US005453933A

United States Patent 19 11 Patent Number: 5.453,933

9 9

Wright et al. 45) Date of Patent: Sep. 26,9 1995

54) CNC CONTROL SYSTEM 5,272,642 12/1993 Suzuki ............................... 364/474.24

75 Inventors: Michael R. Wright, Indianapolis; OTHER PUBLICATIONS
David E. Platts, Plain?eild; Daniel B. International Search Report, Jan. 11, 1995.
French, Carmel; Gerald Traicoff, Article entitled "Object Oriented Programming for Motion
Indianapolis; Michael A. Dupont, Control', D. E. Halpert (1991).
Fishers; Gregory A. Head, Plainfield, Article entitled "MMS:MAP Application Services for the
all of Ind. Manufacturing Industry', Brill and Gramm, Jul. 1991.
- Ultimax Programming, Hurco Manufacturing Co., Inc.,
(73) Assignee: Hurco Companies, Inc., Indianapolis, instruction manual, Hurco Part No. 704-0001-598, Oct.,
Ind. 1992, Revision C.
(21) Appl. No.: 118,445 Primary Examiner-Roy N. Envall, Jr. ar
Assistant Examiner-Thomas E. Brown
22 Filed: Sep. 8, 1993 Attorney, Agent, or Firm-Baker & Daniels
(51) Int. Cl. ........................................ G06F 15/46 (57) ABSTRACT
52 U.S. Cl. ................ 364/474.23; 364/191; 364/474.24
. Field of Search 364/474.22, 474.23 A CNC machine tool control system that includes a con
364/47424, 468,188 193 474. 5. 474.16. trollable, movable tool for shaping a workpiece, a mecha
eaf is s 474 474 26 nism for receiving control instructions describing shaping
f functions to be performed on the workpiece, a processing
56 Ref Cited unit and memory. The control systems includes objects
56) eferences Ute defined according to an object oriented design. One type of
U.S. PATENT DOCUMENTS object is a model of a shaping process to be performed on a
workpiece, including informational parameters regarding
3. 1943, She al. ........................ 36: the physical dimensions of the shape resulting from the
4.885,717 12/1989 Becket al.. ... 364/900 process. The process objects communicates through an
4,939,635 7/1990 Seki .......... ... 364/19 object oriented messaging system to machine objects, which
5,079,713 1/1992 Kawamura .... ... 364/474 represent physical devices present on the CNC machine on
5,095,522 3/1992 Fujita et al. ... ... 395/200 which the control system operates. The system also includes
5,150,303 9/1992 Fukaya .............. ... 364/474 object oriented motion control and exception handler
5,168,441 12/1992 Onarheim et al. . . 364/146 objects, each of which may communication with other
5,177,689 1/1993 Kinasi........... "36 object via object oriented messages. The control system
E; SE R . 3: permits easy modifications to the control system by persons
5235701 8/1993 Ohler et al. . . 395/600 with limited knowledge about the entire control system, and
5237.654 8/1993 Schackelford et al... . . 395/60 is readily adaptable to advances in new CNC machine tools.
5,239,477 8/1993 Matsumura ........... ... 364/474
5,247,447 9/1993 Korncoff et al. ....................... 364/468 38 Claims, 2 Drawing Sheets

-11 -12 -13 -14 -15

NETWORK MASS VIDEO

N-10

CAN BUS 16 MOTON CONTROL 18 COMMUNICATIONS INTERFACE

INTERFACE - BOARD (SERIAL & PARALLEL) N-20

17--- / 23 -/
22 24

CONTROL JOG
PANEL PNDANT

19 21
U.S. Patent Sep. 26, 1995 Sheet 1 of 2 5,453,933

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U.S. Patent Sep. 26, 1995 Sheet 2 of 2 5,453,933

(39 Microfiche, 2419 Pages)

Process

Machine

Kernel

Motion logic
Controller Controller

Platform
Directory Services
Services

Operating
System

Device
GE) (E) Drivers
 5,453,933
1. 2
CNC CONTROL SYSTEM the above simplified example illustrates.
The motion control function of the software receives
MICROFICHEAPPENDIX commands describing how a particular axis or motor should
This application includes a microfiche appendix having be moved. For example, in the above example for logic
39 frames.
control, the logic control function sent the motion control
function a command to raise the spindle. The motion control
FIELD OF THE INVENTION
function takes this "general' command, breaks it down into
smaller, discrete movements (i.e. controllably move the
This invention relates to computer numeric controlled spindle up 0.001" at a time until it has moved up a total of
(CNC) machine tools, and in particular, to the control O 6 inches), and sends and receive electric signals from
systems used to operate such machine tools. precision motors to ensure the movement is carried out. The
motion control function is also able to execute more com
BACKGROUND OF THE INVENTION plex, multi-dimensional commands, such as to move the
axes of a milling machine in a pattern so as to cut an ellipse
15
of specified dimensions in a workpiece.
CNC Control Systems Because the motion control function is the portion of the
The purpose of a CNC machine is to use a set of input software (except for device drivers) that interacts most
specifications describing a physical object to produce a closely with the hardware components that actually carry out
machined part according to the specifications. The part is shaping processes on a workpiece, the motion control func
typically formed from solid block stock material such as 20 tion also receives information about hardware faults from
metal, and shaped by various machine tools such as drills, hardware devices. For example, if a hardware device is
mills, lathes, electrostatic discharge machines (EDMs), unable to execute an instruction, the motion control function
gauging systems and the like. CNC machines are complex will receive a notice of the error from the hardware (or its
and include hundreds of components. Examples of input associated device driver). This information needs to be
devices include keyboards, operator consoles, pressure sen 25 communicated back to the other portion of the CNC control
sitive CRTs, various tools and machine sensors, limit software responsible for requesting the motion control func
switches and network interfaces. Output devices include tion to complete the function the software is currently
motion controllers that send motion control signals to undertaking, so that appropriate action, such as displaying a
motors driving axes or a tool, CRT displays, console status message on the operator CRT, may occur. However, there
lights and audible alarms. Other components include micro 30 are usually many other portions of the CNC control system
processors, memory, disk drives, data buses and wiring software that will also need to be informed of the hardware
harnesses. The software executed by the computer processor fault. Moreover, the portions that need to know about the
is a critical component of a CNC machine, as it coordinates fault will vary depending on the exact fault. In past systems,
the functions of the all the other components of the system. the motion control function has been used to keep track of
In general, CNC software is custom written for the particular 35 which portions of the CNC control system software must be
brand of components a CNC manufacturer or system inte notified of which hardware faults. This not only places an
grator chooses to include in the CNC machine. As a result, increased burden on the motion control portion of the CNC
CNC software is extremely complex, and a software pro control system software, but also makes this portion more
grammer for a particular CNC machine must be intimately difficult to maintain.
familiar with the way virtually every hardware component 40 Computer programmers writing CNC software have gen
interfaces with the software, and with the entire software erally designed the entire software system using structured
system itself. techniques that analyze what the entire CNC machine tool
For example, two representative functions of most CNC must do (functional decomposition). This has resulted in
software are the logic and motion control functions (collec complex, difficult-to-modify software systems. For
tively referred to herein as the "kernel”). The logic control 45 example, software code relating to the user interface by
function keeps track of the specific sequence of steps that which a user describes a part to be machined, can be found
must be taken by various movable hardware components to in other portions of the CNC control system software, such
accomplish a task. For example, the steps required to mount as the motion controller. One example is that when a motion
a differently sized drill bit into the tool holder of a spindle controller receives a signal from a machine tool indicating a
from an automatic tool changer in a milling application 50 fault condition (for example, when an object in the work
might be: (1) send a command to raise the spindle containing area prevents the table from moving to a desired location, or
the currently mounted drill bit so the tool changer will fit a blown fuse), the motion controller might directly display
underneath it, (2) send a command to the tool changer an error message on the CRT display. Because prior CNC
instructing it to move below the spindle, (3) send a com control system software generally is not broken down into
mand to the spindle instructing it to release the currently 55 portions corresponding to the discrete, physical components
mounted drill bit, (4) wait for a signal from the spindle of a CNC machine tool, a change in one portion of the
indicating that the drill bit has been released, (5) send a software is difficult to make and frequently requires changes
command to the tool changer instructing it to move to rotate to other portions of the software.
clockwise 30 degrees to position the new drill bit below the Another example illustrating this problem occurs when a
spindle, (6) interrogate the tool changer to confirm that the 60 user, system integrator or even machine tool manufacturer
tool changer has successfully executed the rotation com wishes to add a new hardware component to the machine
mand, (7) send a command to the spindle commanding it to tool. For example, it may be desirable to replace an AC
engage the new drill bit underneath it in the tool changer, induction motor with a DC brushless motor from a different
and (8) send a command to the tool changer instructing it manufacturer. The new motor will likely use a different
move away from the spindle and work area. Given the 65 communications protocol and have different tolerance speci
hundreds of moving, controllable parts in a CNC machine fications and operating limits. Therefore, the motion control
tool, the logic control function is much more complex than software will need to be modified to be able to communicate
 5,453,933
3 4
with the new motor using its communications protocol. The modeling systems of interactive components in order to
user interface will also need to be modified so that the user determine sequences of actions such systems would perform
may specify the improved tolerance parameters. However, under various conditions. For example, a programmer may
with past CNC software, these changes will have a ripple wish to program a computer to mimic the manner in which
effect throughout the entire software system, greatly increas some particular digital logic network responds to a particular
ing the time required to develop a new software system input stimulus. When the programmer doesn't know beforc
capable of using the new motor. Many of the additional hand what sequence of steps the logic network would carry
revisions are caused by the fact that the data the Software out in response to the stimulus, but only knows how each
needs to access is dispersed throughout the entire software individual component changes its outputs in response to a
system. For example, to add a new software function, the 10 change to its inputs, the programmer often finds it difficult
software may need to know, what tool is presently in the to utilize sequentially organized instructions to program a
spindle, the speed the spindle is rotating, the coordinates of computer to model the behavior of the system.
the axes (location of the table), the readings of a thermal In contrast to sequentially organized software, 'objccl
sensor, information about forces being exerted on the cutting oriented' software is organized into "objects', each com
spindle, and the stage (or step) of processing the workpiece 5 prising a block of computer instructions describing various
is currently in. In past CNC systems, this information would procedures ("methods”) to be performed in response to
likely be diffused throughout various software modules, and "messages' sent to the object. Such operations include, for
the way these data elements interact is either too complex to example, the manipulation of variables and the transmission
discern (execpt to the original software author), or propri of one or more messages to other objects. Messages are sent
etary. 20 and received between objects having certain functions and
These problems with CNC control systems have led to knowledge to carry out processes. When one of the objects
several other problems throughout the industry. There is a receives a message, the object carries out an operation (a
long lead time for system integrators or CNC machine tool message procedure) corresponding to the message and, if
manufacturers to be able to incorporate new hardware necessary, returns a result of the operation. Each object has
components into existing systems. This problem applies not 25 a region where internal states (instance variables) of the
only to new CNC machine designs, but also to efforts to add object itself are stored and where the other objects are not
improved or additional components to an existing CNC allowed to access. The objects comprise concept objects that
machine tool, or to retrofit an existing machine tool with represent concepts and instance objects that represent
CNC capabilities. Another problem is that of scalability. instances of the concept objects. The concepts are clearly
Because CNC control software is usually written for use in 30 separated from the instances. One feature of the object
accordance with an anticipated collection of hardware com oriented system is inheritance. With respect to a ccrtain
ponents, the same software can not be easily adapted for use concept object, there is defined an upper concept object that
in connection with other hardware components. In other has a concept more abstract than a concept held by the
words, CNC software is generally not "scalable,” meaning certain concept object, and the certain object can inherit the
that the software used to operate Sophisticated, high-end 35 functions (message procedures) and knowledge (instance
CNC machines can not also be used to operate "bare-bones,' variables) of the upper concept object to utilize them. For
low-end CNC machine tools. As a result, CNC manufactur example, a concept object "circle' may inherit functions and
ers "reinvent' software having the same functionality knowledge from its upper concept object 'shape.”
merely because it designed to work in a CNC having A programmer"programs' in an object-oriented program
different hardware components. 40 ming language by writing individual blocks of code each of
Programmers for CNC control systems can also be which creates an object by defining its methods. A collection
required to "reinvent' software components not just in of such objects adapted to communicate with one another by
response to new hardware, but also in response to new means of messages comprises an object-oriented program.
standards for inputting descriptions of parts to be formed by Object-oriented computer programming facilitates the mod
the CNC machine. The earliest CNC machines accepted part 45 eling of interactive systems in that each component of the
definitions through punched paper tape. Subsequent CNC system can be modeled with an object, the behavior of cach
machines (such as that disclosed in U.S. Pat. No. 4,477,754) component being simulated by the methods of its corre
interrogated a machine operator through a series of ques sponding object, and the interactions between components
tions to obtain instructions about how to create a desired being simulated by messages transmitted between objects.
part. More recently, several standard data file formats have 50 An operator may stimulate a collection of interrelated
emerged for describing parts to be machined, such as the objects comprising an object-oriented program by sending a
HURCO conversational or RS-274D M&G code programs. message to one of the objects. A method of the object
In the past "part program interpreter' modules of CNC receiving the message may cause the object to respond,
control system programs, each module used for accepting a carrying out predetermined functions which may include
part definition in a different format, would generally have to 55 sending messages to one or more other objects. The other
access, as described above, various data elements and Soft objects may in turn carry out additional functions in
ware routines diffused throughout the CNC control system response to the messages they receive, including sending
software. Again, each different input format has resulted in still more messages. In this manner, Sequences of message
a unique part program interpreter Software program, and and responsc may continue indefinitely or may come to an
these programs all include much common, and therefore 60 end when all messages have been responded to and no new
needlessly duplicative, functionality. messages are being sent. When modeling systems utilizing
Object Oriented Software an object-oriented language, a programmer need only think
in terms of how each component of a modeled system
Most existing programming languages provide 'sequen responds to a stimulus and not in terms of the sequence of
tial' instructions for a processor to implement. These lan 65 operations to be performed in response to some stimulus.
guages have previously been used to implement CNC con Such sequence of operations naturally flows out of thc
trol systems. However, computers are often utilized for interactions between the objects in response to the Stimulus
 5,453,933
S 6
and need not be preordained by the programmer. BRIEF DESCRIPTION OF THE DRAWINGS
Although object-oriented programming makes simulation FIG. 1 is a schematic diagram of the hardware compo
of systems of interrelated components more intuitive, the nents of a CNC machine tool system on which the control
operation of an object-oriented program is often difficult to system of the present invention may operate.
understand because the sequence of operations carried out
by an object-oriented program is usually not immediately FIG. 2 is a schematic diagram of the types of software
apparent from a software listing as in the case for sequen classes included in a CNC control system, and several
tially organized programs. Nor is it easy to determine how representative types of object-oriented objects within sev
an object-oriented program works through observation of eral of these classes.
the readily apparent manifestations of its operation. Most of 10
SUMMARY OF THE INVENTION
the operations carried out by a computer in response to a
program are "invisible” to an observer since only a relatively The control system of the present invention provides a
few steps in a program typically produce an observable real-time CNC software system that isolates system respon
computer output. sibilities into classes that permit a CNC manufacturer or
15
Object-oriented analysis and design methods permit reuse system integrator to manage complexity and change. The
of system analysis and requirements from other products in control system allows different systems to be created from
the same family. Object-oriented software design means that the same model and future, as yet unimagined, technological
software components are created from data and functions advances can be incorporated without redesigning or making
and are organized into objects. An object is an abstraction of 20
massive changes.
something in the real world, reflecting the capabilities of a The system utilizes an object-oriented software environ
system to keep information about it, interact with it, or both. ment. A first class of object types is provided for processes
It is, therefore, an encapsulation of attribute values and their (such as drilling, reaming, milling) to be carried out by
exclusive services. An object's attributes describe the object, machine tool components (the Process Class). Some pro
but not how it works. The object's services are instructions, cesses objects may inherit characteristics of other objects in
programs, procedures, or actions that describe what the the Process class. For example, a "hole" object may have
object will do when something happens. characteristics such as a depth and diameter, which can be
As described above, objects are grouped into classes. A inherited by other process objects, such as a drill, rean or
class includes a description of how to create new objects in bore process object. A second class of object types of is
the class and establishes the basic variables that are common 30 provided which represent instances of machine tool compo
to all of its objects. New objects inherit these common nents, such as a table (axes), a spindle, tool changer or
characteristics from the parent class. This feature allows the operator console. Again, some objects may inherit attributes
software engineer to build on existing design and code by of other objects. For example, an axis group, namely an
creating more specific objects from the easily reused code in object for simultaneously controlling multiple axes to shape
the general class. For example, a software engineer can use 35 complex three-dimensional objects, may be inherit attributes
a general class of characteristics for a "device' to create a of a single axis object. Other objects may be composite
model of a more specific device such as a spindle. Object objects of other tool objects. For example a tool changer
oriented analysis and design explicitly represent common may be a composite object of a collection of different milling
ality in the system's objects and use inheritance to identify bits which may be held in the tool changer (in addition to
and capitalize on commonality of attributes and services. 40 having its own attributes).
The system may only access data through the services, if at Most importantly, during execution of the software com
all. Services hide an object's data and send messages to ponent of the control system, the objects transmit messages
perform operations. This isolates dependency on aparticular to each other. For example a drill process object can be
data structure thus permitting new features to be added defined to hold all the information needed to define a drilling
without changing the arrangement of the original objects. 45 process, and this information may be sent in a message to an
This structure protects the data from the damage that com Machine Class spindle object (to move the spindle down and
monly occurs during changes in monolithic, proprietary form the hole) and to an axis group object (to position the
systems. workpiece in the proper location). However, the portion of
the software which defines the drilling process does not need
OBJECTS OF THE INVENTION 50 to access information regarding how the actual machine tool
One object of the invention is to provide a CNC machine component carries out its task, or how the motion control
tool control system that utilizes an object oriented program module controls the machine components. Therefore, in a
in which objects exchange object oriented messages. software implementation, the same process object can be
used in virtually any CNC machine, without undue regard to
Another object of the invention is to provide a CNC 55 its manufacturer or specific hardware components. More
machine tool control system that is scalable such that it may over, the object oriented messages through which various
be used for either high end or low end CNC machine tools. objects communicate provide a standard interface for adding
Another object of the invention is to provide a CNC additional functionality to a CNC machine tool control
machine tool control that is easily modifiable, in which system.
previously written software can be reused, and in which new 60 For example, the primary purpose of a user interface is to
objects can be added which inherit or comprise composi collect information about a series of machining processes to
tions of previously defined objects. be performed. Once the basic information is collected, the
Another object of the invention is to provide a CNC user interface can execute the processes by: (1) calling a
machine tool control system in which new processes may be process object with data about a new process to thereby
added by a programmer without requiring the programmer 65 create the object; (2) repeat step (1) for each process; and (3)
to know details of how particular hardware components sequentially sending a message to each defined object telling
carry out specific workpiece shaping processes. it to execute itself. Thus, the programmer of the user
 5,453,933
7 8
interface may be completely insulated from motion control by the Kernel's components. New machine tool components
data required for the machine tools to carry out their tasks. can be added to the Machine class and existing components
Because communication between software objects is can be easily modified without making changes to thc
accomplished through messages, software functions can be Kernel.
more easily distributed among different, simultaneously The Process class holds the Process techniques (methods)
executing tasks. For example, instead of a motion control that perform specific common practices on the specific type
module needing to keep track of which task needs informa of machine (low-end milling machine, lathe, punch press,
tion regarding a particular hardware fault, information EDM, gauging system, etc.). The objects in this class usc
regarding a fault may merely be sent to an exception handler multiple Machine Class objects and can be accessed from
object. This allows the motion control module to devote O multiple part program interpreter (operator) programs. This
more processing time to its primary task of controlling class usually contains libraries of canned cycles to handle
motion, and permits all error conditions to be handled in a such operations as milling frames, tapping, and boring, but
uniform manner. Specifically, the exception handler may it also contains any subroutine that several different appli
keep a database of which objects have a need to know about cations need to use. The objects provide easy accessibility to
which types of faults, and report specific faults only to those 15 the complex CNC features. ar
objects. Therefore, in adding a new process or machine The Operator Class (including the Part Program Inter
component object to the system, modification of the motion preter) is an extension of the CNC operator's skills and job
control module can be kept to a minimum as fault conditions functions. It also holds the operator programs such as part
may be handled by the exception handler. programming and system diagnostics. This class makes use
20
There are seven basic Classes of software components: of services provided by other classes to manage control of
Device Drivers, Operating System, Platform Services, the the machinery. Using programs at this level, the operator can
Kernel, Machine Class objects, Process Class objects, and set the system parameters (e.g., maximum feedratc) and
the Operator Class. The Device Drivers class contains the communicate with the machine tool while it is running a part
interfaces to particular hardware such as the hard drive, 25
program. Most of the changes made to a CNC will bc
floppy drive, serial and parallel ports, motion board, and I/O modifications to change what the operator can do. These
device. This isolates all hardware interfaces into a single changes usually affect the part programming and part Cutting
class that only needs to be changed when new hardware environment and can be made at this level with any accom
components are added to the existing system components panying techniques changed in the Process class.
and need to communicate in a different manner with the Engineers changing a control system of the present inven
30
system. tion can easily make changes to the system because they do
The Operating System class is responsible for hardware not need to be experts on the entire system to make a
and software resource management. It manages memory, modification to a single component in a class. One change
timers, and the scheduling of all processes and tasks. This does not have a ripple effect of change throughout the
class makes it possible to port a control system in accor 35 system. Portions of the system that are most likely to change
dance with the present invention system to other hardware such as the user interface and device drivers are separated
platforms. The Platform Services class is responsible for from the Kernel. These components are more accessible to
facilitating the execution of tasks such as error handling and change through PLC programs, customizations to thc
communication between part program interpreters and the Machine class and addition to or modification of operator
lower levels of the system. This class simplifies system 40 programs.
communications and only requires change if advances in Users of the control system of the present invention will
computer science technology need to be incorporated have a more stable design that can be tested for completic
because they improve the efficiency or change the manage ness. The system makes possible the efficient reuse of
ment of initialization and message handling. The Kernel system analysis, requirements, design, and components. The
class handles continuous motion and discrete input/output 45 system forces system designers to consider all nearly all
implementation components. This class forms the stable levels of CNC responsibilities to be handled by object
core of the CNC control system that only needs to be oriented software. In addition, changes at the Device Driver
changed when performance scaling is required. This and Operating System levels may incorporate new technolo
approach is in sharp contrast to prior CNC control systems gies and at the Operator and Process levels will be changed
that require system developers to change the Kernel when 50 to enhance or scale down system features and functionality.
making changes to the Operator Class objects, such as the The core classes, Machine and Kernel, will change infre
Part Program Interpreter. quently due to the "all purpose' nature of the objects in thesc
The remaining three classes (Machine, Process, and two classes.
Operator) specifically tailor any system to be a machine tool The present system uses an open systems, object-oriented
CNC. The Operator and Process classes are the "tools' used 55 design approach. This allows users to tailor hardware and
to communicate clearly to the above hardware-oriented software to gain the competitive edge. The CNC control
classes. The Machine class contains the objects that makes system allows easy integration of hardware and softwarc
this communication understandable by the Kernel compo from different suppliers and permits the porting of systems
entS. to other hardware platforms. Industry standard hardware
The Machine class is a collection of objects that embody 60 interfaces to simplify assembly and maintenance may be
the abstraction of real-world components such as the tool used. The system is dynamically reconfigurable to easily
changer, spindle, or coolant. This class describes all generic permit third party development of software components.
categories of machine tool devices by their basic required The system uses simple, Standard messages in a message
characteristics. Operator programs usually communicate schema. The messages are flexible and allow a user to Sclect
through the objects in this class to the Kernel. The Machine 65 messages they want to use and to alter the messages to mect
class turns operator commands such as "change to tool #6' their needs. The system software is scalable to support less
into a message or series of messages that can be understood expensive and/or a full-featured CNC hardwarc system
 5,453,933
10
using the same software structure. follows:
As with data characteristics, services can also be inherited
from the parent class when a new class or object is created.

/* The message header includes information about the message itself */

typedef struct lc header type
int msg size, f* Length of message */
int header size; f* Length of header info */
lc_msg message, /* The enumerated message number */
int transaction, /* The message transaction number */
enum type; /* The type of message (request / response):
0 = this is a request (set by sender)
1 = request received (set by receiver)
2 = request completed (set by receiver)
3 = request denied (set by receiver)
4 = no service available (set by receiver) */
} lc header type;

20
Of course, the new class or object may use the service or There are three types of messages: actions, information
create a different version of it. Different objects can use blocks (info), and cycles. Actions are system messages that
identical services. Therefore, a software engineer writes the are required to conduct basic communication between sys
code for the service only once and then reuses it after that. tem components and do not change from one machine type
The reusability of existing object-oriented code makes to another. Info messages include a block of information that
development and modification faster because there is less to 25 was either requested by a system component or that is sent
write and maintain. relative to a button-event, key-press or mouse-click for
A diagram of the system of classes of software component example. Cycles are messages that perform customized
classes is shown in FIG. 2. operations that may change from one machine to another.
The software objects use messages to communicate Cycles may be supported by ladder logic sequences in the
between the components. The class structure simplifies
30 Logic Controller program. In addition to using new and
system operations and programming by limiting the mes existing Cycles, the system integrator may take advantage of
sages of interest to each class. For example, the Machine the Softkey and Prompt messages in conjunction with ladder
class does not worry about the Kernel's responsibilities such logic to form customized operations that allow interactive
as travel limits and servo errors. Conversely, the Kernel is input from the operator console. For example, toolchanger
not concerned about ownership or devices because the
35 calibration could be done by invoking a ladder logic
Machine class handles that exclusively. Messages sent from sequence which responds to a specific softkey and then
the Operator and Process classes to the system devices can performs the logic necessary to do calibration for a particu
originate from several sources, including the Part Program lar machine. This would require no hard-coded software in
the system and would be completely configurable by a
Interpreter, the User Interface, Push Buttons on the Console 40 system integrator without the control builder's assistance.
or Jog Pendant, or a Sensor Interface Applications can Any Part Program Interpreter (PPI) may be used as long
communicate with the Kernel through any or all of the as it uses the embodiment's interface.
system classes. For specific functions, a software engineer Components of the Operator Class may include the fol
may bypass a class and connect an application directly to the lowing: Conversational part program interpreter, NC inter
next class or another class down. This is accomplished 45 preter, Manual mode user interface, Auto mode user inter
through the standard message formats supplied for each face, Diagnostics user interface, Program editor for
object component in the system. conversational programming and Program editor for NC
The general format for messages sent between classes is programming
set up as a data structure containing a common header and The Process class contains pre-packaged objects using
the arguments that are unique for each specific message. The 50 multiple class objects. When an application uses packaged
header includes several variables that are common to all cycles, the operator can specify a type of operation and
messages. The messages are designed to be variable length define only the necessary variable information. Then the
for efficiency. The message type is a static identification system makes additional calculations to define the operation
number which is unique to the class of message being sent fully. For example, when the operator is programming a
(e.g., a calibration message). The transaction number, 55 shaping process such as a hole-making drilling operation
unique for each specific message transmission, is assigned at with pecking, the operator simply specifies the peck type and
the time the message is sent and is used to match responses depth (thereby defining the X, Y and Z dimensions) and the
to the messages. system uses a canned cycle to determine the exact move
The response message is set up so that it uses the request ments of the drill during the pecking process. Another
message's ID and transaction field, and the status is set to 60 example would be a milling object which represents a
"received” or “completed” or "denied” as required. This milling operation to be used to shape a workpiece. The
makes it clear which request is associated with the response. object may further include means for defining whether the
Responses have no arguments associated with them. Any shape to be milled is to be removed from the workpiece or
thing that requires arguments to be passed is considered to left remaining in the workpiece. The object may also include
be a new message. For example, the response to an IOSend 65 sequencing status means representative of whether the pro
Node message is an IOInfo message with the data field cess defined by the object has been performed. In one
passed as an argument. A Sample message structure is as embodiment, packaged cycles are contained in libraries that
 5,453,933
11 12
can be used by different operator programs with little or no running applications. Applications register with Dircctory
modification. These cycles are pre-programmed, common Services and receive addresses of the other applications with
machining operations and include drill, tap, peck and ream. which they need to communicate. Directory Services does
The Machine class forms a device-oriented interface not assume any specific communications connections. This
between the details of the Kernel and the operator programs means that the system is dynamically configurable to allow
and canned cycles. The Machine class manages the com addition of other applications that use the interfaces of an
plexity of the system by handling the device responsibilities embodiment of the present invention. Applications store the
between the operator programs and the Kernel. The Machine addresses they receive from Directory Services in their own
class establishes and monitors the operator programs' con directories. Applications, such as the Kernel, that need
nections to the Kernel and handles messages between the 10 machine configuration parameters can retrieve those param
applications and Kernel. Each application has a copy of the eters from the shared memory where the Machine Configu
Machine class included in order to interface in a common
way to the Kernel. Shared data assures that all applications ration Library stores the information.
use the same Machine class state information. An operating system usable in connection with the present
Since the Machine class uses object-oriented design, it invention complies with IEEE-1003.1 POSIX (a standard
contains objects that define specific devices with possible 15 for application programming interface for UNIX) and the
functions for each device. For example, some possible IEEE-1003.4 POSIX standard that defines real-time exten
functions of the spindle object may be run, clamp, and stop. sions. This embodiment uses the Lynx operating system
The object's data describe the speed range and current (LynxOS), a real-time, UNIX-like, operating system that
speed. An operator program may not necessarily use all of runs on any 386 PC/AT or greater compatible computer.
a Machine class object's functions, but the functions are 20 LynxOS has these characteristics: (1) Compliant with
available and supported by the Kernel. POSIX 1003.1, POSIX 1003.4 real-time extensions and
Typically, a copy of the Machine class will be attached to POSIX 1003.4a threads interface; (2) Full UNIX compal
each operator application being used in order to provide a ibility (binary and source with System V, source with BSD
common interface to the Kernel. In addition, a customer may 4.3); and (3) Completely deterministic, including Multi
extend the functionality of the Machine class being used, as 25 tasking with user-defined priority levels, Multi-threadcd
long as the same Machine class is being used by all operator support for real-time ADA, Offers demand-paged virtual
programs. One embodiment of the Machine class contains memory, Runs off-the-shelf Interactive UNIX System V
the following objects: Push-button Console, Jog Pendant, software without recompilation, and Networking and com
Axis, Axis Group, Spindle, Tool Changer, Coolant and Lube. munication facilities including TCP/IP and NFS. The
The Kernel provides mechanisms for coordinating mul 30 LynxOS development tools including over 170 UNIX-com
tiple, servoed axes and to provide discrete I/O control. The patible utilities and the standard UNIX libraries may also be
CNC applications communicate with the Kernel compo used. The tool set used in one embodiment supports DOS
nents, the Logic Controller and the Motion Controller, I/O facilities, Debugger software, Re-entrant device drivers,
through the Machine class. These Kernel components decide Compilers for C, FORTRAN, Pascal, BASIC, and ADA,
how to implement the operator programs' commands for the 35 GNU Package (GCC, Emacs, GDB, C--E), X Window
hardware provided. System, Motif, Network File Sharing (NFS) and Transmis
The Motion Controller provides multi-axis coordination sion Control Protocol/Internet Protocol (TCP/IP).
as in most commercial CNCs. In its basic form, it controls The Device Drivers class forms the interface between the
five coordinated axes plus one spindle and two auxiliary operating system and the hardware devices such as I/O
axes. In addition it supports several types of interpolation 40 peripherals (e.g., serial communications ports), video dis
algorithms including linear, circular, elliptical, helical, and plays, and mass storage devices. The operating System calls
polynomial. Applications communicate with the Motion these drivers when a device is installed (at boot time or
Controller through the Machine class message interface. dynamically) and when application programs necd to access
The Logic Controller (LC) contains two programs: pro a device. The device drivers in the embodiment are capable
grammable ladder logic and the LC engine. The LC uses a 45 of handling multiple devices and respond rapidly to high
window-based programming environment either off-line or priority tasks. The present invention contains the following
at the Operator level to simplify production of a logic types of drivers: PC/AT keyboard and serial mouse, Analog
program to run on the LC. The LC also has software tools input/output card, SCSI device driver, Floppy disk devicc
to change, debug, and monitor the operation of the ladder driver, Ethernet interfaces, Internet message and transmis
logic. 50 sion control protocol, Internet protocol and protocol family,
The Platform Services class of the present invention Internet user datagram protocol, Pseudo terminal driver,
provides the structure that allows operator programs and Hard copy and video terminal interface, NFS client I/O and
third-party software to connect to the system and commu server drivers, CANbus, and MATRIX4
nicate with other software applications. There are four
services that control system connection and communication: 55 DETAILED DESCRIPTION
Initialization Sequence-a file, similar to a PC's autoex
ec.bat file, listing all operator programs in the order that Overview-Hardware
they will start during start up;
Directory Services-a registry of all active programs, FIG. 1 is a schematic diagram of a typical CNC machinc
60 on which the control system of the present invention may
Machine Configuration Library-a shared memory area operate. A standard PC-compatible ISA bus 10 is connectcd
to store default machine parameters for application to CPU processing unit 11 and its associated motherboard,
configuration. This is similar to the win.ini file in the preferably an Intel 80486 class microprocessor. The bus may
Microsoft Windows system; and also access RAM memory 12, which may alternativcly be
Exception Reporter-collects, organizes, stores and dis 65 connected directly to the motherboard, ISA bus 10 may
tributes all errors of interest to the active applications optionally provide an interface to network 13. Mass storage
Directory Services contains a "phone book” that lists all device 14, which may include both hard and floppy disk
 5,453,933
13 14
drives is also connected to ISA bus 10, as are standard Interpreter (PPI) or user interface. This type of software is
communications ports 20, motion control board 18 (prefer generally well-known in the art, and except for the way it
ably a DSPCG, Inc. (Minneapolis, MN) Matrix 4 / Vector 4 communicates the information it obtains to the remaining
combination mounted on a VME bus), and video interface software components, does form a part of the invention per
15. se. The PPI may either interrogate the operator to input steps
In one embodiment, the CNC machine specific hardware to machine a workpiece, or may prompt the user to specify
of the system are interconnected via a CANbus bus system. a data file having a digitally stored part manufacturing
Accordingly, CANbus interface card 16 is also positioned in description. Regardless, once information about the part is
ISA bus 10. CANbus cable 17 connects other CNC machine obtained, the PPI dynamically creates appropriate objects in
hardware components and provides communication therebe 10 the Process class as further described below.
tween, CNC machine operator console 19, jog pendant 21, The control system of the present invention uses object
and servo motors 25, 26. In general, motion control board oriented design and programming object-oriented design
18, or CANbus interface 16 and CANbus cable 17, provide
means for transmitting command signals to a movable tool, means that software components are created from data and
such as servo motors 22–26 and/or the axes or tool fixtures 15
functions and are organized into objects. Software compo
connected thereto. Servo motors 22-24 control movable nents communicate through messages sent between objects.
tools for shaping a workpiece, such as X, Y and Z axes of Objects have two parts: data and methods. Objects are
the machine tool, respectively, while servo motor 25 may abstract representations of the basic things a system handles
control the spindle which rotates a cutting tool. Servo motor (e.g., a spindle, tool changer, or type of motion). An object's
26 may control an tool changer which holds a plurality of attributes describe the object, but not how it works. The
workpiece shaping tools, such as milling bits or may control 20 object's methods, are instructions, programs, procedures, or
a rotary table. actions that describe what the object will do when something
The system uses industry standard cards including the happens. So a spindle object's methods may be initialize,
new CANbus distributed I/O card. This bus allows a user to run, orient, speed override, and stop. The object's data
attach nodes to the system rather than insert cards into the describe the speed range and current speed.
25
cabinet. The high availability of the cards keep prices low Using object-oriented programming, objects can be
and reliability high. Standard board sizes and mounting quickly created using a class, the blueprint for the objects.
holes keep the system open to changes and upgrades. The class establishes the basic variables that are common to
Keyboards, trackballs, and jog pendants are connected as all of its objects, and the new objects inherit these common
CANbus nodes to the system. The keyboard may be located 30
characteristics from the parent class. This feature allows the
away from the main platform without decreasing the quality software engineer to build on existing design and code by
of the signal. However, to comply with safety standards, the creating more specific objects from the easily reused code in
emergency stop button and the power on/off switch are the general class. For example, a software engineer can use
wired directly. a general class of characteristics for a "device' to create a
The control system of the present invention System offers 35
model of a more specific device such as a spindle.
two back plane buses: ISA and VME. Both meet LynxOS A method belongs to an object and indicates how to
and POSIX standards and communicate with the control perform an action or how to react when an action is
system software. Using CANbus and MATRIX4 with either performed on the object. The system may only access data
bus permits real-time path correction based on auxiliary through the methods, if at all. Methods, therefore, hide an
sensors such as vision, secondary axis, and temperature 40 object's data and send messages to perform operations. This
SelSOS. isolates dependency on a particular data structure thus
The system's I/O backbone is the CANbus, a multi permitting new features to be added without changing the
master serial bus. CANbus can be structured to form many arrangement of the original objects. This structure protects
different architectures because it has different types of PC the data from the damage that commonly occurs during
configurations and the CANcore module to standardize the 45 changes in monolithic, proprietary systems.
interface to I/O peripherals. CANcore acts as a CANbus As with data characteristics, methods can also be inher
node allowing the customer to connect peripheral I/O ited from the parent class when a new class or object is
through the industry standard SPI (Serial Peripheral Inter created. Of course, the new class or object may use the
face) Bus. method or create a different version of it. Different objects
The system uses the MATRIX4 to decrease system inte 50 can use identical methods. Therefore, a software engineer
gration costs, increase motor control system performance, writes the code for the method only once and then reuses it
and create component sourcing options for the customer. after that. The reusability of existing object-oriented code
This controller is a fully digital, 4-axis position controller makes development and modification faster because there is
available on both the ISA and VME host platforms. The less to write and maintain. An additional benefit of using
flexibility of the controller design allows a user to adapt the 55 object-oriented methods is the localization of change. Data
controller to any motor design on the market. The controller hiding isolates code from other code and reusing methods
is capable of interfacing to DC brush, DC brushless, and AC removes the need for switch statements and other references
induction motors and allows most parameters to be pro throughout the code to the system's condition or processing
grammed dynamically. This allows immediate updates when state. This limits the ripple effect of changes and makes it
there are changes in the environment or operating condi 60 easier to maintain large, complex programs.
tions. The control system of the present invention software
Overview-Object Oriented Systems contains class libraries, of machining software. These librar
ies contain machining procedures and functions that can be
An overview of the broad categories of the software called with an expected result. These libraries are grouped
components of the CNC machine control system of the 65 into object-oriented classes that may be used as is and/or
invention is shown in FIG. 2. In the Operator class are extended. The core libraries contain the most basic charac
software programs generally classified as the Part Program teristics needed for primitive operations.
 5,453,933
15 16
The software employs a bi-directional messaging inter Controller (LC) engine executes ladder logic/GRAFCET
face to facilitate communication between components. Mes programs to control the machine at the lowest level. There
sages are passed between the CNC applications (PPI and are two programs the LC engine executes: the user program
Process Class) and Kernel. Communication from the appli and the system program. The LC also has tools to change,
cations to the Kernel differs from communication between debug, and monitor the operation of the ladder logic.
the applications in that Kernel communication is more
precisely defined for the Kernel. Each component commu Operating System
nicates through messages. These messages may have differ
ent requirements. Messages are managed for efficient com The real-time, UNIX, execution environment provides all
munication. Unordered, independent messages are executed 10 of the standard advantages of a real-time environment with
immediately. Ordered, dependent messages are queued. A its diagnostics and response capabilities. In addition, X
queue message is not executed until the previous message is Window is a standard, graphical, user interface. X Window
complete, and each component maintains a separate mes permits a variety of input devices (e.g., mice, keyboards,
Sage queue. graphic displays) to be simultaneously shared by several
A key feature of the CNC control system of the present 15 programs. This flexibility allows developers to leverage
invention is the ease with which existing systems can be their areas of expertise without being concerned about the
brought onto the new platform. The obvious advantage of basic system graphics. This window-display interface also
this feature is that it preserves features of existing systems allows the user to run one machine and display its output on
while providing a migration path to future technologies. another, an definite advantage for a CNC application. Motif
There are two ways a user may take to move existing 20 manages the windows created by X Window. This manager
software to the control sytem of the present invention: (1) allows the user to control the size, location of windows on
porting "C' systems for immediate use, or (2) conversion of the screen, and identification of the active window. This
procedural code to C or C-H-. software also provides a library of X Window items to use
in system development. TCP/IP is a network protocol that
Machine Class 25 runs on Ethernet. It allows X Window to perform network
transparent activities such as remote procedure calls. Its file
The Machine Class is an object-oriented interface to the sharing capabilities means that programmers do not need to
Kernel and Process Class. This class contains the machine's download files.
device-specific application procedures to hide the complex
ity of the Kernel and the message interface from the CNC 30 Platform Services
applications. This is accomplished through the interface The Platform Services Class provides these functions:
between the Machine Class and the CNC applications (Pro Initialization Sequence-a file listing all applications in
cess Class/PPI). Applications call standard functions to the the order that they will start during power up;
Machine Class objects which sends a message to the Kernel.
The Machine Class objects handle all communication 35 Directory Services-a registry of all active applications
between the Process Class objects and the Kernel including Machine Configuration Library-a shared memory arca
the creation of the communications port, use of appropriate holding default machine parameters;
communication functions, and passing messages back to the Exception Reporter-collects, organizes, stores and dis
CNC applications. The specific Machine Class responsibili tributes all errors of interest to the active applications
ties are allocation of resources and connection to the Kernel, 40 Applications register with Directory Services and receive
message handling between the Kernel and the CNC appli addresses of the other applications with which they need to
cations, and device state monitoring and management. communicate. Applications store the addresses thcy receive
When the system starts up, the Machine Class allocates from Directory Services in their own directories. Applica
the resources that the application needs and creates a port to tions, such as the Kernel, that need machine configuration
the Kernel from each CNC application. After the port is 45 parameters can retrieve those parameters from the shared
created, the Machine Class logs in to the port creating a memory where the Machine Configuration Library stores the
two-way connection between the Kernel and each running information.
application. This allows messages to be sent back and forth Messages between the applications use POSIX message
from the applications to the Kernel. Multiple copies of the queues. These queues, are created at run time and have
Machine Class may be used in the system. In fact, it is 50 unique names. Each application receives messages through
customary to attach a copy of the Machine Class to each one instrument, but as when using telephones, each appli
CNC application being used. cation can communicate with many different applications.
The Initialization Sequence is the init script file listing all
Kernel applications in the order that they will start during power up.
55 It is executed after the operating system boots. The Initial
The Kernel Class is the mechanism through which CNC ization Sequence's primary responsibilities are to:
applications control machinery. The Kernel provides mecha Load various CNC system drivers (CANbus, MATRIX4,
nisms for controlling discrete I/O and coordinating motion and the serial port driver)
axes. This general controller can be used in a variety of Start Directory Services, the Exception Reporter, the
machining applications. The Kernel contains two compo 60
nents: Logic Controller and Motion Controller. The Motion Kernel, and the user display
Controller performs multi-axis coordination. In its basic Create the Machine Configuration Library
form, it controls five coordinated axes plus one spindle and Start listed applications
two auxiliary axes. In addition it supports several types of A user may create and change this script. It should begin
interpolation algorithms including linear, circular, elliptical, 65 with the device drivers, Platform Services, and the X Win
helical, and polynomial. Applications communicate with the dow System. Other applications in the script may be thc
Motion Controller through a message interface. The Logic CNC applications and the motion subsystem and Logic
 5,453,933
17 18
Controller within the Kernel. To create or change the script, Platform Services Schema
the customer may use an editor (Vi) or the interactive setup The schema defines the data structure qualifiers for all
program. The script can also be created automatically with messages and global data used by Platform Services. Plat
the software installation program. The following is a repre 5 form Services' messages use the following qualifiers:
sentative initialization sequence script.
. String. PhoneListing
f . Description . Value
# Dynamically installed device drivers 10 FieldPir - FieldCount
f . DataType ErrorCode
dynaminst Devices/MATRIX4 instab
gainst /Devices/CANbusinstab The following qualifier descriptions contain definitions in
# System Services the form of text and in "C' code and the definitions of the
ifbin/DirectoryServices "C" code data names.
sleep 5
/bin/ExceptionReporter String
i
# Kernel String is a structure describing a collection of ASCII
Abin/Kernel & 20
characters. The "C" data structure follows:

# User Applications
i
|Apps/bin/Manual & pede? Struct
25 int length;
char characters;
} String;

Platform Services Messages length=number of characters in the string

Messages have a standard grammar using command verbs 30 characters=an array of letters, numbers, and/or symbols
with possible qualifiers. There are three types of qualifiers:
Structure-defines a type of variables. Description
Enumeration-a list of integer values allowing associa- Description is a string explaining a variable concept (e.g.,
tion of constant values with qualifier names. 35 an error condition) in a message. The "C" data structure
Union-a variable that may hold (at different times) follows:
objects of different types and sizes. It is used to typedef String Description;
manipulate different kinds of data in a single storage
area without embedding any machine-dependent infor. FieldPtr
mation in the program. FieldPtr is an index in to the Machine Configuration
Required qualifters begin with a capital letter, and optional database. The 'C' data structure follows:
qualifiers use no capitals. typedef int FieldPtr;
45 Field Count
If the field is an array the FieldCount indicates the number
Message Structure of elements in the array. The "C' data structure follows:
Messages used by the Platform Services have this basic typedefint FieldCount;
Structure:
50
Verb Qualifiers PhoneListing
A verb describes the message request. The verbs used by the PhoneListing is a data structure representing the address
Platform Services' components are- of an application in a directory listing. The "C" data struc
Add-establishes a phone book listing for an application ture follows:
Get-finds the address of an application or the configu- 55
ration information in shared memory
typedef struct
Update-supplies new information for an application {
ino- string processName,
Ping-checks on the status of an application (active or 60 portName Name;
shutdown) int processID;
Request-asks to be informed when a condition has } PhoneListing;
changed
The qualifters are data structure names followed by the data processName=name identifying the application
structure elements. These qualifters can be composed of 65 portName=name of the connection port for the application
other qualifiers (i.e., dynamic data structures). Verbs act on identified
the qualifiers. processID=integer code identifying the application
 5,453,933
19 20
DataType Applications register in the Directory Services' phonic
DataType is an enumeration of data representations. The book by listing their unique ASCII names. Then before an
'C' data structure follows:
application can communicate with another application, it
requests the POSIX message queue address from Directory
5 Services' phone book. Each application has its own phone
book. It lists only the addresses of other applications with
typedef enum which it needs to communicate.
undefined; Application Shutdown
integer,
floatingPoint 10 Directory Services periodically pings all registered appli
} DataType; cations to be certain that they are Still running. If an
application has shut down, Directory Services removes the
Undefined=data type not specified shut-down application from the list of registered applica
Integer-data consisting of whole numbers tions, destroys its copy of that application's port connection,
15 and informs all remaining, registered applications that the
FloatingPoint=floating point data application has shut down. At that point, the applications
String=data expressed with characters decide if they need to disconnect from the shut-down
application. Applications clean up after disconnecting by
Value removing the reference for the shut-down application from
20 their own directories.
Value is a union representing a variable data type.
DataType defines the data's size and type. The "C" data Messages to Directory Services
structure follows:
Applications send messages to Directory Services to
25
register in the phone book and to retrieve phone book entries
typedef union
of other applications. These messages use the standard
message structure described previously.
int integer,
double floatingPoint; Add
String string;
Value 30 An application may send an Add message to Directory
Services to establish a phone book listing for the application.
The Add verb uses the PhoneListing qualifier with thc
integer=data consisting of whole numbers required elements Name, PortName and ProcessID. The
floatingPoint=floating point data message structure is
string=data expressed with characters 35 Add PhoneListing<Name> <PortName> <ProcessID>
ErrorCode Elements
ErrorCode is an enumeration of exceptions. The "C" data The elements for the Add verb can use a string of ASCII
structure follows: 40 characters.
<Name>ASCII character string<PortName>ASCII char
acter string<ProcessIDDnumber representing the pro
typedef enum cess ID
{ Sample Message:
NoSeverity; 45 Add PhoneListing LCLCport1194 151
Information,
Warning; Expected Responses
Fatal;
Error(Code, When Directory Services adds the new entry to its phone
book, an "Added response is sent to indicate that the phone
NoSeverity=error of uncategorized severity 50 listing was successfully updated. A “NotAdded responsc is
Information=error message providing information only sent if Directory Services was not able to update its phone
(no action required) listing.
Warning=error indicating application is having difficulty Added PhoneListing<Name> <PortName> <ProcessID>
completing the task 55 NotAdded PhoneListing<Name> <PortNamc
Fatal=error indicating application is not able to complete <ProcessID>Description <errordescription>
current task Sample Response:
Added PhoneListing LCLCportl194151
Directory Services
Get
Directory Services functions as a registrar for the system 60
applications. The responsibilities of Directory Services are An application may send a Get message to Directory
tO Services to find the address of an application with which it
Maintain a list of applications in the system wishes to communicate. The Get verb uses the PhoneListing
qualifier. The message structure is
Periodically check (ping) applications to see if they are 65 Get PhoneListing<ProcessName>
still running
Provide queue addresses of registered applications Elements
 5,453,933
21 22
The ProcessName qualifier is a string of ASCII charac memory area. The library also contains utilities to create,
terS. load the configuration, print, list, save, restore, and remove
<ProcessName>ASCII character string the information in the System Variables memory region.
Sample Message: System Variables Object
Get PhoneListing LC The System Variables object supports seven data types:
Expected Responses Bytes
When Directory Services retrieves an entry from its phone Strings
book for a requesting application, it sends a "Got' response
to indicate that the phone listing was successfully retrieved. 10
Doubles
A "NotGotten' response is sent if Directory Services was Integers
not able to find the phone listing. Short Integers
Got PhoneListing<Name> <PortName> <ProcessID> Long Integers
NotCotten PhoneListing<Name> This object also includes methods for saving and reading the
Sample Response: 15 parameter information to and from disk. The System Vari
Got PhoneListing LCLCportl19446 ables methods are listed below:
Messages from Directory Services BasePtr-returns the base pointer to the shared memory.
Directory Services sends messages to applications under two Close-closes a connection to the shared area.
conditions: 20 Field-calls the SVField object (described in the follow
Checking to see that the application is still active (Ping) ing section) to find a field specified by the field name.
Informing applications that another application is no FieldCount-gets the number of elements for the field and
longer active (Update) These messages use the standard returns the parameter count.
message structure described previously. FieldSize-gets the size of the field and returns the
25 parameter size.
Ping FieldType-gets the data type and returns "B" for byte,
"I' for integer, "D' for double,
The Ping verb uses the ProcessName qualifier. The mes "S" for string, "H" for short integer, or "L" for long
sage structure is integer.
Ping <ProcessName> 30
FileName-returns the configuration file name used to
Elements <ProcessName>ASCII character string define the shared data area.
Sample Message: Some additional System Variable methods are listed
Ping LC below:
Update 35 Get-finds configuration information in shared memory.
Directory Services sends the application an Update message Update-places new configuration parameters in shared
to inform an application of a change in another application's memory for an application.
status. The Update verb uses the PhoneListing qualifier and GetField-traverses the list of fields in the shared area.
has this structure
Update PhoneListing<Status.> <description> 40 Name-returns the shared area name specified in the
configuration file.
Elements NumberOfFields-returns the number of fields defined
<Status.>enumeration of Status for the System Variables.
conditions<description>ASCII string of characters PostSemaphore-releases the semaphore used to syn
describing the status condition 45 chronize access to the shared area.
Sample Message: Remove-deletes the shared area completely from the
Update LC shutdown system.
Restore-places a saved binary copy of the configuration
Machine Configuration Library 50
parameters into the shared area.
The Machine Configuration Library provides default Save-makes a binary copy of the configuration param
parameters for applications in a shared memory area. This eters and places it on the disk.
service's responsibilities are to Size-returns the total size in bytes of the shared area (not
Load and distribute initialization parameters from the file the amount of shared area being used).
system 55 WaitSemaphore-gets the semaphore used to synchronize
Distribute parameters to applications access to the shared area.
Some common parameters may be maximum acceleration, The PostSemaphore and WaitSemaphore methods allow a
maximum RPM for the spindle, and travel limits and feed program to access the shared area and send several messages
forward gains for each axis. Applications access these without the overhead of getting and releasing the semaphore
parameters under three circumstances: 60 for each Get and Update message. This approach saves time.
During application start-up for initialization parameters SVfield Object
During run time when operational parameters are needed The System Variables object uses the System Variables
When tuning or another operation makes it necessary for Field (SVfield) object to describe each field. Using this
an application to refer to its configuration parameters 65 object improves efficiency of the field access function by
This parameter library uses a C-H object, System Variables, providing detailed field information and eliminating the
to read and write data in the globally accessible shared search for individual fields.
 5,453,933
23 24
This object contains the following methods: Got FieldPtr-fieldPtraDescription<name>
Name-supplies the name of the field (up to 31 characters NotCotten FieldPtr-fieldPtr-Description<name>
including a null terminator). Description< errorDescription>
Type-supplies the field data type ("B" for byte, "I' for Sample Response:
integer, “D” for double, “S” for string, “H” for short Got FieldPtr 253 String “MaxTravelx'
integer, or "L' for long integer). Get Description
Count-supplies the number of elements that may be This message is used to request information about the
stored under the field name. Fields in the Machine Configuration Library. The Fields can
Elements are numbered beginning with Zero. to be described either by using the name or a field pointer.
Size-supplies the size of each field element. In 386/486 Get Description<name>Qualifier FieldPtr-fieldPrid
systems, integers and doubles are stored in four bytes Get Description<name>Qualifier
while strings are variable length. Description<fieldName>
Utilities
There are several utilities available to create and manage 5
the Machine Configuration shared data and the memory Elements
22.
The elements for the Get verb are
SVcreate-builds a configuration file. <name>name of the information requested from a field:
SVsize-checks the configuration file's size and recom 20 Field Count
mends a minimum size. Field Size
SVprint-displays the field name, data type (B, I, H, L, D, Field Type
S), the count (number of elements), and the size of each Field valueOualifierThe Qualifier is a place holder for
field. the results of the Get. It also specifies the data format
SVloadConfig-places the default values into the shared 25 (int, float, string) of the desired
memory area. result.<FieldName>Name of the fieldk
FieldPtrePointer to the field
SVlistData-creates a file showing all of the data values
currently stored in the shared memory area. Sample Message:
SVsave-makes a copy of the shared memory area under Get Description “Field Count” intzcountdFieldPtr 23
30
the file name specified in the configuration file. Get Description “Field value" FloatingPoint
SVrestore-dumps the shared area in hex bytes to be used <value) Description "MaxTravelX”
for detailed debugging tasks.
SVremove-deletes the shared area from the system. The Expected Responses
configuration file and any binary "save' files are left 35
intact. Configuration Library returns the following:
SVshmdump-displays the shared area in hex bytes. This Got Description<name>Qualifier FieldPtr-fieldPtr>
can be used for low-level debugging. Got Description<name>Qualificr
Messages to Machine Configuration Library Description<fieldName>
Applications send messages to the Machine Configuration 40 Sample Response:
Library. Get Description “Field Count' int. 10 FieldPir 23
Get
Get Description “Field value' FloatingPoint 23.5
Description “MaxTravel X”
An application may send a Get message to the Machine 45 Update
Configuration Library to access information. It uses this Update Description
format:
This message is used to change information about the
Get Qualifier Fields in the Machine Configuration Library. The
Get FieldPt Fields can be described either by using the name or a
This message requests the<fieldPtr> or the Field Descrip 50 field pointer.
tion. If the <fieldPtr> is zero, then this message requests the Update Description<name>Qualifier FieldPtr-fieldPlrd
pointer to the description<name>. If the Description is Update Description<name>Oualifier
empty, then this message requests the description of the field Description.<fieldName>
pointed to by<fieldPtre. It is an error if the<fieldPtre is zero 55
and the Description to be empty.
Get FieldPtr-fieldPtre Description<name> Elements
Elements The elements for the Get verb arc
The elements for the Get verb are 60
<name>name of the information requested from a field:
Field valueOualifierThe Qualifier is new value for the
<fieldPtr-Pointer to a field in the Configuration fieldkFieldName>Name of thc
Library<Name>Name of the Field fieldkfieldPridPointer to the field
Sample Message: Sample Message:
Get FieldPtr 0 String “MaxTravelX” 65 Update Description “Field value” int 10 FicldPur 23
Expected Responses Update Description “Field value' FloatingPoint 23.6
Configuration Library returns the following: Description “MaxTravelx”
 5.453,933
25 26
Expected Responses Device Layer
The Configuration Library returns the following: Directory Service
Updated Description<name>Qualifier Field Of course, the customer may also define additional error
PtrCfieldPtre
categories. Then when a message arrives, the Reporter
matches its severity and category with the types of messages
Updated Description<name>Qualifier each application indicated it wanted to receive. For example,
Description<fieldName> an application may need only the fatal, motion control
Sample Responses: messages, and another may need all logic control errors.
Updated Description “Field value' int 10 FieldPtr 23 10
After the messages are filtered in this manner, the one-shot
Updated Description "Field value' FloatingPoint 23.6 messages are broadcast to all interested applications and
Description "MaxTravelX" removed from the queue. All latched messages are broadcast
Exception Reporter to interested applications and kept in the queue until spe
cifically removed by another message.
The Exception Reporter receives all unsolicited error
messages (e.g., servo faults) sent by the Kernel. The Excep 15 Message Formats
tion Reporter responsibilities are to Messages sent to the Exception Reporter either report an
Receive error reports for applications and Kernel error or request error information. There are two verbs used
Distribute error reports to applications in the Exception Reporter messages: Update and Request.
This makes error handling uniform across all applications. It 20 Update
collects and organizes the errors for applications that have
registered with the Exception Reporter to receive particular To inform an application of an error condition, the Excep
types of messages. In addition, the Exception Reporter keeps tion Reporter sends the application an Update message. The
a list of all current pending error messages. When an Update verb uses the Error qualifier and has this structure
application starts up and checks in, it can receive all mes 25 Update Error-ErrorCode> <description>
sages of interest to it. Elements
Applications specify the severity and/or category of errors
they want to receive. So an application may tell the Excep <ErrorCode>enumeration of
tion Reporter to notify it when any I/O errors are generated. exceptions<description>ASCII string of characters
Another application may want to be informed only of the describing the error
30
fatal errors that shut down the machine. Sample Messages:
Update Error Fatal loss of encoder; X axis
Error Messages and Severities Expected Responses
The Exception Reporter sends the error message to an
The Exception Reporter filters errors for applications so that 35 application. If the error message was successfully sent, it
the applications only receive the messages they need. There returns an "Updated' message. If the error message was not
are two basic types of messages in the Exception Reporter sent successfully, it returns a "NotUpdated' message. The
queue: responses use these formats:
One-shot messages Updated ErrorzErrorTypes
Latched messages 40 Not Updated Error <ErrorType2 <ErrorValues Desc
When a one-shot message arrives, the Exception Reporter <errordescription>
determines which applications need to receive the message,
sends copies of the message to those applications, and then Request
removes the message from its queue. When a latched An application may send a Request message to Exception
message arrives, the Exception Reporter determines which 45
Reporter to ask that it be informed of specified error con
applications need to receive the message and sends copies of ditions.
the message to those applications. However, latched mes
sages are not removed from the queue until another message Request ErrorCode<Code>
arrives instructing the Reporter to remove the stored mes Elements
sage. The latched messages that have not been cleared form 50
the group of current pending messages that a newly started <Code>enumeration of exceptions
application may need to receive. Sample Message:
The messages may have three severities: Request ErrorCode Fatal
Information-describes a condition that may be of gen Expected Responses
eral interest to other applications. 55
There are two expected response verbs: Requested and
Warning indicates that operation of the machine has NotRequested. Both verbs use the ErrorCode qualifier.
halted though the power is still on. The operator may Requested ErrorCode<Code>
need to take some action to continue operations. NotRequested ErrorCode<Codex
Fatal-tells the system applications that the servo amp 60
has been shut down and the power has been taken away Operator Class
from the machine control hardware. The operator must Operator Class applications include part programming
take some action to resume operations. software. The conversational language used in a fully
There are also categories of errors that may be of interest featured package has a question/answer format using mul
to applications: 65 tiple choice and fill-in-the-blank questions, as well as clearly
Motion worded operator prompts. To further simplify part program
Logic Control ming, the system displays graphic illustrations of plan view,
 5,453,933
27 28
side views, and/or an isometric view with dimensional RS-274-D Package
scaling in the X, Y, and Z axes. A RS-274-D package provides conventional NC (G-codc)
The conversational part programming package features programming capabilities. This package allows the operator
the following: to save and load part programs to and from remotic Com
5
Packaged Cycles puters running CAD/CAM applications or other peripheral
Part and Toolpath Graphics Verification for Conversa devices (e.g., paper tape readers). Communication between
tional and NC programs these devices is handled over RS-232-C serial ports. Thc NC
Programmable Safety Areas editor in this package has the following features:
“No-Calc' Programming 10 Character insert or overwrite modes
Estimated Run Time Optional sequence numbers
99 Tool References Automatic sequence numbering by a programmable
increment
Automatic Speed and Feed Calculation
Inch/Metric Programming 15
Block-to-block cursor moves (forward and backward)
Modal Parameter Blocks Character-to-character and word-to-word cursor moves
(forward and backward)
Automatic Rough/Finish Pass Jump to program beginning or end or Scroll up and down
Data Block Search
on one page
After the operator completes a part program, there are 20 Jump to block or sequence number
several additional features of the software that can be used
to improve efficiency and accuracy: Jump to or replace a matching NC word
Error Checking Automatic syntax checking of NC data blocks
Test Run Function 10-element tag queue for “bookmarking” the program
Program Review 25 Jump to one of the tags
Program Text Printout NC block insert and delete
Graphics Printout Copy, move, or delete a range of NC blocks
Upload/Download Utility Interaction with the graphical system for program verifi
The automatic calculation feature allows the system to 30
cation NC programs can be loaded into conversational
calculate certain unknown dimensions after sufficient infor PPIs through this interpreter.
mation has been entered. This feature computes and displays PPI Messages
Cartesian and polar data for a programmed move. For
example, if the “X” and “Y” end coordinates are entered, the The Part Program Interpreter messages have the standard
system automatically calculates the XY length and the XY 35
grammar using command verbs with possible qualificrs.
angle parameters. The XY angle is the angle of the line There are three types of qualifiers:
segment (from start point to end point) measured counter Structure-defines a type of variables.
clockwise from the 3 o'clock position. If the XY length and Enumeration-a list of integer values allowing associa
the XY angle are entered, the system calculates the "X" and tion of constant values with qualifier names.
'Y' end coordinates. 40 Union-a variable that may hold (at different times)
Cutter Compensation objects of different types and sizes. It is used to
manipulate different kinds of data in a single storage
When beginning the part program, the operator describes area without embedding any machine-dependent infor
all of the tools that will be used. Then the program can mation in the program. Required qualifiers begin with
automatically allow for the diameter of the tool when 45 a capital letter, and optional qualifiers use no capitals.
determining the toolpath for an inward spiral or when Message Structure
connecting milling segments. With cutter compensation in
use, the tool is offset from the print line a distance equal to Any of the Part Program Interpreters used in the system
the radius of the tool. The operator may also indicate have the same basic message structure:
50
whether to compensate on the right as in conventional Verb Qualifiers
milling or the left for climb milling. If the cutter compen A verb describes the message request. The verbs used by the
sation feature is not needed, the operator does not select it PPI are
as an active option when programming a block. Interpret-finds information about the axis positions and
55
speed
Packaged Cycles Update-supplies new information about the axis posi
Packaged cycles are pre-programmed, common machin -tion and speed
ing operations such as drilling, tapping, pecking, and boring The qualifters are data structure names followed by the data
and reaming. Since the system contains packaged cycles, the structure elements. These qualifters can be composed of
operator can specify a type of operation and define only the 60 other qualifters (i.e., dynamic data structures). Verbs act on
necessary variable information. Then the system makes the qualifiers.
additional calculations to define the operation fully. For PPI Schema
example, when the operator is programming a drilling
operation with pecking, the operator simply specifies the The schema defines the data structure qualifiers for all
peck type and depth and thc system uses a canned cycle to 65 messages and global data used by any Part Program Inter
determine the exact movements of the drill during thc preter (PPI). The messages use the following quali?ters:
pecking process. String
 5,453,933
29 30
Description Configuration Parameters
The following descriptions of these qualifiers contain defi
nitions of the qualifters in the form of text and in "C" code The Integration Tools, described later in this chapter,
and the definitions of the "C' code data names. allow integrators to modify interactively the behavior of the
5 controls as they adapt the controls to the machines. OEMs
String
can modify the parameters for the following:
Kinematics
String is a structure describing a collection of ASCII Servo Tuning
characters. The 'C' data structure follows: Safety Regions
10
Maximum Feeds and Speeds
Lead Screw Mapping
typedef struct Remote Communications
int length; Language
char characters, 15 Version control of configuration files permits the integra
} String;
tor to extend previous versions of parameters and record the
changes for backtracking purposes.
length-number of characters in the string
characters-an array of letters, numbers, and/or symbols Machine Class
20
The Machine Class of the control system of the present
Description invention forms a device-oriented interface between the
Description is a string explaining a variable concept (e.g., Kernel and the CNC applications. The Machine Class estab
an error condition) in a message. The “C” data structure lishes and monitors the CNC applications' connections to
follows: 25 the Kernel and handles messages between the applications
typedef String Description; and Kernel. Each application includes a copy of the Machine
Class to facilitate a common interface to the Kernel. Also,
Interpreter Messages shared data assures that all applications use the same
Any Part Program Interpreter working in the system must Machine Class state information.
use two standard messages: Interpret and Update. 30 Since the Machine Class uses object-oriented design, it
contains objects that define specific devices with all of the
Interpret possible functions for each device. For example, a spindle
The Interpret messages send pieces of an RS-274 program object may have the possible functions of run, clamp, and
to the Interpreter. stop. The object's data describes the speed range and current
35 speed of the spindle. A CNC application may not necessarily
Interpret Description<programBlocki> use all of a Machine Class object's functions, but the
The Interpret message directs the PPI to begin execution functions are available and supported by the Kernel.
of the Part Program. A CNC application may also hook into packaged cycles
<programBlock>RS-274 program block from the Application Tool Kit. These cycles define common
40 machining operations such as drill, bore, and tap and operate
Expected Responses at a higher level in the control system than the Machine
Class. By using these same Machine Class object methods,
If the PPI is able to interpret the program block, it a customer may customize and expand the packaged cycles
responds with an Interpreted message. If the PPI is not able to meet specialized needs without concern for the details of
to interpret the message, it responds with a Notinterpreting 45 Machine Class operations.
message. The expected responses for any of the Interpret Multiple copies of the Machine Class may be used in the
commands are
Interpreted<Qualifierd control system. It is recommended that a copy of the
Machine Class be attached to each CNC application being
Notinterpreting<QualifiercDescription<errordescription> used in order to provide a common interface to the Kernel.
50 In addition, a customer may extend the functionality of the
Update Machine Class being used, as long as copies of the same
Machine Class are being used by all applications.
An RS-274 program is made up of many modals. The Described herein are two functional Machine Classes
initial values of these modals can be set using the Update according to the present invention: (1) Milling Machine
message. 55
Class; and (2) Sample, generic Machine Class. The sample,
Update Description<modalName>Qualifier generic Machine Class is a simple example designed to
<modalName>Name of the Modal to be modified Quali assist in gaining an gain understanding of the message
fiercontains data type and a value for the modal. interface. The Milling Machine Class is one that may be
60
implemented for a basic milling machine.
Expected Responses Milling Machine Class
The PPI responds with an Updated message to indicate The Milling Machine Class allows customers with milling
that the modal has been set. If the modal is undefined, an machines to become immediately operational. To use this
NotUpdating error message is returned. 65 Machine Class, customers simply link to the Machine Class
Updated<Qualifierd library with their CNC application and gain access to the
NotUpdating<QualifierdDescription<errordescription> following objects:
 5,453,933
31 32
Flow Control Communications
Push-button Console
Messages to the Machine Class devices can originate
Jog Pendant from several sources:
Axis Part Program Interpreter
Axis Group User Interface
Spindle Push Buttons on the Console or Jog Pendant
Tool Changer Sensor Interface
Coolant To simplify system operations and programming, the
O
Lube control system has a specific division of labor bctween its
All of these objects allow a CNC application to grab components. For example, the Machine Class does not
ownership of the device, initialize the device, monitor its worry about the Kernel's responsibilities such as travel
current state, and release ownership. When an application limits and servo errors. Conversely, the Kernel is not con
has grabbed ownership of a device, it then has the authority 5 cerned about ownership or devices because the Machine
to issue action requests to that device using the methods Class handles that exclusively. r
provided. The Milling Machine Class can also be used in This system structure also simplifies system communica
combination with the packaged cycles in the Application tions and complies with the open systems concept. CNC
Tool Kit to customize the operation of a milling machine. applications may communicate with the Kernel through any
20 or all of the system layers. For specific functions, the
customer's software engineer may bypass a layer and con
Sample, Generic Machine Class nect an application directly to the next layer or another layer
A sample Machine Class may be used as a pattern to down. This, of course, is accomplished through the standard
develop new Machine Classes. It contains the minimum message formats supplied for each control system compo
object-oriented devices with their methods that are needed to 25 ent.
operate a typical machine tool:
Flow Control-controls the communication from the
CNC application to the Kernel’s synchronous queue. Communication Connections
Push-button Console-reserves all necessary buttons and 30
An application may communicate to the System compo
lights on the console for an application. nents in two ways: (1) Through the system layers; or (2)
Axis-allows an application to control an individual axis Directly to the components. When an application uses the
or joint. Machine Class layer, three advantages result:
Axis Group-user-defined groups of coordinated axis 1. Automatic message sequencing to the Kernel compo
moves (e.g., X, Y, Z, A, and B). 35 nents (Logic and Motion Controllers)
Spindle-basic functions of a machine tool spindle. 2. Ownership handling for multiple processes
Tool Changer-basic functions of a tool changer. 3. Simplified communication to devices
The control system permits communication through the
Shared Memory Machine Class layer to the Kernel components. To operate
40 efficiently, a CNC application's part program interpretcrand
In an alternate embodiment of the invention, an area of the its user interface (also called a man-machine interface-MMI)
computer's memory is reserved for the Machine Class need the operational simplification provided by the pack
information. The shared memory contains ownership and aged cycles from the Application Tool Kit and the features
state information for each device. Each copy of the Machine of the Machine Class.
Class looks at this region to access information about the 45 However, some programs do not need the features of these
devices. However, access to this area is controlled so that middle layers. For example, the diagnostic and tuning pro
applications can only view and change device information grams within a CNC application are not concerned with the
through the Machine Class. system's devices or ownership rules. These specialized
programs can communicate efficiently by connecting
50 directly to the Kernel functions. Another program that
Rules of Ownership bypasses the middle layers is the Exception Reporter. It is
Since multiple applications may attempt to access the not interested in the machine devices or even the Kernel
same device, the concept of device ownership is central to functions and can connect directly to the messaging func
tions.
the operation of the Machine Class. Ownership of a device 55 If a customer is using only one CNC application to control
means that an application has reserved that device though the entire system, that application must manage device
the application may not be using device at the moment. access between different parts of the program.
The application that "owns' a device has full access to it
while other applications have read-only access. Applications
are permitted to send messages to devices only if they have 60
Message Schema
ownership of those devices. This minimizes the inter-com
ponent logic required for any application often used to The Machine Class messages use the qualifters, listed in
determine permission conditions for a command. However, the Schema below, to define the messages. QualificrS are data
some decision logic is still needed within each application. structure names followed by the data structure elements.
Systems with only a single application may be structured 65 These qualifters can be composed of other qualificrs (i.e.,
to never grab ownership of a device. In this situation, there dynamic data structures). The message verbs, described in
would be a single owner of all devices. the following section, act on these quali?ters.
 5,453,933
33 34
String Group
String is a structure describing a collection of ASCII Group is a structure describing a group of axes. The "C"
characters. The 'C' data structure follows: data structure follows:

typedef struct typedef struct

{
int length; int id;
char characters; int numberAxes;
} String; 10 Axis Daxes;
} Group
length-number of characters in the string
characters-an array of letters, numbers, and/or symbols id-Axes group id
15 numberAxes-number of axes in group. Range 1-Num
berAxis,
DataType axes-array of AxisD's
DataType is an enumeration of data representations. The State
"C' data structure follows:
20
State is an enumeration of the current conditions of a
device. The 'C' data structure follows:
typedef enum
{
Undefined;
Integer; 25 typedef enum
FloatingPoint; {
String, Uninitialized;
DataType; Calibrated;
Stopped;
at OrientPosition;
Undefined-data type not specified 30 } State
Integer-data consisting of whole numbers
FloatingPoint-double precision floating point number Uninitialized-object has not been initialized.
String-data expressed with characters Calibrated-object has been calibrated.
35 Stopped-object is not moving
OrientPosition-object has arrived at the orient position
Value
Value is a union representing a variable data type. Parameterinfo
DataType defines the data's size and type. The "C" data ParameterInfo is a structure describing information spe
structure follows: 40
cific to a device example of a "C" data structure for a tool
changer follows:
typedef union
{
t integer, 45 typedef struct
doublefloatingPoint; {
String string; int toolid;
Value int CarouselPosition;
} ParameterInfo
integer-data consisting of whole numbers 50
floatingPoint-floating point data tooliD-integer representing the tool identification num
string-data expressed with characters
ber. Range: 1-NumberTools
VelocityType
55
AxisD VelocityType is an enumeration of velocity representa
tions. The 'C' data structure follows:
AxisID is an enumeration describing an individual axis.
The "C' data structure follows:
60 typedef enum
{
typedef enum Undefined;
{ XYZ;
Xaxis, XYZAB;
Yaxis; Spindle,
Zaxis; 65 } WelocityType
AxislD
XYZ-velocity for 3 axis machine
 5,453,933
35 36
XYZAB-velocity for 5 axis machine
Spindle-velocity of the spindle -continued

Velocity Position endPosition;

5 Attributes attributes;
Velocity is a structure describing speed and direction. The Linear
"C' data structure follows:
endPosition-represents the linear position at the end of
the move
typedef struct 10 attributes-attributes describe condition that affect thc
{
VelocityType type; move. "Until Limit Switch' is an examplc of an
Value data; attribute.
Velocity
- a 15
Tool
type-indicates the type of Velocity data in the structure
data-velocity data, Units of (m/see) for linear axis and Tool is a Qualifier used to describe a tool. The “C” data
structure follows:
(radian?see) for rotary axis.
Override 20
typedef struct
Override represents a speed multiplier. The “C” data
structure follows: int toolID;
} Tool
typedef double Override;
Override-representation of speed multiplier. Value of 25
one (1) indicates 100%. tooliD-Integer representing the tool identification num
Range: 0.1-2.0. ber. Range: 1-NumberTools,
Increment Gear
Increment represents a delta position. The "C" data struc- 30 Gear is a Qualifier used to describe gear ratio. The 'C'
ture follows: data structure follows:
typedef double Increment;
Increment-representation of a delta move. Units for
increments are meters. 35 typcdef struct
{
Offset int gearID;
double gearRatio
Offset is a structure describing Delta position. The "C" } Gear
data structure follows:
40
gearlD-integer representing the gear identification num
ber
typedef struct gearRatio-floating point number representing the gear
{ ratio
int count;
double delta; 45
Offset Machine Class Message Formats
count-number of axes deltas described in structure. The Machine Class messages begin with verbs to describe
(range 0-max.Axes) the message requests. These verbs reflect the actions of the
50 methods listed for the device objects described in the next
delta-array of axis deltas. Meters are used for linear axis, section. In the list below, each verb is defined and possible
and radian is used for rotary axis. message formats are shown after the definitions. Many
Machine Class verbs stand alone to direct the actions of
Feedrate
objects. For those verbs, no message formats are not listed.
Feedrate represents coordinated linear speed of the Car- 55
tesian axes. Feedrate uses units of (meters/second). The 'C' Grab
data structure follows:
typedef double Feedrate; Requests ownership of a specific device.
Linear 60 UnGrab
Linear is a Qualifier used with "Move' verb to describe a Releases ownership of a specific device.
linear move. The 'C' data structure follows:
Initialize
65
Establishes default parameters necessary to operatic a
device.
 5,453,933
37 38
Unlnitialize Cancel
Forces a re-initialization of a specific device (must ini Ceases operation of a specific device immediately (recov
tialize after this verb is used). ery will not be possible).
Get
Retrieves the current information from a specific device. Step
Get Description<name>Qualifier Engages the predefined operation of a specific device in a
GetkParameterinfo) forward direction.
10

Update
UnStep
Establishes a specific operational parameter for a device.
Update Description<name>Oualifier Engages the predefined operation of a specific device in a
15 reverse direction.
Update<Override>
Update<Gear>
Update{Feedrate> <values Machine Class Objects
Enable 20 The Machine Class's objects are representations within
the system of the devices on a machine and the functions
Enables special operation of a specific device. necessary to manage those devices (e.g., flow control, tool
Enable<Powere changer, axis, and spindle). All Machine Class objects have
two parts: data and methods.
Disable 25 The object's methods, are instructions, functions, proce
Disables special operation of a specific device. dures, or actions that describe what the object does in
DisableCPowere
response to an event. A method belongs to an object and
indicates how to perform an action or how to react to an
external event. An application may only access an object's
Clamp 30 data through its methods, if at all. Methods send messages
Engages the clamp on an axis or spindle. to perform operations. The Machine Class objects with their
methods are described in the following sections.
UnClamp
35
Disengages the clamp on an axis or spindle. Flow Control Object
Calibrate In an alternate embodiment of the invention, the control
system's Milling Machine Class's Flow Control object
Establishes a reference point for a specific device. controls the communication between a CNC application and
40 the Kernel's synchronous queue. This object allows a CNC
Run application to set up a communications port to the Kernel
and monitor the current state of the Kernel for the applica
Begins continuous operation of a specific device. tion. An application must get ownership of the Flow Control
object to gain control of the Kernel’s synchronous queue.
Cycle 45 The following methods are included in this object:
Marks the starting position of a sequential operation of a Grab-requests ownership of the Kernel’s synchronous
specific device. queue.
Cycle Description<cycleID> UnGrab-releases ownership of the Kernel's synchro
50
nous queue.
Move Initialize-establishes default parameters necessary to
operate the Kernel's synchronous queue.
Engages coordinated operation of a specific device GetzState>-gets the current active state of the Kernel's
Move Linear synchronous queue.
Move Velocity 55 Enable<Powerd-enables power for the Kernel's syn
Move<increment> chronous queue.
DisableCPower>-disables power for the Kernel's syn
Dwell chronous queue.
Begins null operation of a specific device for a specified 60
Run-directs the Kernel to process synchronous requests
time.
continuously.
Dwell FloatingPoint(times Stop-directs the Kernel to stop processing requests from
the synchronous queue.
Stop Cancel-directs the Kernel to stop all activity immedi
65 ately and flush the queue.
Ceases operation of a specific device in a manner that Step-directs the Kernel to process a single request in the
makes recovery possible. synchronous queue.
 5,453,933
39 40
Push-button Console Object Axis Group Object
The Milling Machine Class's Push-button Console object The Machine Class's Axis Group object describes a
allows an application to initialize and reserve all necessary user-defined group of axes. The axis group handles multiple
buttons and lights on the console. In this way, the operator 5 axis motion for coordinated moves such as lincar and
can press buttons to control power, start a cycle, hold the circular and time-coordinated joint moves (point-to-point).
motion of the machine, and interrupt an operation while an The object defines the axes kinematics, handles ownership,
application monitors these actions. When an operator and includes these methods:
presses a button, a message is sent to the application Initialize-establishes default parameters necessary to
controlling that button. If the buttons are not enabled by an 10 operate the axis group.
application, they are ignored by the Logic Controller. Grab-requests ownership of the axis group.
The following methods are included in this object: UnGrab-releases ownership of the axis group.
Initialize-establishes default parameters necessary to Get-States-gets the current active state of the axis
operate the push-button console. group.
Grab-requests ownership of the push-button console. 15
Get-ParameterInfoD-returns current parameters.
UnGrab-releases ownership of the push-button console. Move<Linear>-engages coordinated operation of the
Get-requests specified information from system compo axis group as defined by the point vector, feedrale,
netS. attribute, and termination type.
Enable-enables remote operation on the push-button Move <Joint>-engages coordinated operation of the axis
console. group using point-to-point time coordination.
Disable-disables remote operation of the push-button Dwell-pauses in motion defined by time in tenths of
console. seconds.
Update-establishes a specific operational parameter for Update<Group>-(axes) identifies which axes belong to
the push-button console. 25
this group.
UpdateCOverride>-indicates the feedrate override fac
tO.
Jog Pendant Object UpdategFeedrate)-(value) indicates the speed applicd
The Milling Machine Class's Jog Pendant object allows 30 to a given Axis Group.
an application to initialize and reserve all necessary buttons Update<OffsetsD-indicates the offset used for Part Zero
and lights on the jog pendant. When an operator presses a and other general offsets.
button, the Kernel can generate a Move message immedi The Axis Group object has these additional methods:
ately after receiving an Enable message from an application. Enable<Power>-enables power to the axis group
If the buttons are not enabled by an application, they are 35
Disable-Power>-disables power to the axis group.
ignored by the Kernel.
The following methods are included in this object: Stop-stops the specified axes.
Initialize-establishes default parameters necessary to
operate the jog pendant. Spindle Object
40
Grab-requests ownership of the jog pendant. The Spindle object describes all possible functions of a
UnGrab-releases ownership of the jog pendant. machine tool spindle. This object grabs ownership of the
Get-requests specified information from system compo spindle axis and sends messages to the Logic Controller to
netS. initialize, enable, and handle the spindle's orientation angle,
Enable-enables remote operation on the jog pendant. 45 the maximum RPMs, and all other necessary operations.
Disable-disables remote operation of the jog pendant. This Machine Class object contains the following methods:
Initialize-establishes default parameters necessary to
operate the spindle.
Axis Object Uninitialize-forces a re-initialization of the spindle.
50 Grab-requests ownership of the spindle.
The Milling Machine Class's Axis object allows an appli UnGrab-releases ownership of the spindle.
cation to control an individual axis or joint. The following
methods are included in this object: GetzState>-gets the current active state of the spindle.
Initialize-establishes default parameters necessary to GetzParameterinford-gets current information param
operate an axis. 55 eters for the spindle.
Grab-requests ownership of an axis. Run-begins continuous operation of the spindle in the
UnGrab-releases ownership of an axis. specified direction and at the RPM of the movc.
GetzState> gets the current active state of an axis. Update<Override>-overrides the speed by a specified
factor.
GetzParameterInfoD-returns current parameters. 60
Update-Gear> initiates a remote change of the spin
Clamp-engages the clamp on an axis. dle's gear speeds.
UnClamp-releases the clamp on an axis. Clamp-holds the tool in the spindle.
Calibrate-establishes a reference point for an axis. Unclamp-releases a tool from the spindlc.
Move<Velocity>-moves the axis at a specified velocity. 65 The Spindle object has these additional methods:
Move<Increment>-moves the axis a specified distance. Enable-enables remote operation of the spindle's
Stop-halts axis motion. manual push-button.
 5,453,933
41 42 w
Disable-disables remote operation of the spindle's Kernel-Machine Class Communication Example
manual push-button.
Stop-stops motion of the spindle. The following communication example demonstrates data
moving through the Machine Class to the Kernel compo
Tool Changer Object 5 nents. In this example, the CNC application is operating a
spindle using the following steps:
The highly detailed Tool Changer object describes all 1. Application grabs ownership of the Spindle. It receives
possible functions of a tool changer. This object has access an “OK” or a “Reserved” response.
to the data indicating the number of tools in the changer, the 2. Application requests SpindleRun.
current tool in the spindle, and the carousel position. The 10 3. Machine Class sends these requests to the Motion
tool changer grabs ownership of the required resources such Controller:
as the spindle and axes. The tool changer uses the storage Update <Gear> (directs Logic Controller to activate
slot number rather than the tool number for positioning. The sequence)
tool number and related data are included in the Tool Wait until LCflag (directs MC to wait for the LC flag)
database. This object contains the following methods: 15 Move Velocity <rpm.> (directs MC to apply voltage to
Initialize-establishes default parameters necessary to the spindle axis)
operate the tool changer. Update <Flag> SpindleAtSpeed (directs LC to report
Unlnitialize-forces a re-initialization of the tool changer. when up to speed)
Grab-requests ownership of the tool changer. Wait until LCflag (directs MC to wait for LC flag
UnGrab-releases ownership of the tool changer.
20 before continuing)
4. The Motion Controller returns "OK' or "Conflict'
GetzStates-gets the current active state of the tool responses.
changer.
Get-Parameterinfo> gets current information param 5. The Motion Controller sends a SpindieGear request to
eters for the tool changer. 25 Logic Controller and waits for LCTIag.
Update<Toold-sets the storage slot number for a tool in 6. LC executes spindle enable and gear change logic:
the spindle. spindleCrient=Off
spindleEnable=On
Enable-enables remote operation on the tool changer. spindleCon=On
Disable-disables remote operation of the tool changer. 30 select gear speed based on RPM
Calibrate-sets the indexer position. 7. LC sends request to MC to creep spindle axis.
This tool changer object also contains these methods: 8. MC sends "atCreep” message to L.C.
Cycle-marks the starting position of a sequential opera 9. C selects gear. If an error occurs an error message is
tion of the tool changer. sent to the Exception reporter and the Machine Class
Stop-halts tool changer motion. 35
flushes the queue.
Step-moves the tool changer one logical step at a time. 10. LC sets LCflag to satisfy first MCWait (indicates that
it is OK to start axis).
Coolant Object 11. MC begins spinning the Spindle axis based on Move
The Coolant object describes all possible functions of the 40 parameters. If an error occurs, send an error message to
coolant mechanism. This coolant object contains the follow Exception Reporter, and the Machine Class flushes
ing methods: queue.
Grab-requests ownership of the coolant device. 12. MC gives SpindleAtSpeed request to LC,
UnGrab-releases ownership of the coolant device. 13. LC waits for SpindleAtSpeed input or time-out. If an
GetzState>-gets the current active state of the coolant
45 error occurs, send error message to Exception Reporter,
device. and the Machine Class flushes queue.
Stop-indicates when to stop the coolant. 14. LC sets LCflag to satisfy second MC Wait (indicates
sequence is complete).
Run-begins continuous application of coolant and iden 15. LC sends Completion response to Application (if
tify the type of coolant (mist, flood, or both). 50
requested by Application).
Enable-enables automatic clearance plane detection and 16. Machine Class sets DalState=SpindleRunning (if
automatic shut-off.
requested by Application).
Disable-disables automatic clearance plane detection
and automatic shut-off. Customizing a Machine Class
55
Lube Object The open systems design of the control system of the
present invention permits modification of the Machine Class
The Lube object describes all possible functions of the to handle machines that have not been used by the control
lubrication mechanism. This lube object contains the fol manufacturer. This is possible because the devices are
lowing methods: 60 independently defined from the relationships between the
Grab-requests ownership of the lubrication device. devices. The Kernel's Logic Controller and the applications
handle the actual device interdependencies during operation.
UnGrab-releases ownership of the lubrication device. A system user may add features to a device definition
GetzState-gets the current active state of lubrication and/or modify the characteristics of the device without being
device. 65 forced to change other devices. This allows the customer to
Stop-indicates when to stop the lubrication. develop an implementation of the system customized for a
Run-begins continuous application of lubrication. specific machine.
 5,453,933
43 44
The Machine Class's object-oriented design allows soft Message Structure
ware engineers customizing the Machine Class to quickly
create new Machine Class objects by inheriting from exist The messages of the control system of the present inven
ing Machine Class objects and then modifying them. tion have a standard grammar using command verbs with
Because of the advanced programming features of C++, a 5 possible qualifiers and variable attributes. There are threc
software engineer need not alter the source code of the types of qualifters:
control system for the objects in order to modify them. The Structure-defines a type of variables.
new objects then inherit the common data characteristics Enumeration-a list of integer values allowing associa
from the parent objects. This feature allows software engi tion of constant values with qualifier names.
neers to build on existing design and code by creating more 10 Union-a variable that may hold (at different times)
specific objects from the easily reused code in the existing objects of different types and sizes. It is used to
Machine Class objects. manipulate different kinds of data in a single storage
As with data characteristics, methods can also be inher area without embedding any machine-dependent infor
ited from the parent object when a new object is created. Of mation in the program.
course, the new object may use the method or create a 15 in the list of messages presented below, required data
different version of it. Methods send messages to perform elements begin with a capital letter, and optional elements
operations. This isolates dependency on a particular data use no capitals. Messages used by the Kernel have this basic
structure thus permitting new features to be added without Structure:
changing the arrangement of the original objects. Verb Qualifters
20
A verb describes the message request. Qualifters are data
structure names followed by the data structure elements.
Kerne These qualifters can be composed of other qualifters (i.c.,
The Kernel of the control system provides mechanisms dynamic data structures). Verbs act on the qualifiers.
for coordinating motion axes with discrete input/output (I/O) 25
The verbs used by the Kernel components are
control. This general controller can be used in a variety of Run is used to control the execution of the synchronous
machining applications. The CNC applications communi buffer (MC and LC),
cate with the Kernel components, the Logic Controller (LC) StopRun--is used to control the execution of the syn
and the Motion Controller (MC), through the Machine chronous buffer (MC and LC).
Class. 30 Move-directs the Motion Controller to move along a
Since the control system's software uses object-oriented linear path or move at fixed velocity.
design and programming techniques, the software compo Wait-tells the MC or the LC to not execute any messages
nents are created from data and functions organized into after the Wait message until a StopWaiting message is
objects. The Logic Controller and Motion Controller com Sent.
ponents communicate with each other and with the CNC 35
StopWait-tells the MC or the LC to begin executing
applications through special objects called messages. These messages again.
messages use a common message structure, and both have a Get-tells the MC or LC to send information to an
common message interface. Each component has an asyn application.
chronous queue and a synchronous queue. These queues
function in the same manner in both controllers. 40 Update-tells the MC or LC that an application wants to
Messages may be synchronous or asynchronous depend change the value of a parameter.
ing on the requirements of the application. The synchronous Flush-tells the Motion Controller to delete all of the
messages are ordered and, therefore, dependent on the messages in its synchronous queue.
execution of previous messages in the queue. The asynchro 45
nous messages are independent of previous messages so that
they can be executed immediately. Kernel Qualifters
The Kernel's schema describing the message qualifiers is
shown on this and following pages. The quali?ters define the
Kernel Message 50
data structures for all messages and global data used by
Kernel.
The system messages provide two-way communication
between the applications and the Kernel components. These
messages have the following capabilities: String
Single commands
Initialization parameters and configuration sent through 55 String is a structure describing a collection of ASCII
characters. The 'C' data structure follows:
the messages
Synchronous messages are queued
Asynchronous messages are executed immediately typedef struct
There are different categories of messages: 60 {
Flow control int length;
char charact.crs,
Parameters } String;
Diagnostics
Requests 65 length-is the number of characters in the string.
Data characters-is an array of letters, numbers, and/or sym
Error bols.
 5,453,933
45 46
Name y-position for the Y axis. Range: Yi-Y (units:
Name is a structure that identifies the subject of the meters)
message with a descriptive term. The "C" data structure Z-position for the Z axis. Range: Z-Zmay (units:
follows: meters)
typedef String Name
XYZAB
Description XYZAB is a structure describing a position for the X and
Description is a structure used to define the basic char 10 Y and Z and A and B axes. Linear position is expressed in
acteristics of the subject of the message. The 'C' data meters. Rotary position is expressed in radians. The "C" data
structure follows: structure follows:
typedef String Description
Value 5 typedef struct
{
double x,
Value is a union representing a variable data type. double y;
DataType defines the data's size and type. The "C" data double a,
structure follows: double b,
20 } XYZAB;

typedef union x-position for the X axis. Range: X-X (units:

{ meters)
1nt integer,
doublefloatingPoint; 25
y-position for the Y axis. Range: Y-Y (units:
String string; meters)
} Walue Z-position for the Z axis. Range: Z-Z (units:
meters)
integer-is the data consisting of whole numbers. a-position for the A axis. Range: A-A (units:
floatingPoint-floating point data. 30 radians)
string-is the data expressed with characters. b-position for the B axis. Range: B-B (units:
radians)
PositionType
PositionType is an enumeration of Position representa 35
tions. The 'C' data structure follows: ZS is a structure describing a position for the Z axis and
the Spindle. Linear position is expressed in meters. Rotary
position is expressed in radians. The "C" data structure
typedef enum follows:
40
{
Undefined;
XYZ;
XYZAB; typedef struct
ZS; {
Spindle; double z;
} PositionType 45 double spindle;
} ZS;
XYZ-position for 3 axis machine.
XYZAB-position for 5 axis machine. Z-position for the Z axis. Range: Z-Z (units:
meters)
ZS-position of the Z axis and spindle. 50
spindle-position for the spindle. (units: radians)
Spindle-position of the spindle.
XYZ Position

XYZ is a structure describing a position for the X and Y 55 Position is a structure describing a position. The "C" data
and Z axes. The "C" data structure follows: structure follows:

typedef struct typedef struct

60 {
double x, PositionType type;
double y; Value data;
double z; } Position
} XYZ;
65 type-indicates the type of position data in the structure.
X-position for the X axis. Range: X-X (units: data-position data; meters are used for a linear axis and
meters) for a rotary axis.
 5,453,933
47 48
Contact
-continued
Contact is an enumeration types of physical contact for
attributes. For example, a probe attribute is a move until a Attrib Serent
probe makes contact or break contact. The "C" data structure } AttributeType
follows:
LimitSwitch-indicates that the move is terminated on
either make or break of limit switch.
typedef enum Probe-indicates that the move is terminated on cither
{ 10 make or break of probc.
Undefined;
Make, Overrid
Wei-CaSO bles or disabl
CSa)S OWO ide fTO OVC.
Break; Motion Hold-enables or disables override for move.
Contact Absolute-position is described in absolute coordinates.
Make-contact is made.
Incremental-position
dinates.
is described in incremental coor
Break-contact is broken. Deceleration-deceleration attribute.
EnableDisable
Concurrent-this move can be concurrently executed
with another move.
EnableDisable is an enumeration describing ifa attribute 20 Linear
is enabled For example, the Feed rate override is enabled or
disabled. The 'C' data structure follows: Linear is a qualifier used with the Move verb to describe
a linear move. The 'C' data structure follows:
25
typedef enum
{ Undefined: typede? struct
Enable; {
Disable; Rio
ttributespist
attributes,
} EnableDisable 30 Position

Enable-turn on
ibute. w-
DS turn O Rt position-indicates the endpoint of the linear move.
1Sable-turn O attribute. data-attribute modifying the motion description.
35
TerminationType VelocityType
TerminationType is an enumeration
Ys describing the ending VelocityType is an enumeration of velocity represcinta
condition of a move. The 'C' data structure follows: tions. The 'C' data structure follows:
40

pede? el typedef enum

Undefined; {
PrecisionEndPoint, y ned;
NoDeceleration, 45 XYZAB;
} DecelerationType Spindle;
VelocityType
PrecisionEndpoint-end point of line must be reached
with in in-position tolerance. XYZ-elocity for 3 axis machine.
NoDeceleration-Move is part of continuous contour. 50 XYZAB-velocity for 5 axis machine.
End point is not important. Spindle-velocity of the spindle.
AttributeType Velocity
AttributeType is an enumeration of attributes. The "C" is Velocity is a structure describing a position. The “C” data
data structure follows: structure follows:

typedef enum typedef struct

60 {
undefined VelocityType type,
Limit Switch Valuc data,
Probe Position
Owerrides
MotionHold
About
incremental
65 type-indicates the type of Velocity data in the Structurc.
Deccleration data-Velocity data, Units of (m/sec) for linear axis and
(radian/sec) for rotary axis.
 5,453,933
49 50
VelocityMove Programmable interpolation rate-5 milliseconds to 20
milliseconds
VelocityMove is a qualifier used with the Move verb to Provides status information for
describe a constant velocity move. The "C' data structure
follows: position (command and actual)
velocity
following error
typedef struct Leadscrew and backlash compensation using linearly
interpolated tables
Velocity velocity; 10 Leadscrew compensation corrects for mechanical error up
Attributes attributes; to 200 times per second
} WelocityMove
5 millisecond block transfer rate resulting in more
velocity-indicates the rate and the reference frame of the detailed information being processed faster
OWe. Non-linear control for circle compensation
attributes-attribute modifying the motion description.
15 Acceleration control regulates velocity, allowing tighter
coordination between more than one axis while mini
RunAttribute mizing mechanical wear on the machine
RunAttribute is an enumeration of Run message Coordinated interpolation with the spindle
attributes. The "C' data structure follows: 20 Programmable calibration and referencing sequence
Enhanced Servo Algorithm interfaces with the motion
controller board to monitor machine position 10,000
typedef enum times per second
{
Undefined; 25
SingleCycle; Configuration Parameters of the Motion Controller
Immediate; The Motion Controller configuration parameters define
End OfCycle;
MotionHold; the travel limits, PID gain parameters, kinematics, and
RunAttribute additional miscellaneous parameters.
30
SingleCycle-requests that the motion control stop after Travel Limits
the end of each cycle.
Immediate-requests that the motion command be This parameter establishes the valid travel limits. They
executed immediately. can be negative to positive or positive to negative along the
35 X, Y, and Z axes.
EndofCycle-marker for separating moves in a cycle.
MotionHold-indicates a motion hold condition. PID Gain Parameters
ErrorCode The gain parameters are used for closed loop control of
ErrorCode is an enumeration of types of error codes. The 40 each axis (x to b). These parameters are
'C' data structure follows: proportional (P)
integral (I)
derivative (D)
integral limit
typedef enum 45 velocity feed forward
{
NoSeverity; The parameter values are downloaded to the appropriate
Information; hardware for controlling the axis. Then, the modified PID
Warning; algorithm with velocity feedforward residing on the hard
Fatal; ware controls each axis.
} ErrorCode 50 The Application Tool Kit may be utilized to set and adjust
the parameters.
NoSeverity-error of uncategorized severity.
Information-error message providing information only Programmable Kinematics
(no action required).
Warning-error indicating application is having difficulty 55 The user may specify the relationships between axes to
completing the task. support a variety of axis configurations. The forward kine
Fatal-error indicating application is notable to complete matics determine the position and the orientation of the
current task. end-effector given the joint angles. The inverse kinematics
determine the joint angle given the position and orientation
Motion Controller 60 of the end-effector. The possible kinematics parameters
aC
The Kernel's Motion Controller performs multi-axis
interpolation generating target points for the servo hardware.
The Motion Controller supports high speed spindles (up to Y position=YoJo YJ1+Y2Ji-YJFYJ.
60,000 RPM), rigid tapping, encoderjog, and touch probing. 65 Z position=ZoJo-ZJ-ZJ-ZJ-ZJ.
An exemplary motion controller has these features:
Five (5) coordinated axes plus one (1) spindle B position=Boot-BJ-BJ-BJ-BJ
 5,453,933
S1 52
Miscellaneous Motion Control Parameters StopRun
Some additional parameters that can be set by the Motion The StopRun message is sent to the Motion Controller to
Controller are halt the execution of the message in the synchronous buffer.
DAC (digital analog converter) balance parameter The motion can halt execution of message immediately
Maximum acceleration (with controlled deccleration of motion) or at a block
Axis sense
boundary. Block boundaries are delimited by Cycle HcadcrS.
Axis resolution
StopRun RunAttributezattributed
This StopRun message asks the Motion Controller to stop
Maximum rotary RPM 10 execution of the synchronous buffer.
Limit switch to marker pulse (index pulse) StopRun RunAttribute <attribute>
Lead screw compensation table attributed immediate deceleration motion at thc maximum
acceleration rate.
Motion Controller Messages 15
SingleCycle-stop execution at the first block end
(singleCycleHeader) with out exceeding maximum
The messages of the control system are objects, such as acceleration.
C++ objects. Each message object is transmitted in binary
form to the receiving application's mailbox and then rebuilt Expected Responses
into an object. This section describes the Motion Controller
message verbs: 20 When the Motion Controller receives a StopRun message.
Run Update it halts execution of the message in its synchronous buffer
Move StopRun and responds with a StoppedRunning message (format
Wait Flush below).
Get StopWait StoppedRunning <Qualifierd
25
Modals establish a condition that persists until another Move
modal changes it. The Motion Controller modals are
OverrideEnable The Move message in the Motion Controller has two
MotionHoldEnable qualifters: Linear and Velocity. The Move message uses this
IncrementalEnable 30 basic structure:
DecelType Move<Qualifiers <attributes>
These modals can also be used as one-shot modals within
messages to temporarily set a modal value during the Move Linear
execution of the message and restore the mode prior to 35 The Move Linear message directs the Motion Controllcr
execution. The concurrent modal, used only as a one-shot to move along a linear path. The path is defined by thc
modal, tells the system that a message is linked to the next position specified in the message from the end point of the
message and that both must be executed as one. This could previous move. The message structure is
span more than one pair of messages. Move LinearCPosition> <attributed
40
Elements
Run
<Position>XYZ
The Run messages are used with the StopRun messages to XYZAB
control the execution of the synchronous buffer. The Run ZS
message asks the Motion Controller to start executing mes 45
S
sages from its queue. <attribute>until switchKbreakimake>
RunkQualifierd until probezbreakimake>
Run RunAttribute Cattributed find index pulse
The Run RunAttribute directs the Motion Controller to override<enableldisable>
begin execution of the messages in the synchronous buffer. 50 motion holdkenable disable>
attribute>none
probeCenableldisable>
<absolutelincremental>
SingleCycle The Run SingleCycle directs the Motion decelktype>
Controller to execute messages in the synchronous ConCurrent
buffer a block at a time. Block are delimited by 55 Sample Messages:
SingleCycleHeader messages. Move Linear XYZ 10 11.1 12.0 until Switch break
Move Linear XYZA 10.5 20.0 100.1 find IndexPulse
Expected Responses Expected Responses
NotMoving<Qualifierd
If the Motion Controller is able to begin execution of 60 <attributes>Description<errordescription>
messages from the synchronous buffer, it responds with a Moving<Qualifierd <attributes>
Running Message. If the Motion Controller is not able to Move Velocity Move
execute the messages from the synchronous buffer, it The VelocityMove message asks the Motion Con
responds with a NotRunning message. The expected troller to move its axes at a specified velocity.
responses for any of the run commands are 65 Move VelocityMoveCVelocity> <attributed
Running<Qualifiere Elements
NotRunning <Qualifier>Description <errordescription> <Velocity>XYZ
 5,453,933
53 54
XYZAB Update
XYZABS
S An Update message is sent to the Motion Controller when
<attribute>until switchkbreakimake> an application wishes to change the value of a parameter.
until probezbreakmake> 5
find index pulse
override<enable disable>

Update Name <FieldName> DataType <Type2 Value <Data>

<FieldName> Description
Feed rate floatingpoint Sets the value of the
feedrate to be used
by the following
motion blocks
Override floatingpoint Set the value for the
feedrate override.
OverrideBnable EnableDisable Enable or disables
the effect of the
feedrate override
MotionHoldenabl EnableDisable Enable or disables
the effect of
MotionHold
Probe EnableDisable Enable or disables
the Probelnput
ZeroPosition Position Set the Zero for the
coordinate system
Header Header The Update Header
message allow the
applications sending
the messages to the
Motion Controller to
embed User Header
information into the
Queue.

motion holdkenableldisable> 35 Expected Responses

probeCenableldisable> Updated Name <FieldName> DataType <Type2 Value
decelktype> <Data>
ConCurrent NotUpdated
Expected Responses Name<FieldName>DataTypeCTypes Value
40 <Data>Description<errorDescription>
Moving VelocityMove-Velocity> <attributes
NotMoving VelocityMoveCVelocity> Get
<attributed Description A Get message is sent to the Motion Controller when an
<errordescription> 45 application wishes to access information from the Motion
Wait Controller. The message allows the application to find and
read motion control parameters and state variable and
A Wait message is usually sent to the Motion Controller's motion registers. These registers are
synchronous queue. The message asks the controller to not Current position
execute past this message until a StopWaiting message is 50 Index position
Sent.
Probe position
Wait Message Commanded position
Wait messagegidd Velocity
Sample Messages: 55 Following Error
Wait message 1152
Expected Responses Get Name
Waiting messagezid>
NotWait messagegiddDescription<errorDescription> 60
StopWaiting Message Get Name
Get Name <FieldName> DataType <Types
The StopWaiting message is sent to the Motion Controller <FieldName> <Typex Description
to cancel a Wait message. Probe Position Position Holds the position of
StopWaiting messagegidd 65 the axes at the last
Expected Response probe contact.
Index Position Position Holds the position of
Stopped Waiting messagegidd
 5,453,933
SS 56
Supports local or bussed I/O including CANbus and
-continued Pamux
Get Nane Programmable scan rate down to 20 milliseconds and
Get Name <FieldName> DataType <Typee dependent on the size of the program
<FieldName> <Typed Description Programmable off-line or on-line
the axes at the last Program using existing off-the-shelf products
index pulse.
Current Position Position Gcts current position Supports on-line LC monitoring
of the axis Supports on-line I/O monitoring
Commanded Position Gets the commanded 10 a
Position position of the axis On-line debugging
Following Error Position Gets the following Simulation
Veloci Weloci E R axis f Communicates through messages
elocity elocity s velocity o Supplies a window-based translator to convert com
Override floatingpoint Gets the value for 15 mon, logic control file formats into the LC file format
the feate
Wel.
Optional embedded Logic Controller in hardware with
- 1

OverrideBnable EnableDisable Indicates if Override programmable scans down to 1 millisecond

is enabled.
MotionHoldEnab Enable)isable Indicates if Logic Controller Messages
MotionHold is
enabled. O 20 The messages of the logic control are objects, such as C++
Probe EnableDisable Indicates if Probe is objects. Each message object is transmitted in binary form
enabled. to the receiving application's mailbox and then rebuilt into
an object. Three types of message can be sent to the Logic
Expected Responses Controller:
Got Name<FieldName>DataType-Type2 Value<Data> 25 Synchronous queue control (Run, Stop)
NotCotten Name<FieldName>DataType-Type> Send data (Update)
Flush Access data (Get)
(Get
When the Logic Controller receives user-defined mes
The Flush message is sent to the Motion Controller when Sages, it stores them in its data table. Logic must be added
a application wants the Motion Controller to delete all of the to the ladder program to evaluate and execute the message.
messages from its synchronous message queue. An example of a user-defined message appears in the
Flush(ProcessName> following table:
Expected Responses
Flushed 35
NotPlushed Type Definition Data
o 1 Tool changer - automatic, tool number
Motion Controller Notes 2 - retract
A. A. 3 - extend
The following describes some of the control options 40 2 Coolant onioff 0 - off, 1 - on
which may be desired in the Motion Controller according to 3 Enable servo power
the present invention.
Calibration Sequence Run
The Motion Controller contains a programmable 45 The Run messages are used with the StopRun messages to
sequence of primitives which include: control the execution of synchronous buffer. The Run mes
Move until not limit switch (off) sage asks the Logic Controller to start executing messages
Move until index pulse from its queue.
Move to index pulse Run-Qualifiers
Update position Run RunAttributeCattribute>
Update position offset The Run
A. RunAttribute directs the Logic Controller to
p p begin execution of the messages in the synchronous
Probing 55
buffer.
attribute>none
The Motion Controller's probing configuration includes: SingleCycle The Run SingleCycle directs the
Move to position on probe head Logic Controller to execute messages in the synchro
Move until
till not
not probe
prob (off) nous buffer a block at a time. Block arc dclimited
by SingleCycleHeader messages.
Logic Controller 60 Expected Responses
The Kernel's Logic Controller (LC) is an engine o that If the Logic Controller is able to begin execution of
executes logic
dth programs
- - by scanning inputs,h executing
hi pro messages from the synchronous buffer, it responds with a
grams, and then writing outputs to operate the machine tool. Running Message. If the Logic Controller is not able to
The LC has these features: 65 execute the messages from the synchronous buffer, it
Executes ladder logic programs responds with a NotRunning message. The expected
Executes GRAFCET programs responses for any of the Run messages are
 5,453,933
57 58
Running<Qualifierd
NotRunning<Qualifier) Description<errordescription>
Updated <Qualifierce
StopRun NotUpdated <Qualifierc Description <errorDescription>
5 Flag Access Logic Controller
The StopRun message is sent to the Logic Controller to data table by Names
halt the execution of the message in the synchronous buffer. FlaglD Access Logic Controller
The motion can halt execution of message immediately data table by flag id
LCMsg Generic Logic Controller
(with controlled deceleration of motion) or at a block Message
boundary. Block boundaries are delimited by Cycle Headers. 10 Program Loads sections of the
StopRun RunAttributezattributed Logic control message
This StopRun message asks the Logic Controller to
stop execution of the synchronous buffer. It uses this
format
StopRun RunAttributezattribute> 15 Update Flag
<attribute)immediate-deceleration motion at the The Update Flag message is used to change a value in the
maximum acceleration rate. Logic Controller data table. These messages are interpreted
SingleCycle-stop execution at the first block end at the beginning of each LC program scan. The Flag can be
(singleCycleHeader) with out exceeding maxi referenced through a Name or an ID.
mum acceleration. 20
Update Flag Name <FlagName> DataType <Type2 Value
Expected Responses
When the Logic Controller receives a StopRun message, <Flag Value2
it halts execution of the message in its synchronous buffer 25 Update Flag
and responds with a StoppedRunning message. ID<FlaglD>DataType-Type2 Value-Flag Value)
StoppedRunning<Qualifierd Update LCmsg
The Update LCmsg is used to send a generic mes
Wait sage to the Logic Controller. The actual message
A Wait message is usually sent to the Motion Controller
30 is interpreted by the ladder program.
Update
in its synchronous queue. It asks the Motion Controller to LCmsg-msgType>Size.<MsgSize>ValueCmsg>
not execute past this message until a StopWaiting message
is sent.
Wait Message 35 Update Program
Wait message<idD An application uses the Update Program message to down
load ladder program messages to the Logic Controller. The
Expected Responses Program is downloaded by breaking it up into segments and
40 sending the segments to the Logic Controller. The "Sequen
Waiting message<id> ceNumber' is used to make sure the program segments are
NotWait message<idDDescription <errordescription> received in order.
Sample Messages Update Program ProgramlD<Progld>Sequence
Wait message 1152 <SeqNumber>String<progSegment>
45
StopWait Message
Get
The StopWaiting message is sent to the Motion Controller An application sends a Get message to the Logic Con
to cancel a Wait message.
StopWaiting message <id> 50
troller when it wishes to access information from the Logic
Controller's data table.
Expected Responses
StoppedWaiting message<idZ Get Flag Name<FlagName>DataType <Type2
Get Flag ID<Flag|D2DataType-Types
Update
55
Update messages are sent to the Logic Controller by Expected Response
Application program to provide information to the ladder
program. The message may update a flag in the Logic The Logic Controller responses to the Get messages at the
Controller data table, send a generic message, or provide a end of each of the ladder program scans. The Got message
new ladder program to the Logic Controller. is used to return the value of the requested flag. The
Update <Qualifierd ° Notgotten message indicates the requested flag was not
defined.
Expected Response
The Logic Controller process Update messages at the Got Flag
beginning of its scan. It responds with a Updated message to ID<FlagID>DataTypezTypes Value(Flag Values
indicate that the Update message was successfully executed. 65 Not Gotten Flag
If the Logic Controller is not able to perform the Update, a ID<FlagID>DataTypeCType2 Description
NotOpdated Message is returned. <errorDescription>
 5,453,933
59 60
Ladder Logic Programming in I/O, facilities debugging of logic sequences, and helps
The ladder logic programming environment gives the with machine wiring or switch adjustments.
OEM off-line tools and a controller resident monitor to The features of the Logic Monitoring Tool are listed
customize the LC. There arc three components of the ladder below:
logic programming environment: Incorporated into the CNC executive software system
Ladder Logic Programming Tool (off-line) Accessible though the CNC's platform diagnostic mode
Ladder Logic Debug Tool (remotely hosted, serially Displays states of inputs and outputs in real-timc
linked) Allows the integrator to force the states of outputs and
Logic Monitoring Tool (controller resident) 10 view the responses of the inputs
The programming environment provides version control Reads from an alias file to attach symbolic namcs to I/O
for the logic programs and back-up to any point in the point definitions on the screen
changes. This feature also allows the OEM to branch off at
a selected point and start new development paths for new Motion Control Hardware
machine strategies. 15
Programming Tool The present invention System uses the aforementioned
MATRIX4 multi-axis servo controller board. The system's
An OEM can create and change ladder logic programs approach to motion control maintains digital control
using familiar notation and concepts provided in the Ladder throughout the position, velocity, and current loops as part of
Logic Programming Tool. This tool gives the developer an 20 the CNC. As a result, the system achieves more precise,
easy-to-use off-line, graphical method for creating, editing, faster, and more robust closed loop control than other servo
running, testing, and downloading logic control programs controls. Many control functions are isolated in the motion
for the controller. With the tool the engineer can design control software on the host computer. This approach give
control programs from initial concept to final operation the user more flexibility when responding to changing
using top-down design procedures. The following are pro 25 industry needs. This also facilitates retrofitting a new CNC
gramming tool's features: on existing machines. The MATRIX4 controller board is a
Supports programming in ladder logic: fully digital, 4-axis position and velocity controller. The
Coils and Contacts board provides constant velocity control as well as spindle
Virtual Coils and Contacts orient capability. When coupled with the VECTOR4 daugh
Timers 30 terboard, the system permits the CNC to control DC brush,
Counters DC brushless, and AC induction motors and permits most
Branches parameters to be programmed dynamically. Dynamic pro
Function Blocks for math (add, Subtract, multiply, divide, gramming allows an engineer to update the motion control
trig.) parameters immediately when there are changes in the
Function Blocks for interface to CNC 35 environment or operating conditions.
Output in "ANSI-C" source code form for cross-compile
to target coprocessor board Motion Control Configurations
Outputs a symbol table that may be read by other pro Due to the system's configuration-flexibility, OEMs can
grams-useful for parameterization and creation of 40 use machines with multiple motors. This is possible bc.cause
shared data tables the CNC hides the motors from the application software by
Supports programming in sequential function charts sending CNC messages through the power modules to
(GRAFCETSFCs) maneuver the motors. This structure allows easy swapping
Produces hard copies of program and data documentation of motors without drastic changes in the machine design.
Supports programming in timing diagram form 45 For each controller board, an OEM can configure up to
Version control allows the integrator to make incremental four axes with each axis independently supporting a differ
changes with an audit trail ent type of motor. Four boards can be used together to
support up to 16 motors. The power modules between the
Ladder Logic Debugging Tool CNC and the motors are inexpensive replacements for the
The on-line debugging tool runs on a Windows worksta 50 proprietary drives common in many systems today. These
tion with a serial (RS232) link to the controller. This tool modules can be purchased from many different supplicrs.
provides the following features: Motion Control Software
Graphic illustration of the contacts and coils in the ladder
program as they energize and de-energize 55
The motion control software in the CNC translates part
Ability to monitor and set values in the data table includ programming requests into basic position and Velocity
ing counter and timer accumulators instructions. As shown in the illustration on the next page,
Display of the GRAFCETsteps and transitions as they the motion control software is divided into functional com
activate and deactivate ponents. The operator uses the Part Program Interpreter
Ability to command the Logic Controller engine to 60
(PPI) software to direct the motion of the axes. The PPI
execute one scan at a time
software may make use of pre-programmed, packaged
cycles to perform common operations such as drill and tap.
Logic Monitoring Tool The PPI sends requests to Process or Machine Objects.
The real-time Logic Monitoring Tool gives the integrator This software loads the requests and manual operations,
a way to observe the states, inputs, and outputs of the 65 such as tool change or coolant on/off, into shared memory,
machinery during cycling on the machine tool itself. The The Interface Driver software has these functions:
software allows the integrator to watch for timing problems Extracts and processes requests from shared memory
 5,453,933
61 62
Interpolates motion lines Defining the Configuration File
Performs leadscrew mapping In development work for this platform service, the first
Sends position/velocity targets to the MATRIX4 board step is definition of the configuration file containing the
The Interface Driver can accommodate simultaneous 5 system parameters. An ASCII file may be used to define the
commands from the host to multiple DSPs. The driver shared variable name, its size, and each data field in the
software converts requests from the PPI into position and shared memory. For example:
velocity targets that are fed to MATRIX4 through the
Motion Interface. The driver also uses a "C' library and
function prototypes to define commands for the MATRIX4 10 # This is an example configuration
GT. 1/1992
board. NAME /mnt/mydirectorylsharedfilename
The "C" library in the driver software defines the follow SIZE 4096
1ng: SOF
# NAME TYPE COUNT SIZE
Axis designators 15
kTermsX INTEGER 4
Module designators kTerms Y INTEGER 4.
Multiple read parameter types kTcrims2
kTermsS
INTEGER
INTEGER
4
4
Disable interrupts masks iTermsX INTEGER 4
iTerms Y INTEGER 4
Servo modes of operation 20 iTermsz. INTEGER 4
Axes per module iTermsS
wTernsX
INTEGER
INTEGER
4
4
Maximum number of axes per module wTermsy INTEGER 4
Output loop gains wTerms2.
wTermsS
INTEGER
INTEGER
4
4
Control Law indices 25 i limit DOUBLE 4
max accel DOUBLE 4
Control PID gain indices pwm freq INTEGER 4.
Error codes lines INTEGER 4
poles INTEGER 4.
Maximum and minimum velocities and accelerations hall INTEGER 4
Block transfer rate codes 30 deadband INTEGER 4
loopType INTEGER 4
Function prototypes motorParam INTEGER 4.
The motion control software also includes utilities to field INTEGER 4
Otor INTEGER 4
program the motor technology for the application. These TravelLimits DOUBLE 3
utilities permit engineers to configure, tune, and maintain 35 Units STRING 1 7
applications as well as document system performance.
The MATRIX4 board accepts the motion commands and The first two lines for the SystemVariables configuration file
closes the servo control loop. Since axes move by having are comments beginning with the "#" sign. All keywords
voltages applied to them, the MATRIX4 board converts the must be in capital letters in the file. The second line uses the
position/velocity instructions into voltages (0 to 10 volts) 40 NAME keyword to specify the name of the SystemVariables
and applies the voltages to the axes being controlled. The file. An absolute path name should be used. The third line
MATRIX4 board does not need to understand the machine
specifies the size of the data area using the SIZE keyword.
The size should be specified in 4K increments, even if the
tool’s operation since that function is handled by the soft data space used is less than that. The SOF (start of fields)
W3C. 45 keyword must precede the defined fields.
The six supported field types are byte, string, double,
integer, short integer, and long integer. The first column
Machine Configuration Library identifies the name of the field. Field names are limited to 30
characters plus a null terminator making it a total of 31
The Machine Configuration Library provides default 50 characters. The second column defines the field type, string,
parameters for applications in a shared memory area. This double and integer. There is no limit to the length of a string.
service's responsibilities are to The third column defines the number of elements to be
Load and distribute initialization parameters from the file stored for that field name. The example shows the field
system "kTermsX' to contain 4 integers, "TravelLimits' 3 doubles
Distribute parameters to applications 55 and "Units' 1 string containing 7 characters (including any
null terminator). -
In one embodiment, this parameter library uses a C++ At this time, the SIZE field is used only for the string data
object, SystemVariables, to read and write data in the type. It indicates the length of the string (including null
globally accessible shared memory area. The library also terminator).
contains utilities to create, load the configuration, print, list, 60
save, restore, and remove the information in the System Utilities
Variables memory region. After creating a configuration file, the engineer needs to
The information in this section provides the details nec set up the memory area and load the configuration param
essary for an engineer who wants to modify or develop new eters. The library contains utilities to create the shared
configuration programs. For more general information about 65 memory area, load the configuration, print, list, save, restore,
these functions, refer to the "Platform Services' discuss and remove the information in the SystemVariables memory
herein. region. These utilities are
 5,453,933
63 64
SVsize -continued
SVcreate
SVprint Available Bytes. 2553)
SVloadConfig Build Completed.
SVlistData
SVSave SVprint
SWrestore
SVremove Once the shared data area has been created, the engineer
10 may display the data description using the SVprint utility.
SVshmdump The SVprint utility displays the field name, data type (B, I,
These utilities are described in the order they are most D, S, H, L) the count (number of elements) and the size of
commonly used beginning with the SVsize utility. each String field. Below is an example showing integer (I),
double (D) and string (S) data types. This utility also shows
SVsize 15 the size of each string field.
The first utility an engineer may need, SVsize, establishes
the size of the shared memory. In the example below the NAME....../mnt/mydirectoryisharedfilename)
4096 SIZE value provides enough space for the defined SIZE.......... (4096
shared data area. The Total Bytes Used parameter indicates 20 Name Typ Count Size
the total amount of space required for the shared data TravelLimits
definition that the engineer specified. This figure must be Units
increased up to the next 4K value and used as the SIZE deadband
parameter in the configuration file. field
25 hall
Terms.S
TernsX
Sizing Amnt/mydirectorylsharedfilename) Terns.Y
Size Indicated (4096) iTerms2.
Header 12 i limit
Table 1100) kTermiss
30 kTernsX
Data (431)
Total Bytes Used 1543 kTerms Y
Available Bytes (2553 kTerms2
Size Completed. lines
loopTyp
maxaccel
35 lOO
motorParam
SVcreate poles
pwm freq
After defining the shared data area, the engineer may wTermsS
wTernsX
create the shared data area using the SVcreate utility. Below 40 wTerns
is an example using this utility program. wTerms.2,

Building.../mnt/mydirectoryisharedfilename SVloadConfig
Size........ (4096) 45
Shmid...fmnt/mydirectorylsharedfilename) created. Next the engineer may load default values into the shared
kTerms)
kTerms Y
memory using the SVloadConfig utility. This utility uses an
kTerms2. ASCII file describing the values assigned to each field. The
kTermsS format of the file follows:
iTermsX
Terms Y 50
iTermsz.
TermsS # These are the default values used for SharedVariable example
wTermsX programs.
wTerms.Y # FieldName Index Wallic
wTerms.Z.
wTermsS 55 kTermsX O 7000
i limit kTermsX 1 30000
max accel kTerms) 2 12000
pwm freq kTermsX 3 19400
lines i
poles kTerms Y O O
hall 60 kTerris Y 20000
deadband kTernsY 2 5000
loopTypc kTermsY 3 7000
motorParam f
field kTerms Z. O 2000
OtOI kTerms.Z. 18000
TraveLimits kTermsz. 2 3000
65 kTerms2. 3 5350
Units
Bytes Used...... 1543
 5,453,933
65 66
Table of Contents
-continued Data Storage
kTermsS O TOOO The header is divided into three fields:
kTermsS 1 30000 Number of fields defined in the shared area (first 4
kTermsS 2 12000 bytes)
kTermsS 3 19400 Offset into the shared area (used when allocating space
t
iTermsX O O for new fields)
iTermsX 15000 An integer storing the semaphore handle (used to
iTermsX 2 4000 synchronize access to the data area only)
iTermsX 3 O 10 The header structure is as follows:
i
Terms Y O O
iTerms Y l 28000
iTerms Y 2 15000
Terms Y 3 O typedef header {
i int number of fields;
Units O Metric 15 long offset into datastorage;
int semaphore;
header,
In the SVloadConfigutility, lines beginning with aii sign are
interpreted as a comment. The first column specifies the field The second four bytes of the header contain a long integer
name while the second column is the index. The fields or 20 (also four bytes) of the offset into the shared area. This value
indexes do not have to be defined in any specific order. The is used when allocating space for new fields in the shared
third column is the value. If a field cannot be found or a area. In this scheme the table of contents (the field descrip
value is invalid, an error message is printed. tions) grow downward while the data storage area grows
SVistData
upward. Finally, the header information contains an integer
25 storing the semaphore handle used to synchronize access to
The engineer may list all the data values that are currently the data area only. This means the semaphore is not used
stored in the shared area using the SVlistData utility. This when getting information about the fields, but only for
utility outputs a file that can be read using the SVloadConfig reading and writing into the data area.
utility. The value for each field by index is printed. Note: The byte sizes described in this document for
30 integer and double reflect those of a 386 and 486 architec
SVSave tre,
The second section of the shared area is the table of
After modifying the data stored in the shared area, an contents. This area contains a series of field descriptions
engineer may want to save the information to disk. This can each can be described using this data structure:
be done using the SVsave utility. Below is an example using 35
this utility.
#define (FIELD NAME LENGTH 3.1
typedef struct field description
NAME......(fmnt/mydirectorylshared filename) {
SIZE.......... (4096) 40 char fieldname FIELD NAME LENGTH;
Save Completed char type,
unsigned int count;
unsigned int size;
The save utility saves the shared area under the filename unsigned int offset;
specified in the configuration file with a .sav extension. field description;
SWrestore 45
The first 31 bytes of each field description contains the field
To restore a previously saved file, use the SWrestore name. This is the same name that is used in the configuration
utility. Below is an example using this utility: file. At this time an upward limit of 31 characters (including
Null terminator) is allowed. The next byte in the description
50 indicates the field data type. The six field data types are
NAME....../mnt/mydirectorylshared filename) represented by these letters:
SIZE.......... (4096) B-byte
Restore Completed I-integer
D-double
55
SVshmdump S-string
There is another utility, SVshmdump, that may be of H-short integer
interest for debugging the shared area at a very low level. L-long integer
This program dumps the shared area in hex bytes and is The next four bytes describe an integer representing the
number of elements to be stored under this name. This can
useful when the engineer wants to inspect the shared area. be considered an index into an array beginning with the
Shared Memory Organization index Zero for the first element. An integer representing the
size of each element is stored after the count. Doubles use
The SystemVariables area can be described as a contigu eight bytes and integers four, with user defined the string
ous area of shared memory. This memory is divided into 65 sizes. The final four bytes of the field description contains
three sections: the offset from the beginning of the shared area into the data
Shared Memory Storage Header storage area where the stored values are kept for the field.
 5,453,933
67 68
Writing a Program SystemVariables Methods
An engineer wishing to write a program to access the The Machine Configuration Library uses an object, such
shared memory area may want to examine the following as a C-H object, SystemVariables, to read and writic data in
example. This program simply creates a SystemVariables
object, passing the configuration filename to the object. the globally accessible shared memory area. The System
Calls are made to the SystemVariables object for getting the Variables methods are defined below and the possible return
size, mapping the fields to field objects, getting and updating values are listed for each method.
data, and other necessary actions.

include <stream.h>
include "SystemVariables.hpp”
main (int argc, char *argvl)
int error,
doubledoublevalue;
if (argc < 2)
{
cout << form (“Usage: %s configuration-filename n', argv[0]);exit (-
1);
}
f* Instantiate a SystemVariables object, specifying the configuration file
name to be used if
SystemVariables systemVariables(argv[1), error);
f* Check the error code returned from the constructor calli
if (error)
perror ("SystemVariables Constructor');
exit (-1);
f* The Size method call is one of many calls that will return information
about the shared area *.
if (systemVariables.Size() = 0)
{
perror ("Invalid size”);
exit (-1); -

fk
Here is a simple call to get the value stored in the 0th index of the field
called "max accel'.
*/
error = systemVariables.Get("max accel", doublevalue, 0);
cout << form ("max accel value %f n'doubleValue);
fk
Finally, close the connection to the owed data area.
+/
if ((error = systemVariables. Close()))
{
perror ("Cannot close shared area");
}

Basept

This class method returns the base pointer to the shared

59 area. The function prototype for this method is—
Below is the make file used to compile and link this char *BasePtr ( )
Return Values:
program: A non Null pointer on success.
55

CFLAGS=-X-Fusilocal/include Close
OBJE/
EXE=1 This class method closes a connection to the shared arca.
LIB-fusr/local/lib/
OFILES-c S(OBJ)example.o The function prototype for this method is
S(EXE)example: S(OFILES) int Close ( )
g-H--X S(OBJ)example.o S(LIB)libSV.a-o S(EXE)example Return Values:
S(OBJ)example.o: example.cc
g++ -c S(CFLAGS) example.cc -o S(OBJ)example.o 0-Success
-1-Error. Check"Errno' for a description of the error.
65 An error may occur during an unmap call of thc shared
The SystemVariables methods are described in the following area or a close call to the shared arca file. Errno is Sct whicn
section. these errors occur.
 5,453,933
69 70
Description Get
This class method returns a character string describing the This method retrieves the value stored for a given field by
field. The string contains the field name, type, count and size C.
(in case of string types). The calling program must perform int Get (char *fieldName, int &data, int index)
a delete on the returned description. The application may use int Get (char *fieldName, char *data, int index)
the Field or GetField method calls to obtain the Field
parameter used in this call. The function prototype for this int Get (char *fieldName, double &data, int index)
method is The index parameter is optional. If it is not used, the 0th
int. Description (svField &field, char *description) See index is searched. Care must be taken when getting
10 string values. The engineer must make sure the
Also: GetField, Field character pointer that is passed into this method has
allocated enough space to store the character String.
Field A good way to do this is to use the FieldSize method
to get the size of the character string. Then allocate
This method finds the Field for the field specified by 15 the space before calling this method.
fieldName. The function prototype for this method is Return Values:
int Field (char *fieldName, SvField &field) 0-Success,
Return Values: -1-Invalid field type.
0-Success -2-Field not found.
20 -3-Shared Area Not Initialized.
-2-Cannot find field.
-3-Shared Area Not Initialized. See Also: Get, -4-Invalid Index.
Update. The Get method also retrieves the value stored for a given
field as specified by the sffield reference.
25
int Get (sffield &field, int &data, int index)
FieldCount int Get (sffield &field, char *data, int index)
This method gets the number of elements for the field int Get (sffield &field, double &data, int index)
specified by fieldName. The count is returned in the param The Field pointer is found using the Field or GetField
eter count. The function prototype for this method is methods.
int FieldCount (char *fieldName, int &count) The engineer must make sure the character pointer that
Return Values: is passed into this method has allocated enough
0-Success space to store the character string. A good way to do
-2-Cannot find field. this is to use the FieldSize method to get the size of
-3-Shared Area Not Initialized. the character string. Then allocate the space before
35 calling this method.
Return Values:
FieldSize 0-Success,
-1-Invalid field type.
This method gets the size of the field specified by field -3-Shared Area Not Initialized.
Name. The size is returned in the parameter size. The 40 -4-Invalid Index See Also: Field, GetField, FieldSize.
function prototype for this method is
int FieldSize (char *fieldName, int &size) GetField
Return Values: This method call is used to traverse the list of fields in the
0-Success shared area. By using a zero in the parameter data you will
-2-Cannot find field. 45 begin at the top of the list. After each call the data parameter
-3-Shared Area. Not Initialized. will be incremented. The list can be traversed by calling this
method successively until a return value of -1 is return. The
FieldType function prototype for this method is
int GetField (svPield &field, int &data)
This method gets the data type for the field specified by SO Return Values:
fieldName. The type returned in the parameter type is I for 0-Success
integer, D for double, S for string, B for byte, H for short -1-End of list.
integer, and L for long integer. The function prototype for -3-Shared Area Not Initialized. See Also: Get,
this method is Update.
55
int FieldType (char *fieldName, char type) Name
Return Values:
0-Success This class method returns the shared area name specified
-2-Cannot find field. in the configuration file. The function prototype for this
-3-Shared Area. Not Initialized. method is
60
char *Name ( )
FileName NumberOfHields
This class method returns the configuration filename used This class method returns the number of fields defined for
to define the shared data area. The function prototype for this 65 the SystemVariables. The function prototype for this method
method is is
char *FileName() int NumberOfFields( )
 5,453,933
73 74
this eliminates the search for the individual field. In addition,
this provides information about individual fields by making -continued
calls to the SVfield class methods. This section describes the RESERVED 20 = 0x0020,
SVfield class method calls. RESERVED 40 = 0x0040,
RESERVED 80 = 0x0080,
Name USER DEFINED Ol = 0x0100,
USER DEFINED 02 = 0x0200,
This class method returns the name of the Field. Field USER DEFINED 04 = 0x0400,
names are currently limited to 31 characters including the USER DEFINED 08 = 0x0800,
USER DEFINED 10 = 0x1000,
Null terminator. The function prototype for this method is 10 USER DEFINED 20 = 0x2000,
char *Name ( ) USER DEFINED 40 = 0x4000,
USER DEFINED 80 = 0x8000,
Type ALL CATEGORIES = 0xFFFF.
ExceptionCategoryValues;
typedef enum ErrorCodes
This class method returns the field data type. The return 15 {
value may be I (integer), D (double), S (string), B (byte), H EX NO ERROR,
(short integer), or L (long integer). The function prototype EX_NOT FOUND,
for this method is EX REPLACE ME 001,
EX REPLACE ME 002,
char Type () EX REPLACE ME 003,
EX REPLACE ME 004,
20
Count
This class method returns the number of elements that
may be stored under this field name. Elements are numbered Machine Class Creating a New Machine Class
beginning with 0. For example, an integer field with a count
of five may be accessed using an index from 0 to 4. The Creating a completely new Machine Class is a more
function prototype for this method is complex process than simply modifying an existing
int Count ( ) Machine Class. A customer may create a new Machine Class
for one of the following reasons:
Size Existing Machine Classess do not contain the objects
30 needed to operate the customer's extremely specialized
This class method returns the size of each field element. machine
Under the Lynx OS (for 386/486 systems) integers and The customer wants to replace the messaging interface.
doubles are stored in four bytes, strings are stored by any
size. For example, a string field with a count of seven and a The customer has a specialized Kernel and needs to
size often means there are seven character strings of length 35
develop a Machine Class to communicate with it.
ten (including the Null terminator). The function prototype As with all development efforts there are two main stages:
for this method is preparation and development.
int Size ( ) Preparation
Exception Reporter 40 To prepare for development of a completely new Machine
Class, the customer should analyze the target machine tool
The error codes used to filter error messages are available to identify all of its devices.
in the file "ErrorCodes.hpp." This file may be modified and The customer must also identify the system tools to assist
expanded to meet the customer's needs. in this effort. Some of these tools are
45 OS utilities
ifndef ERRORCODESHPP
ANSI C compiler
idefine ERRORCODESHPP CH programming features (compiler, inheritance of
i
# FileName: ErrorCodes.hpp
object characteristics, and isolation of changes)
50 UNIX-based development tools
# SHeaderS The customer needs to become familiar with two important
# SLogS
i
control system components:
static char *ERRORCODESHPPRC string = "SHeaders"; Well-documented Kernel interface including message
typedef enum ExceptionSeverityValues parameters and Logic Controller flags (in this manual)
55 Full source code for the sample, generic Machine Class
NO SEVERITY = 0x0000,
INFORMATION = 0x0001, An understanding of these two components simplifies the
WARNING = 0x0002, development effort by helping the customer to connect the
FATAL = 0x0004,
All SEVERITIES = 0x0007,
new Machine Class to existing Kernel functions.
ExceptionSeverityValues; 60 Development Steps
typedef enum ExceptionCategory Values
NO-CATEGORY = 0x0000, The steps a developer should follow when creating a new
MOTION = 0x0001, Machine Class are as follows:
LOGIC CONTROLa 0x0002, 1. After a thorough analysis of the target machine, name
DEVICE LAYER = 0x0004, 65 all of the devices needed to operate the machine. These
DIRECTORY SERVICE = 0x0008,
RESERVED 10 = 0x0010, become the new Machine Class objects.
2. Identify all of the methods used by each device. It is
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often helpful to use the same verbs as those used by model of a hole-making process capable of forming a hole
existing Machine Class objects. In that way, the devel in a workpiece, the model of the hole-making process
oper can connect and use the existing messages. including definitions of the X, Y and Z dimensions of the
3. Match the available Kernel functions to the new hole.
Machine Class objects. Create new messages where 8. The CNC machine tool control system of claim 1
needed. wherein at least one of said shaping objects comprises a
The Appendix includes representative source code which model of a milling process capable of being formed in a
may be useful to programmer to create and use a CNC workpiece, the model of the milling process object including
control system in accordance with the present invention. a two-dimensional definition of a shape.
However, it should be understood that variations in the 10 9. The CNC machine tool control system of claim 8
source in the appendix will likely be appropriate to accom wherein the model of the milling process object further
modate the design of the particular CNC machine tool with includes information representing whether the defined shape
which it is used. Moreover, those of skill in the art will is to be removed from the workpiece or left remaining as a
appreciate that many variations to the invention as described form in the workpiece.
herein may be made without departing from the spirit and 15
10. The CNC machine tool control system of claim 1
scope of the invention, and such variations are with scope of wherein at least one of said objects comprises a model of a
the below claims. contouring process capable of being performed on a work
What is claimed is: piece being turned in a lathe.
1. A CNC machine tool control system for a CNC 11. The CNC machine tool control system of claim 1
machine tool of the type comprising a controllable, movable 20
wherein said generating means includes status means for
tool for shaping a workpiece, means for receiving control indicating whether a process defined by one of said objects
instructions describing shaping functions to be performed on has been performed on a workpiece.
the workpiece, a processing unit and memory means, com 12. The CNC machine tool control system of claim
prising: wherein said generating means includes sequence storing
means for receiving and storing in the memory means 25
means for indicating the order in which a process repre
workpiece shaping instructions; sented by one of said objects should be performed relative
means for transmitting command signals to a movable to other of said objects representing other processes to be
tool to thereby cause the movable tool to move; and performed.
means for generating control signals, said generating 13. The CNC machine tool control system of claim 1
wherein at least one of said objects comprises a composite
means including an object oriented software program 30
object of multiple instances of another object representing a
comprising a plurality of objects, each said object process, the composite object further including physical
including a plurality of instructions and associated data, coordinate information regarding the locations on the work
said generating means including message means for piece in which each instance of the process is to occur.
transmitting information between said objects, at least 14. A CNC machine tool control system for a CNC
one of said objects including a model of a shaping 35
machine tool of the type comprising a controllable, movable
process to be performed on a workpiece by the movable tool for shaping a workpiece, means for receiving control
tool, said generating means coupled to said message instructions describing shaping functions to be performed on
means, said generating means generating control sig the workpiece, a processing unit and memory means, com
nals responsive to messages from said shaping objects, prising:
said generating means communicating said control 40
means for receiving and storing in the memory means
signals to said transmitting means. workpiece shaping instructions;
2. The CNC machine tool control system of claim 1
wherein at least one of said objects may be dynamically means for transmitting command signals to a movable
allocated in the memory means. tool to thereby cause the movable tool to move; and
3. The CNC machine tool control system of claim 1 45 means for generating control signals, said generating
wherein at least one of said objects comprises a model of a means including an object oriented Software program
movable tool for shaping a workpiece, and wherein at least comprising a plurality of objects, each said object
one of said movable tool objects exchanges messages with including a plurality of instructions and associated data,
at least one of said shaping process objects. said generating means including message means for
4. The CNC machine tool control system of claim 3 50 transmitting information between said objects, at least
wherein said shaping object includes a software procedure one of said objects including a model of a movable tool
specifying messages said shaping object needs to Send to for use in connection with shaping a workpiece, said
one of said movable tool objects to complete the shaping movable tool objects including instructions and data
process. relating to functions of a movable tool, said generating
5. The CNC machine tool control system of claim 1 55 means coupled to said message means, Said generating
wherein at least one of said objects comprises a location means generating control signals responsive to mes
object including information about the location on the sages from said movable tool objects, said generating
workpiece where a process is to be performed, and wherein means communicating Said control signals to Said
a shaping process object is associated with said location transmitting means.
object. 60 15. The CNC machine tool control system of claim 14
6. The CNC machine tool control system of claim 1 wherein at least one of said objects comprises a model of a
further including first and second objects each comprising a shaping process to be performed on a workpiece by the
model of a shaping process to be performed on a workpiece, movable tool, and wherein at least one of said movable tool
and wherein said second object includes at least one instruc objects exchanges messages with at least one of said shaping
tion which is inherited from said first object. 65 process objects.
7. The CNC machine tool control system of claim 1 16. The CNC machine tool control system of claim 14
wherein at least one of said shaping objects comprises a wherein said generating means includes status means for
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indicating whether one of said movable tool objects is in use the workpiece, a processing unit and memory means, com
by a another object. prising:
17. The CNC machine too control system of claim 14 means for receiving and storing in the memory means
wherein the system comprises first and second objects each workpiece shaping instructions;
comprising a model of a movable tool for shaping a work
piece, and wherein said second object includes at least one means for transmitting command signals to a movable
instruction inherited from said first object. tool to thereby cause the movable tool to move;
18. The CNC machine tool control system of claim 14 an object oriented software program comprising a plural
wherein at least one of said objects comprises a model of a ity of objects, each said object including a plurality of
tool capable of forming a hole in the workpiece and the size 10 instructions and associated data, each of said objects
of the hole formed by the tool. carrying out operations with respect to a corresponding
19. The CNC machine tool control system of claim 14 concept and exchanging, with other said objects, mes
wherein at least one of said objects comprises a model of a sages indicative of what operation should be carried out
tool capable of milling a workpiece and the size of the tool. or a status of said sending object;
20. The CNC machine tool control system of claim 14 15 a motion controller software module for receiving mes
wherein at least one of said objects comprises a model of a sages from at least one of said plurality of objects, the
movable table on which a workpiece may be mounted and received messages including commands indicating
coordinate data regarding the position of the table.
21. The CNC machine tool control system of claim 14 desired movements of a movable tool; and
wherein at least one of said objects comprises a model of a said motion controller software module further compris
tool changer and includes descriptions of a plurality of tools. 20 ing means for sending command signals to said trans
22. The CNC machine tool control system of claim 14 mitting means to thereby cause the movable tool to
wherein at least one of said objects comprises a model of a OW.
rotatable spindle capable of receiving a tool, said spindle 29. The CNC machine tool control system of claim 28
object including means for storing information regarding wherein said motion controller software module includes
whether a spindle is rotating. 25 means for sending object oriented messages to a plurality of
23. The CNC machine tool control system of claim 14 said objects.
wherein at least one of said objects comprises a model of an 30. A CNC machine tool control system for a CNC
operator interface console through which an operator may machine tool of the type comprising a controllable, movable
utilize the CNC machine tool control system. tool for shaping a workpiece, means for receiving control
24. The CNC machine tool control system of claim 14 30 instructions describing shaping functions to be performed on
further comprising: the workpiece, a processing unit and memory means, com
a motion controller module for receiving messages from prising:
said objects indicating desired movements of a mov means for receiving and storing in the memory means
able tool and sending command signals to the movable workpiece shaping instructions;
tool to cause the movable tool to move in accordance 35
means for transmitting command signals to a movable
with the desired movements. tool to thereby cause the movable tool to move;
25. The CNC machine tool control system of claim 24 an object oriented software program comprising a plural
wherein said movable tool object periodically sends a mes ity of objects, each said object including a plurality of
sage to said motion controller module requesting informa 40 instructions and associated data, each of said objects
tion regarding the location of the movable tool. carrying out operations with respect to a corresponding
26. The CNC machine tool control system of claim 24 concept and exchanging, with other of said objects,
wherein said motion controller module includes storage messages indicative of what operation should be car
means for storing locations of movable tools, and wherein ried out or a status of said sending object;
said motion controller module provides a message including 45 a motion controller software module operatively associ
location coordinates in response to messages from said ated with said transmitting means and comprising
movable tool objects inquiring about the current coordinates means for receiving from movable tools signals indi
of the machine tool represented by said movable tool object. cating faults with a movable tool;
27. The CNC machine tool control system of claim 24
wherein: a device fault software module comprising:
at least one of said movable tool objects includes a model
50 means for storing information regarding detected faults
of a rotatable spindle capable of receiving a tool, said from movable tools;
spindle object including means for storing information means for storing, for each detected fault, a sublist of
regarding whether a spindle is rotating; said objects to which to send an object oriented
message identifying the detected fault, and
at least one of said objects comprises a model of a 55 means for sending, upon receiving information regard
movable table on which a workpiece may be mounted ing a movable tool fault, an object oriented message
and coordinate data regarding the position of a table; to each said object associated with the fault.
and said system further comprising: 31. The CNC machine tool control system of claim 30,
a composite object comprised of said rotatable spindle wherein said object oriented messages sent by said device
object and said table object, said composite object 60 fault software module are sent via said object oriented
including software means for simultaneously coordi software program.
nating the relative positions of the spindle and the table 32. The CNC machine tool control system of claim 30,
using said rotatable spindle object and said table object. wherein said messages sent by said device fault software
28. A CNC machine tool control system for a CNC module are sent through a call to an operating system to
machine tool of the type comprising a controllable, movable 65 another program.
tool for shaping a workpiece, means for receiving control 33. A CNC machine tool control system for a CNC
instructions describing shaping functions to be performed on machine tool of the type comprising a controllable, movable
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tool for shaping a workpiece, means for receiving control of a plurality of objects, each said object including a
instructions describing shaping functions to be performed on plurality of instructions and associated data, Said
the workpiece, a processing unit and memory means, com objects being capable of receiving and transmitting
prising: messages to other of said objects in the System, and
wherein:
means for receiving and storing in the memory means at least one of said objects comprises a shaping process
workpiece shaping instructions, object comprising a model of a process to be per
means for transmitting command signals to a movable formed on a workpiece by a movable tool;
tool to thereby cause the tool to move; at least one of said objects comprises a movable tool
an object oriented software program comprising a plural 10 object comprising a model of a movable tool capable
ity of objects, each said object including a plurality of of shaping a workpiece,
instructions and associated data, said objects including the object oriented software system includes motion
a plurality of transmitting objects and a plurality of control means for receiving an object oriented mcs
receiving objects, said object oriented software pro sage containing movable tool motion information
gram including message means for transmitting a plu 5 and transmitting motion commands to a movable
rality of messages to said receiving objects from said tool to cause the movable tool to move in accordance
transmitting objects, and wherein at least one of said with the motion information;
objects comprises a motion control object capable of receiving workpiece shaping information and storing the
receiving object oriented messages from other of said workpiece shaping information in one of said shaping
objects specifying motion operations to be performed 20 process objects,
by a movable tool, the motion control object operably transmitting an object oriented message from a shaping
associated with said command signal transmitting process object to a movable tool object, and
CS.
34. The CNC machine tool control system of claim 33 transmitting an object oriented message from a movable
wherein said motion control object further comprises: tool object to the motion control means, to thereby send
25 a command signal to a movable tool and cause a
means for receiving fault signals from a movable tool; and workpiece to be shaped by the movable tool.
means for sending an object oriented message to another 36. The method of claim 35 wherein said shaping process
of said objects in the control system identifying the object is dynamically allocated in memory.
received fault signal. 37. The method of claim 35 wherein said shaping process
35. A method of operating a control system for a CNC 30 object includes embedded software commands identifying
machine tool control system of the type comprising a one of said movable tool objects to which a message is sent.
controllable, movable tool for shaping a workpiece, means 38. The method of claim 35 wherein the object oriented
for receiving control instructions describing shaping func software system operates in conjunction with a real time
tions to be performed on the workpiece, a processing unit multitasking operating system.
and memory means, the method comprising the steps of: 35
providing an object oriented software system comprised c: ; c. : :