Configuring the AutoComp System

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Configuring the AutoComp System: Overview

Configuring the AutoComp System consists of specifying variables in either the User Options window and the System Configuration window.

The variables set in the User Options window are:

• "Security Levels"
• "Operation Modes"
• "Specifying Temporary Setup Overrides"
• Force Front on Cycle Complete
• "Access AutoComp from CEI Remote View"

The variables set in the System Configuration window are:

• "Routine Path"
• "System Global Parameters"
• "Cycle Notifications"
• "Run Data Variables"
• "Data Tag Variables"

Note: The System Configuration window also allows access to the windows where the CNC interface and the gage converter are selected.

User Option Window

Press the Configuration button to open the User Options window

User Options Window in Production Mode (Supervisor Level)

The User Options window provides the following functionality:

• Security level can be specified. (Access Level).
• Operation Mode can be specified.
• The Force Front checkbox forces the Main Window to the front of the desktop when a cycle completes.
• The Run Remote Client checkbox configures AutoComp to be monitored with CEI Remote View (contact CEI for information)

The Machine Name field is editable. The machine name becomes part of the run data file name. These files are named as follows:

<routine(machine)> <timestamp>.csv

• The System Configuration button allows access to the System Configuration window where file management and global parameters can be configured.
• The Delete Gage Data Files button allows any gage data files that match the defined gage converter filter in all gage converter folders to be deleted.
• The List Gage Converter Folder Files button allows the user to list all files in the gage converter folders.
• MT Connect functionality is available. See the configuration window for the IP address and port to use in the MT connect agent. For more information, please refer to the Caron Engineering MT Connect Adaptor Manual.
• Import/Export Configuration files with Offline Routine Editor.

Security Levels

AutoComp has two (2) security levels:

• Operator Level restricts access to system configuration parameters and editing routines. At operator level, routines can be loaded and unloaded. The current offset data and data log files can be viewed also.
• Supervisor Level access allows all operations.

Security level and the supervisor’s password can be set in the User Options window. See User Options Window.

Note: At operator level, a supervisor password must be entered in order to close AutoComp.

Setting Security Level

Set security level as follows.

1. Go to the User Options window by pressing Configuration in the Main Window tool bar.
2. Press the radio button next to the desired security level.
3. After setting the access level and other parameters, press Apply.

Changing Security Level

At operator level, change to supervisor level as follows:

1. Click on Supervisor Level in the tool bar at the top of the Main Window.
2. Type the supervisor password and press Enter.

Note: AutoComp can only be exited at supervisor level.

Changing Supervisor's Password

To change the supervisor password:

1. Set the security level to Operator.
2. Click Change Supervisor Password.
3. Type the new password in the New Password field.
4. Retype the new password in the Verify New Password field.
5. Press Apply.

Supervisor Login

1. In the Main Window tool bar, click Supervisor Level.
2. Enter the password and press OK.

Operation Modes

AutoComp has two operation modes: Production Mode and Setup Mode.

• In Production Mode, AutoComp analyzes gage measurements automatically. AutoComp loads the proper routine if it is not already active, suspends an active routine if necessary, performs compensation calculations, and updates CNC offsets, the Data Grid, and the History Chart.
• In Setup Mode, AutoComp loads and suspends routines. However, any dimension can be re-measured until its cycle or sub-cycle is accepted or canceled. Re-measurement overwrites the data, in effect canceling the old measurement for that dimension.
• Unlike Production Mode, compensation data remains in the Active column of the Data Grid until the operator accepts or cancels the cycle, using one of the two buttons that are displayed in the Run Screen tool bar, only in setup mode:
  • Accept sends the compensations to the CNC. The Data Grid and the History Chart are updated. Accept only works if all critical dimensions have been entered.
  • Cancel discards the cycle of data and clears the Active column of the Data Grid.

In setup mode, temporary setup overrides can be chosen.

Setting Operation Mode

To set operation mode:

1. Go to the User Options window by pressing Configuration in the Main Window tool bar.
2. Press the radio button next to the desired operation mode.
3. When finished setting Operation Mode and other parameters in the User Options window, press Apply.

Specifying Temporary Setup Overrides

If using Setup mode, temporary setup override options are displayed in the Operation Mode section of the User Options window.

• Disable Trend/Skip: Check this to temporarily ignore dimension skip and trend settings during setup.
• Comp All Dimensions: Check this to temporarily ignore system flags to NOT compensate rejected dimensions or dimensions that exceed the wear limit during setup.
• Setup Cycles: Select the number of cycles to run in setup mode before automatically switching to production mode. The default (0) means that the user must manually switch to production mode when needed.

When finished setting temporary setup overrides, and other parameters in the User Options window, press Apply.

Force Front on Cycle Complete

AutoComp can be configured so that the Main Window is forced to the front of the desktop when a cycle completes. To do this, check Force Front on the right hand side of User Options window.

Force Front Check Box on User Options WIndow

When finished setting Force Front, and other parameters in the User Options window, press Apply.

Access AutoComp from CEI Remote View

AutoComp can be configured to be monitored with CEI Remote View (contact CEI for information).

To do this, check Run Remote Client in the lower left of the User Options window.

Run Remote Client Check Box on User Options Window

Note: The Machine Name field is editable and is displayed in the title bar in Remote View. The machine name is contained as part of the run data log file name.

When finished setting Run Remote Client, Machine Name, and other parameters in the User Options window, press Apply.

MTConnect

MTConnect data communication is supported by AutoComp. The IP address and port number to use in MTConnect is displayed in the User Options Window.

MT Connect IP Address and Port

System Configuration Window

The System Configuration button in the User Options window opens the System Configuration window.

System Configuration Window

When configuring the AutoComp system, this window allows viewing or changing the routine storage path, specifying run data file locations, setting system global parameters and cycle notifications.

Gage and CNC Definitions

Gage Converters and CNC System Buttons

These buttons open sub-windows where gage and CNC definitions are set.

System Global Parameters

System global parameters are set in the System Configuration window.

System Global Parameter Section of Sys. Config Window

The parameters that are selected (“checked”) by default are:

• Wear Offset Compensation
• Dimension Limits as Deviation.

INFO Button

The INFO button is at the bottom right of the System Configuration window's System Global Parameters section.

INFO button on System Global Parameters in System Configuration Window

Hover over a check-box with a mouse to display a brief description of that check-box item. This hover functionality is not available with a touch screen.

The INFO button allows use of a touch screen or a mouse to dis- play information on each item in the Configuration Information window.

Configuration Information Window (CompOnReject Tab)

Comp On Reject Parameter

This determines how the system handles out-of- tolerance dimensions. If this value is checked, the system will perform the compensation algorithm for the entire cycle, even if a dimension is out of tolerance.

If unchecked, and a single dimension is outside its reject limits, no compensation will be done for any dimension in the cycle (for a single gage routine) or subcycle (for a multi-gage routine).

Comp Rejected Dimensions

The Comp Rejected Dimensions feature determines whether or not rejected dimensions are compensated (only used if CompOnReject is true).

If this value is checked (and CompOnReject is also checked), then dimensions outside their reject limits are compensated.  

Comp After Wear

Comp After Wear determines whether AutoComp will continue to compensate a tool after its wear limit as defined in the routine has been reached.

Note: The wear limit is set by dimension in the routine.

If checked, compensation will continue on dimensions that have exceeded their wear limit.

Clear Offset On Tool Change

Clear Offset on Tool Change determines if the CNC offset is cleared (set to 0) when an operator clears an AutoComp dimension tool life (either from the Tool Change button of the Run Time Details View, or the Tool Life Indicator on the History Chart).

If checked (default), the CNC offset will be cleared when the AutoComp tool life is reset (for Focas, DNC2, and Okuma P controls).

Expire Tool On Wear Limit

Expire Tool on Wear Limit determines if the CNC tool life management Tool Expired (or NG) flag is set when a dimension has exceeded its wear limit.

Only valid if the CNC is using tool life management, and for dimensions with ToolGroup/GroupOffset values set. (Currently used with Okuma P and Focas controls only.)

Wear Offset Compensation

Wear Offset Compensation determines whether AutoComp writes compensation data to the tool geometry offset of the CNC, or to the tool wear offset (if available).

If checked (default), tool wear offsets are written.

Dimension Limits Deviations

This determines whether tolerance and compensation values are entered as deviations from the dimension nominal when editing a dimension/routine.

If checked (default), they are entered as deviations. Otherwise, they must be entered as actual values.

Offset Display as Deviation

This controls whether actual gage values are displayed as deviations from the nominal in the Data Grid.

If checked, they are displayed as deviations. Otherwise, the actual gaged values are displayed as received from the gage.

Example:

In the following example, the data file has two dimensions. The nominal for the first dimension is 1 and the second dimension’s nominal is 2. When the Offset Display as Deviation check-box is unchecked, the gage values in the data grid appear as the actual values received from the gage. This can be seen in the following screen capture.

Gage values as Actual(Outlined)

When the Offset Display as Deviation check-box is checked, the gage values will appear in the data grid as deviations instead. This can be seen in the screen capture below.

Gage Values as Deviations(Outlined)

Note: When a dimension's nominal is 0, the absolute values and deviation values will be the same.

CNC Decimal Precision

CNC Decimal Precision determines the number of decimal places to the right of the decimal point that the CNC compensation value is rounded to.

The default value is five. To change it, click in the field and enter the desired value.

Note: Gage converter precision is based on this number, plus one. For example if CNC decimal precision is 5, gage converter decimal precision is 6 decimal places to the right of the decimal point.

Skip Count Functionality

Skip Count sets the number of compensation cycles to skip processing in an automated environment where a delay is required between production of a part and its gaging.

A value of 0 is the default skip count. The default skip count for new routines can be set in the System Configuration window.

The skip count is initiated on a dimension only after a compensation is produced.

If a routine is suspended, the current skip value for each dimension is saved and used to initialize the skip on the next routine load.

If a routine is unloaded, the skip is initialized for each dimension on the next load as defined in the Dimension Parameters tab of the Routine Editor.

Skip/Trend Functionality:

Skip and trend interact as follows:

• There is no skip on a dimension until a compensation is produced.
• From that compensated cycle, for skip cycles, everything pertaining to that dimension is ignored, meaning that there are no updates to wear, trend buffer, etc.
• At the end of skip cycles, functionality returns to 'normal' as if there was no skip.
• Trending continues until the next cycle that produces a compensation for the dimension, at which time the skip functionality is initiated again for that dimension.

Viewable Data Cycles

This allows the number of data cycles that are viewable in the Data Grid to be set.

A Viewable Data Cycles value of 10 is the default for each newly created routine.

In the History Chart and Data Grid, ten cycles can be viewed at a time in the History Chart. If the number of viewable data cycles is set to more than ten, a scroll bar allows scrolling through the cycles. The last cycle (represented by the right-most square “point”) in the graph corresponds to the last column in the data grid below the graph.

Note: The more cycles are viewable in the grid, the LONGER it will take to load a routine, as the grid must be filled with the historical data. This could affect processing time and should be tested by the operator to find an acceptable balance.

Trend Reset Time and Trend Reset Over

If AutoComp has not received data in the time set in the Trend Reset Time field, the trend is reset for every routine newly-loaded (first load only) for the trend reset period.

When entering the Trend Reset Time in the field, use the format minutes.seconds. For example, a Trend Reset Time of two minutes and 3 seconds would be entered as "2.3".

Trend Reset Over: This condition lasts for the trend reset period, after which (assuming gage data are being processed) routines that have not yet been loaded since trend reset began will no longer have trend buffers reset on the first cycle.

Trend Reset Over is initialized to 1 if the Trend Reset Time is set above zero. This value can be changed in the same format as Trend Reset Time.

Log Level

This is for support purposes only, and should remain the default value of 0.

Application Language Settings

The application language settings allow the user to set the decimal designator and language list separator. This overrides the PC language settings.

For example if the PC is set to a language that uses a "," as the decimal designator, setting the decimal designator to a "." in this field overrides the PC language settings to utilize a "." instead of the "," as the decimal designator.

To change the decimal designator or list separator, click in the field and select the new designator or separator in the window.

Decimal Designator Selection Window

Load Routine Variable and Path

Load Routine Variable is only available with controls where AutoComp has access to read/write variables, for example Mazak, Focas, and Okuma P200/300 (Mill and Lathe) controls.

The Load Routine Path directs AutoComp to the path or turret on which the Load Routine Variable resides.

These system global parameters work in conjunction with the Routine Editor's AutoLoad Routine Value.

AutoComp Cycle Notifications

The AutoComp system allows the user to pass macro variables to a control when completing a cycle, compensating a dimension, and exceeding the wear limit on a tool.

Note: These are global defaults for all newly created routines. Cycle notifications can also be set for each individual routine in the Routine Editor.

AutoComp Cycle Notifications Section of Sys. Config. Window

Cycle Complete Variable

There are three Cycle Complete fields:

• Cycle Complete Macro: The CNC macro or common variable set on each cycle completion
• Cycle Complete Value: If all dimensions have been measured when the last routine dimension is processed (signaling a complete cycle), then the Cycle Complete Value is written to the Cycle Complete Variable.
• Cycle Missing Dimensions Value: If any dimension measurements are "Missing" on cycle completion, the Cycle Missing Dimensions Value is written to the Cycle Complete Variable. If an error causes a measurement field to contain non-numeric data, it will appear as "Missing".

Wear Limit Notification Variable

There are three Wear Limit Notification fields.

• Wear Limit Macro: The CNC macro or common variable set on each cycle completion. A macro value of 0 (zero), means no macro variable is to be set for wear limit status. Any individual dimension with a tool wear limit of 0 will not be considered as ever exceeding its wear life. Default values for this parameter are defined in the system configuration process.
• Wear Exceeded: If any dimension has exceeded 100% of its tool life, the Wear Exceeded value is written to the Wear Limit Macro variable.
• Wear GOOD: If all dimensions are within tool life limits, the Wear GOOD value is written to the Wear Limit Macro variable.

Compensation Ack

There are three Comp Ack fields.

• Comp Ack Macro: CNC macro or common variable set on each cycle completion. A macro value of 0 (zero) means no macro variable is to be set for Good/Reject status. Default values for this parameter are defined in the system configuration process.
• Cycle Has Reject: If any dimension in the cycle was outside of the upper or lower reject limits, the Cycle Has Reject value is written to the Comp Ack Macro.
• Cycle GOOD: If all dimensions are within reject tolerances, the Cycle GOOD value written to the Comp Ack Macro variable.

Routine Path

The Routine Path button allows viewing or changing the routine .ini file location. Under most circumstances, this location should remain the default.

Routine Path Button on Sys Config Window

When finished setting this and other variables, press OK.

Run Data Variables

The buttons and fields in this section of the System Configuration window specify:

• RunData Main Path
• RunData Reset Times
• Purge RunData Times.

RunData Variables in System Configuration Window

Before looking at how to set these run data variables, it is important to have an "Run Data Files and Data Tag Overview" of how they are interrelated with each other and with the Data Tag variables.

Run Data Files and Data Tag Overview

Main Path: Run data files are stored at a location designated using the RunData Main Path button, and displayed next to that button.

ProcessDataTag is included as a column in the run data files. It is a user-defined field that is associated with the process, and can be used, if desired, to name sub-folders in which to store run data.

SubFolders: Instead of using the main path, the run data files can be stored in sub-folders created under the main path (by part or lot number for example) that change dynamically.

The ProcessData Tag as SubFolder button is used to specify that a sub-folder is to be used for storing process data (by dynamically changing the process data tag). The process data tag is changed by a text file containing the new process data tag:

AutoCompRunDataSubfolder.txt

This file is contained in a "watch" folder. The file has a single line of text (which is the name of the process data sub-folder to be created off the main run data folder).

There are two ways these text files can be created:

• Create the text file manually. A <CR><LF> is required to end the tag.
• Use the CEI_COMTOFILE application for RS232-based file drops (ie BarCodeReader), also requiring a <CR><LF> to end the tag, or use the manual option of the CEI_ COMTOFILE application.

ProcessData Tag Watch: Use the ProcessData Tag Watch button to set the folder that AutoComp is to watch for process data tag change files. The path is displayed next to the button.

Run Data file names: The format of run data file names is as follows:

<routine name>(<machine name>)_<creation time stamp>.csv

Run data files can be imported into Excel.

Note: Run Data Detail

As always, a new run data file signals a process context change and resets the Cpk to N/A for the next four cycles. The other historical data for loaded or suspended routines will remain intact.

If the run data folder is a network share that becomes unavailable, AutoComp (and DataCollect) will automatically and temporarily use the run data subfolder in the installation folder to store run data information. Subfolders will be created as needed (if the ProcessData Tag As SubFolder option is used). Under this condition, each time a new run data file is opened (from an unloaded or suspended routine being reloaded, a run data lifetime expiration, or a run data sub- folder change) an attempt will be made to reconnect to the network share. If successful, run data files will be stored there. Run data files created locally while the network share was down will remain local until manually moved.

Note: There is the possibility of losing one cycle of data when the network share becomes unavailable.

While the network share is unavailable, a new run data file will be created every time a routine is loaded. On every routine load, the network share will attempt to be accessed as the target of the run data, and a failure results in a new "local" file being started.

Run Data Main Path

Run data files (AutoComp historical data based on routine and machine names) can be stored anywhere on the network. (See "Run Data Files and Data Tag Overview", for more information.)

The RunData Path Main Path button specifies where run data files will be stored.

RunData Main Path Button on Sys Config Window

When finished setting this and other variables in the User Options window, press OK.

Run Data Reset Days, Hours, and Minutes

The Run Data Reset fields allow setting the lifetime of run data files by days:hours:minutes. There is a 0->60 second resolution on this lifetime, as files are checked every minute for expirations.

If all fields are 0 (zero) the run data file continues to append data until the routine is unloaded.

If the Run Data Reset fields are used, a run data file for a routine will be closed and a new run data file started when the specified reset time expires (based on the file creation time). This will continue until the routine is unloaded.

Run Data Reset Times Fields in the Sys. Config. Window

Note: If the ProcessDataTagAsSubFolder option is used and the target run data folder changes, a new run data file is started.

When finished setting variables in the System Configuration window, press OK.

Data Tag Variables

Current Data Tag:

The current label logged with each cycle as the data tag in the run data file. If using sub-folders, this is the name of the sub-folder that run data files are created in.

Process Data Tag Watch:

The Process Data Tag Watch button allows the user to specify the folder to “watch” for process data tag change files.

ProcessData Tag Watch Button

After choosing or creating a folder, Press OK. The folder and path are displayed in the System Configuration window:

ProcessData Tag Watch Button with Folder and Path

Process Data Tag as SubFolder:

Run data files can be stored in a sub-folder off the RunData Main Path.

The sub-folder is named by the current process data tag, and changes when a new process data tag change file appears.

To store run data files in a sub-folder, check the ProcessData Tag as Sub-folder check-box.

ProcessData Tag as SubFolder Checkbox

When finished setting variables in the System Configuration window, press OK.

Purge Run Data Files

The Purge RunData options are located in the RunData section of the System Configuration window.

Purge RunData Times

The Purge Run Data function deletes all run data files in the current run data folder except:

• l the file associate with the currently loaded routine (if any)
• l the newest file for each routine in "suspended" mode.

The check boxes specify when all run data (other than above exceptions) will be purged:

• Purge Daily: Deletes all run data files older than 24 hours, based on the current PC time. System checks for the required purge on startup, and at 8 hour intervals.
• Purge Weekly: Deletes all run data files older than one week, based on the current PC time. System checks for the required purge on startup, and at 8 hour intervals.
• Purge Monthly: Deletes all run data files older than 30 days, based on the current PC time. System checks for the required purge on startup, and at 8 hour intervals.
• Purge NOW: Deletes all run data files immediately.