Computer-Controlled Hot Wire Equipment:
The New Industry Standard in EPS Hot Wire Technology!
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The ACS 1010 Commercial Foam Cutter
System Features:
MECHANICAL
The
ACS 1010 will have features that will allow the user ease of operation with
minimal intervention and maintenance. Each
of the three axes will have a single motor for position control.
Unlike the competition who utilize up to eight motors for positioning,
the three motor approach allows this machine to be more efficient and there is
less chance for equipment malfunction. This approach eliminates the need
for motor synchronization and or re-synchronization as well as reducing the
number of moving parts subject to failure. The ACS 1010 uses a polymer linear
bearing approach, which virtually eliminates any maintenance.
These bearings utilize a new technology
that has been developed for linear bearing applications.
Below is a bullet list of features found in this new bearing technology.
Ø
Low Noise
o
the bearings are flat polymer inserts. This
feature allows the bearings to contact the rails over a large surface area
rather than traditional ball bearings that have single contact points.
This large surface area contact eliminates metallic noise from bearing to
rail contact when in motion.
Ø
Long-term, Maintenance-free
Operation
o Polymer bearings of this type employ a much larger bearing surface area, which reduces the risk of galling when overloaded or when misalignment occurs. In addition, these bearings are self-lubricating and there is absolutely no need to lubricate for the life of the bearing, which provides for long-term maintenance-free operation. Each bearing block has an installed wiper that cleans the rail of any debris as the bearing glide across it which also aids in maintenance free operation.
The ACS 1010 will have a usable working surface with dimensions of (LxWxH) 106” X 106” x 59”’. This area should well be suited for a standard 8’ x 3’ x 4’ block of foam or accommodate up to three blocks of foam at one time. The machine footprint is (LxWxH) 10’ X 10’ X 8’ and can be shipped in a standard tractor-trailer setup.
ELECTRICAL
The
control electronics that will control the ACS 1010 have been
chosen in a manner that will allow the system to be controlled locally or
from a remote location up to 50’ away via a serial link.
The electronic controller is of the Personal Computer type controller and
the user will be able to interface with the command and control software via
mouse movements.
Each
axis will have a single dedicated motor drive unit. These motor drive units are SMART DC brushless servomotors.
The Motor is a complete, compact and
user-friendly integrated control system that features a brushless DC servo
motor, motion controller, encoder and amplifier all built into one small package.
Unlike the cogging of stepper motors, the non-cogging DC brushless servomotor
approach lends itself to longer life and smooth maintenance free operation.
The
ACS 1010 includes a detailed series of safety mechanisms and safety features to
insure complete trouble free operation. There
are two E-stop buttons, one button located on top of the power controller box
and one e-stop located inside the control room on the operator interface.
These E-Stops, when activated, totally disable the machine from operation
by interrupting the current flow to the hot wires and motors.
All
of the motors and the hot wire voltage systems are fed thru a system fault sense
circuit that will interrupt operation instantaneously when there is leakage
current or an overload on any circuit. The
ACS 1010 also includes a test circuit for periodic testing of the fault sense
device. The fault sense circuit
will have the same effect as the E-stop buttons.
If the fault sense is activated, the machine will have to be restarted
and all of the axes will have to be re-homed.
The
cutting wire is made of High life Inconel X750 wire (up to 2 year life on a
single wire). This type wire is
designed for long life and high heat strength.
This type of wire also allows for less stress from heat fluctuations and
stretch over the life of the wire.
ACS
1010 System:
Ø
Pentium class networkable controller
o ACS Electronics for Interface and Monitoring
o Input/ Output Modules for Controller command and control
o 19” LCD Flat Panel Interface
ACS Custom Control Software
Listening
and Communication layer.
Hardware
Communication Layer
DXF
to G code Data Conversion Layer
Active
OCX Drivers
User
interface screen(s).
Associated
indicators, (Located on user interfaces to indicate operation and error
conditions)
Data
saving feature that allow the user to save unlimited files and or projects (dependent
upon size of hard drive unit)
Custom
software is a no cost feature and end users will have free unlimited access
to all current versions of software as they are made available
Automated
current adjustment for up to 10 wires
Upon Start-up, the ACS
control software automatically detects motors and does a system update if
any motor was changed out.
This allows the software shortcut to be placed in
the Start-up directory of Windows to allow automatic restart on loss of
power making it simpler for operators.
A full Machine settings
window allows for customization to physical dimensions of the machining
space.
Machine tolerance levels can
be set to ensure no product damage occurs in the unlikely event of motor
drop-out or path divergence.
Slow-down
proportional-to-angle is a feature that can be tailored to minimize
machining time while providing the best surface finish through sharp turns.
Customizable G-Codes for
user-defined wire positions.
Customizable M-Codes for I/O
control and commands or subroutine calls
Ability to call G-Code
subroutines.
Ability to repeat a section
of G-code.
SAE or metric scaling.
On-screen and keyboard
real-time jogging.
Auto-Detection of Windows
compatible Joystick for Jog control.
Menu selectable Inputs
set-up window.
Wait-On-Input definable
M-Codes.
Customizable outputs
assignable to user-definable M-Codes.
Can automatically send user
defined Motor commands upon start up of cut routine.
Terminal screen diagnostics
page for testing/troubleshooting.
User selectable homing
routines with configurable offsets.
Advanced settings screen
includes events set-up for E-Stop conditions.
Software
simulation mode that allows for dry run cuts before material is even touched
by a wire.
Automatic
wire power up/down before and after cutting routines.
Indicators
and Interfaces
Ø
Automated on screen indication to show
wire progress and current location of wire in foam.
Ø
On line context sensitive help to
let the user have access to the online operational manual
Ø
One main interface screen that all
of the cutting functions can be carried out.
Ø
One interface screen where the user
can bring in a DXF file and automatically convert the file to G code
Mechanical components
Ø
Nema class Electronic housing to
enclose electrical input output devices
Ø
All associated fasteners and wiring for
interface
Ø
Machined and fabricated components to
interface mount and interconnect controller to motion system.
Machine Dimensions:
Length: 120”
Width:
120”
Height:
96”
Construction:
Gusset
Reinforced Powder Coated Aluminum Framing Extrusion
Sealed
MDF Working Surface
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