RapidPath Series

RapidPath™ is MachMotion's trademarked EtherCAT motion controller solution.

WARNING!
Improper setup of this motion controller can cause DEATH, INJURY or serious PROPERTY DAMAGE. Do not attempt to use this controller until thoroughly reading and understanding this manual.

1. Introduction

1.1 Overview

RapidPath is an EtherCAT software motion controller solution.

1.2 Tools Required

A small, flat head or #1 Phillips head screwdriver is needed for the I/O terminals. It is not included.

1.3 Software Startup

Before you can run Mach 4 with RapidPath for the first time, you must configure the EtherCAT network.

On the desktop of your control, there is a Mach4 shortcut for your machine type. Below is an example of the Mach4 shortcut.

Profile

After double clicking on a profile or opening a profile from Mach4 Loader, RapidPath will attempt to start (or verify that it is already started) the EtherCAT network. This may take up to a minute.

The EtherCAT network will usually only need to be started once after a control has been rebooted. Stopping and restarting Mach 4 will not result in the EtherCAT network needing to be stopped or restarted.

Once the EtherCAT network is operational, a window will come up (see below) asking to Press Cycle Start to Enable Mach and Home All Axes. Select [Cancel] since motion is not yet possible.

Enable and Home All axes

On subsequent startups, once motion and limit switches are set, press [Cycle Start] and the control will enable and home all axes. This prompt can be turned off in the MachMotion plugin if desired.

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3. Spindle Setup (is this still applicable for the 2000 series kneemill?)

3.1 Wiring a Spindle

3.1.1 VFD from MachMotion

The process for setting up a VFD from MachMotion is extremely simple.

3.1.2 VFD Other Than from MachMotion

Any VFD can be wired into the Spindle Control RJ45 jack by cutting the end off of a CAT5 cable and wiring the loose ends to the VFD according the following pin out.

Function

Analog 0-10VDC

CW Relay

Drive Enable

GND

N/C

CCW Relay

RJ45 Pins

Colors

(T-568B)

White & Orange

Orange

White & Green

Blue

White & Blue

Green

White & Brown

Brown

3.1.3 No VFD

Figure 21 No VFD Spindle Wiring

3.2 Spindle Configuration

3.2.1 Spindle Range Setup

For the control to know how to scale the analog voltage output, the maximum RPM for the spindle motor must be defined. If the machine has different ranges, the software can have multiple maximum speeds. The software uses a different range for each different speed configuration.

For example, one range could be set as 75 to 300 RPM for a low speed. A medium speed range could go from 300 to 1200 RPM and high speed range could run from 1200 to 2400 RPM. The control will output 10V when the MaxRPM is called for any speed range.

To define the range(s), go to Configure->Control. Select the Spindle tab as shown below.

Pulley Speed Setup

Enter in the maximum and minimum speeds for each range. The accel and decel time should also be defined for each range (seconds to max rpm). Press [OK] to save changes.

Note: Only set up multiple ranges if the machine has different gears/pulleys.

Note: If the spindle is turning the wrong direction check the reversed box in the applicable range.

The ranges can be changed from the control by using M40-M45. The macros can be used to just change ranges or they can be used to automatically change gears on the machine. To shift the machine range 0, run M40. M41 is range 1, M42 is range 2, and so on.

3.3 Turning on the Spindle

To control the spindle use the following M-Codes with an S word for spindle RPM in the MDI line (Ex. M3 S2000).

M-Code	Function
M3	Clockwise
M4	Counterclockwise
M5	Stop

Table 5 Spindle M-Codes

If the spindle is not running correctly at this point some settings may need to change inside the VFD. In this situation, reference the VFD manufacturer manual.

Note: See the Mitsubishi VFD Installation Guide for setup information if it was purchased from MachMotion.

4. Limits and Homing Setup

Note: For the highest level of safety, wire the limit switches Normally Closed.

Note: Each motor has three signals, the max travel (motor ++), the min travel (motor --), and the home (motor home). All three must be enabled and set to the correct device and input name for everything to work correctly using the wiring description above.

Note: Under the active low column the active state can be changed by clicking on the [X] or check mark. If the limit switches are normally open the red X should be used. However, this is not recommended as it is not as safe.

4.1 Homing Setup

WARNING

4.2 Soft Limits Setup

With machine homed correctly and soft limits set, the machine will not hit a physical limit switch. If at any time a command is made for the machine to move outside of the soft limits (while they are enabled), an error will appear in the status line and motion will stop. To set up the soft limits, follow the procedure outlined below.

Home the machine.
Select to view Machine Coordinates on the Locked screen view so that the DRO’s are red.
Jog the machine to the maximum distance from the homing switches.

Note: Make sure to stay inside the physical limit switches. If the machine is jogged outside of the limit switches, it completely defeats the purpose of soft limits.

Record the machine coordinates at the end of the travel.
Open the menu bar and click Configure->Control and select the Homing/SoftLimits tab as shown below.
Enable soft limits on each desired axis and enter in the recorded values.

Note: If the value is positive, place it into the Soft Max limit and set the Soft Min limit to zero. Otherwise, with a negative value, set the Soft Max to zero and the Soft Min to the recorded value.

Press [OK] to save changes. Test the soft limits by jogging the axes to maximum amounts in all directions.

Figure 26 Soft Limits

5. Input Setup

6. Output Setup

6.4 Using Outputs

Outputs 0-5 can be controlled with M-Codes. One M-Code will turn an output on, and the next M-Code turns the output off. Use the table below for a reference.

Custom M-Codes	Functions	Default Output
M200	Output 0 on
M201	Output 0 off
M202	Output 1 on
M203	Output 1 off
M204	Output 2 on
M205	Output 2 off
M206	Output 3 on
M207	Output 3 off
M208	Output 4 on
M209	Output 4 off
M210	Output 5 on
M211	Output 5 off

Table 7 M-Codes for Outputs

The outputs can also be accessed inside the MachMotion plugin.

7. Advanced Options

A number of advanced features can be accessed and configured in the MachMotion plugin such as periodic oiler control and custom user messages (Global Messaging). Begin by going to Configure->Plugins to open the MachMotion plugin.

insertimage Figure 39 - MachMotion Plugin Options

The Machine Parameters tab contains custom options for the control, including dialogue options, lube system, tool measurement/offsets, and tool changer options.

7.1 Lube System Setup

The system may require an oiler. Enable the lube system, choose an action trigger, set the lube output, set the time run time of the oiler, and the time between cycles. In the example below the lube output will turn on when the spindle is running for 10 seconds every 15 minutes.

Figure 40 Lube System Setup

It is also possible to define input activated user messages/actions. See the section on the Global Messaging System below.

7.2 Tool Setter Setup

Before you measure tool to setup your tool table, the tool setter options must first be defined. Begin by going to Configure->Plugins to open the MachMotion plugin.

Figure 41 tool Setter options

The Tool Setter Type options are manual or automatic. The Tool Setter/Gage-Block Position Type options are fixed (e.g., a bed mill) and random (e.g., a knee mill). If fixed, the tool setter/gage block position should be determined. In machine coordinates, the Z-axis position of the table should recorded and saved.

To use the automatic tool setter, the remaining tool setter options must be configured. A probe input must also be wired in and setup as the Digitize input signal.

Figure 42 Digitize input signal

7.3 Global Messaging System

Global Messaging is used to setup user alerts or messages as well as to control I/O functionality based on certain conditions. To access the Global Messaging System, go to Configure -> Plugins -> MachMotion and select the Global Messaging System tab. The system allows the machine to watch for specified conditions, and take action when those conditions are met. For information on creating, editing, or deleting a message, visit our knowledge base online at: http://machmotion.com/support/kb#11714098. You can also navigate to it by visiting MachMotion.com and selecting the Knowledge Base link under the Support menu option.

13. Appendices

13.1 Default Factory Settings

These are default settings but are not required for the system to function correctly.

Signal	Mapping Enabled	Device	Input Name	Active Low
Input #0				X
Motor 0 Home	ü			ü
Motor 1 Home	ü			ü
Motor 2 Home	ü			ü
Motor 0 ++	ü			ü
Motor 1 ++	ü			ü
Motor 2 ++	ü			ü
Motor 0 – –	ü			ü
Motor 1 – –	ü			ü
Motor 2 – –	ü			ü
E-Stop	ü			ü

Table 20 – Default Inputs Signals

Signal	Mapping Enabled	Device	Input Name	Active Low
Output #0	ü			X
Output #1	ü			X
Output #2	ü			X
Output #3	ü			X
Output #4	ü			X
Output #5	ü			X
Spindle FWD	ü			X
Spindle REV	ü			X
Coolant On	ü			X
Mist On	ü			X

Table 21 – Default Outputs

13.2 Warranty Information

MachMotion warranty policy is subject to change. Updated information is available at our website:
https://machmotion.com/warranty

The MachMotion Team
http://www.machmotion.com
14518 County Road 7240, Newburg, MO 65550
(573) 368-7399 • Fax (573) 341-2672