PDF32 32 bit high speed controller. The latest technology from Farley.

A machine owner should asked themselves why purchase a new machine when you can upgrade your controller for 10% of the cost of a new machine.  A Farley machine is that well designed and built, it could last up to 20 years.  Worldwide, machines that were installed in the early 80's are still in production today, therefore a retrofit/upgrade would be justifiable 

Pictures from a recent Farley retrofit, Customer has had his Farley machine for 10 years, he knows his machine is built to last, but the controller needs to be updated with the latest Farley technology in order for his company to get the best out of his machine.  Please read on were we go into further detail about this controller.

Index

Farley has developed a controller that is more powerful, extremely user friendly and fully compatible with existing machines. Their intention was to find a system that can be easily installed, inexpensive and can be upgraded and infinite. The other aim was to bring the machine up to the latest technology using current CNC software developments and offering as many productivity enhancing options as possible.

For these reasons Farley Laserlab developed the PDF32 32 bit high speed controller.

Named after an outstanding electronic engineer, Pino Di Frederico, the Farley PDF was the first and remains the best,   32 bit CNC system designed specially for flat plate processing operation.

The power of the system, with 2-5 millisecond servo update times (200-500 times per second), combined with its extensive diagnostics, user settable parameters and ease of use, will make a significant and noticeable difference in both the speed of processing and in the quality of cutting.

Farley decided to build the PDF32, not because other CNC systems on the market were inferior, but because no single system completely had the right elements in one package. More importantly, Farley wanted to have control over the very heart of the system, so that they could quickly adapt to new developments in the cutting and drilling field.

         1.0       Enhanced operator control and flexibility

The sophistication of the Farley CNC design is such that, while it contains a whole host of features, diagnostics, parameters etc, the operator interface is clear and easy to understand.

There is no need for long and involved training programmes or high degrees of computer skills to make full use of the PDF32.

Processes permitted, the system can be run in completely automatic mode, where all the speeds, feeds, volts, currents, gas flows etc. are all set by the program, or the Operator can take control of certain aspects directly, such as cut speed, jog speed, height control if they feel that the programmed parameters are inappropriate for the particular job at hand.

Machine operation is assisted by the clear, full colour graphics display via a large (14”) VGA monitor. The PDF32 features “real time” graphics for the operator to preview nests and to follow the cutting path of the machine.

          1.0.1 Future-proof upgradeability- easily serviceable

The modular architecture of the PDF32 is specifically designed to allow easy upgrades and customisation.

Being built around fully commercial third party components (such as the processor, graphic card etc) also make it robust and readily serviceable.

The serviceability of the PDF32 is further enhanced by the on board diagnostics and error logging features.

     1.0.2 Communication & Compatibility

The PDF32 has extensive communications capabilities both into and out from the CNC.

ü  Full error checking DNC.

ü  Standard RS 232

ü  Ethernet DNC communication is available in a manner that the machine can be connected to your network and even accessed remotely (after security check) for service, upgrade, and Data monitoring.

ü  The machine reads standard ISO word address code.

          2.0       THE FARLEY PDF32 ADVANTAGE

More often than not, higher productivity and faster return on investment is achieved using a high performance Farley PDF32 controller.

A few of the major benefits the Farley PDF32 Controller will provide for your company are listed below.

ü  More uptime with quick setup of tools and jobs

ü  Easy setup with multiple table home positions.

ü  Less time wasted on loading programmes with the high capacity part program storage and large battery backed RAM of the Farley CNC. Permits in-CNC storage of numerous large and small cutting programmes. This speeds up production as the programmes do not need to be constantly downloaded from the design PC to the CNC and the PC does not need to “feed” the program to the CNC.

ü  User alterable EEPROM storage for 45 “standard shape” storage. These programmes can have variable dimensions and be designed and nested at the controller.

ü  Easy setup with on-screen machine position display with reference to home, start of component, end point or current move

ü  Simple sequence search and retrace system to pickup lost cuts (some competitive systems have no retrace, others take at least eight (8) steps).

ü  Easy fault finding with in-built diagnostics for monitoring functions of all switches, solenoids etc. This is in addition to the standard alarm functions, which detect malfunctions of the machine and programming errors.

ü  Simplified operation with integration of plasma parameters into the machine controller.

ü  Reduced cycle time with the unique Farley partial tool retract feature.

         3.0       FARLEY PDF32 CNC CONTROL DESCRIPTION

The Farley PDF32 Multi-bus control has been designed specifically for the unique needs of a high performance profiling machine. It provides a control that is exceedingly powerful and yet very simple to use. Features include a high level programming language whilst still maintaining simple G code commands. DNC and RS232 interfaces are also provided.

The PDF32 control supports direct programming at the machine, (such as for simple one-off components or small batches), common shapes using the packaged standard shapes library, and direct downloading of jobs pre-programmed at the remote design station(s).

An important service and support feature of the Farley PDF32 control is the standard Motorola and commercial hardware used in its design and construction. This means many of the controller components are locally available from original manufacturers and/or third party vendors.

          3.0.1 PDF32 Specifications

a.         Media for inputting cutting program

i.          DNC (RS232 or Ethernet)

ii.          MDI 3.5” floppy disk  (optional)

b.         Input code on floppy disk-        ASCII RS232

c.         Minimum input data step-          0.01 mm

d.         Maximum input data step-         +/- 999,999.99 mm

e.         Minimum output unit-                0.01 mm / pulse

f.          Language-                               English

g.         Units-                                       Metric or Imperial

h.         Programming-                        International standard G code format

          3.0.2 Panel 

      The ergonomically designed front panel on the Farley PDF32 control groups the most frequently used controls near to the operators hand. Less frequently used controls are placed progressively further away.

All control switches fall readily to hand and feature both tactile and audio feedback. Switch mechanisms are located behind the tough ‘wipe clean’ Mylar touch panel. All critical functions are illuminated to show current status.

The control functions provided are only those truly required for advanced profiling operations. The Farley control is not an add-on, generic CNC controller; it is an integral part of the purpose designed Farley profiling system.

          3.0.4  Display

The large 14” VGA colour graphics monitor is easy to read, permits full text display of programmes as well as full cut path graphics. The current job, or a different past or future job may be displayed at any time. Features include Zoom, Pan, position display with reference to home, start of component or current move.

          3.0.5  Keyboard

Familiar computer style keyboard layout, with QWERTY key positioning makes manual data entry simple and fast.

          3.0.6  Switches and controls

All major operation command buttons are logically grouped according to function. Panel controls include plate piercing time overrides, individual tool on/off, raise/lower, and cutting speed override - from 0 to 150% of programmed speed.

Two-button retrace system to automatically pick up lost cuts. (Some competitive systems have no retrace facility; others require at least 8 manual entries).

          3.0.7  Diagnostics

In addition to standard alarm functions which detect minor programming errors, incorrect machine settings and machine malfunctions, a complete set of on-screen system diagnostics are built-in to the controller.

The Farley diagnostics routines allow manual operation of all switches and solenoids. Control settings can be directly monitored via the display screen. All of these control functions are wired through the PDF32 CNC control ensuring fast and easy fault finding.

          3.0.8 DNC

DNC provides fast, reliable, error free transmission of data directly from the CAD/CAM station to machine control. No physical transfer of media (such as punch tape or floppy disks) is necessary. Two way (background) DNC permits the operator to obtain programmes from the programming station without interrupting the programmer. The machine operator can even upload revised or corrected/amended programmes to the programming station.

The “background” operation of Farley DNC communications means that the operator can create, download or modify a machine program, even while the machine is processing another job. (Note: Background operation requires a multi-user computer operating system such as UNIX, OS-2).

          3.0.9 RS232

In-built RS232 port permits the direct input and output to a portable computer for communication and service. (The optional 3.5” floppy drive also uses this connection).

          3.0.10 Memory

Large (optional up to 4 Mb or more) capacity RAM permits program storage at the machine. Memory capacity is usually sufficient for more than one complete days production requirements.

          3.0.11Programming

Programming may be done either from a remote programming station via DNC link, or directly from the machine keyboard. Either input method can be used whilst the machine is cutting a job.

Alphanumeric programme names allows programmes to be saved under actual job, customer or part name.

Programming co-ordinates may be entered as absolute, incremental or mixed dimensions. Subroutines and calculations can be included in manual data input programming at the machine.

The international standard G code format is used.