 48, 49, 50 Galvo Orientation, 48

R
Recipe Region Auto Mode, 19 Download button, 11, 19 Operator Level, 11 Supervisor Level, 19

Product No.: 01007-100

2002 Preco Laser Systems, LLC. All Rights Reserved.

Issued: 09/25/02