2 - Software applications

S4X

System: S4XE.30

Serial No.: S4_1553

Version: V20160202EN

Original instructions
(c) Salvagnini 2016

Document version: V20160202EN

Machine number: S4_1553, last saving on: 2/2/2016

Italy: SALVAGNINI ITALIA SPA, Via Ing. Guido Salvagnini 1, I-36040 Sarego, Vicenza
T. +39 0444 72 5111, F. +39 0444 43 6404, E. [email protected]

www.salvagnini.com
 Table of contents
1 Salvagnini Console............................................................................................................... 9
1.1 Preface.......................................................................................................................... 9
1.1.1 What Salvagnini Console is............................................................................... 9
1.1.2 Typographical conventions................................................................................ 9
1.2 Work session............................................................................................................... 10
1.2.1 Preliminary actions.......................................................................................... 10
1.2.2 Connecting to the work session....................................................................... 10
1.2.3 Exiting from the work session.......................................................................... 12
1.2.4 Turning the system off..................................................................................... 12
1.3 Graphical interface...................................................................................................... 13
1.3.1 Menu bar......................................................................................................... 13
1.3.2 Quick selection button bar............................................................................... 14
1.3.3 Value viewer.................................................................................................... 15
1.3.4 Toolbar............................................................................................................ 15
1.3.5 Line production................................................................................................ 16
1.3.6 Status bar........................................................................................................ 16
1.3.7 Production control............................................................................................ 18
1.3.8 Program management..................................................................................... 18
1.3.9 Sheet source................................................................................................... 18
1.3.10 Production information..................................................................................... 18
1.4 Descriptions of the menus........................................................................................... 19
1.4.1 Control [Control].............................................................................................. 19
1.4.2 View [View]...................................................................................................... 20
1.4.3 Applications [Applications]............................................................................... 20
1.4.4 Tools [Tools].................................................................................................... 23
1.4.5 Help [Help]....................................................................................................... 29
1.4.6 Production [Production]................................................................................... 31
1.5 Functions for production.............................................................................................. 38
1.5.1 Messages [Messages]..................................................................................... 39
1.5.2 Events list [Events list]..................................................................................... 40
1.5.3 File transfer [File transfer]................................................................................ 41
1.5.4 Production Manager [PrdMgrPX]..................................................................... 43
1.6 Managing production................................................................................................... 43
1.6.1 Introduction...................................................................................................... 43
1.6.2 Managing programs......................................................................................... 44
1.6.3 Managing production lists................................................................................ 46
1.6.4 Starting production.......................................................................................... 51
1.6.5 Line production................................................................................................ 56
1.7 PackModus mode........................................................................................................ 58

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 1.8 Editing a program........................................................................................................ 59
1.9 Compiling a program................................................................................................... 60
1.9.1 The program is correct.................................................................................... 61
1.9.2 Errors in the program....................................................................................... 62
1.10 Special situations......................................................................................................... 62
1.10.1 Recovering a time-out error............................................................................. 62
1.10.2 Communication breakdown............................................................................. 64
2 Office Console..................................................................................................................... 67
2.1 Preface........................................................................................................................ 67
2.2 Functional areas.......................................................................................................... 67
2.2.1 Menu bar......................................................................................................... 68
2.2.2 Fast selection buttons...................................................................................... 69
2.2.3 Customization area.......................................................................................... 71
2.2.4 System selection area..................................................................................... 71
2.2.5 User interface area.......................................................................................... 72
2.2.6 Status bar........................................................................................................ 72
3 Programming the punching machine............................................................................... 73
3.1 Preface........................................................................................................................ 73
3.1.1 Description of the S4 machine......................................................................... 73
3.1.2 Description of the options for the S4 machine................................................. 76
3.1.3 Description of the SDEX software package..................................................... 78
3.1.4 Sheet orientation and punch positions............................................................ 80
3.1.5 Head set-up tables.......................................................................................... 81
3.2 Declaration instructions............................................................................................... 82
3.2.1 COD instruction - Program identification......................................................... 83
3.2.2 END instruction - End of program.................................................................... 83
3.2.3 DIM instruction - Blank size declaration.......................................................... 84
3.2.4 BFF, AFG, SFG and EFF instructions - Pre-punched blank declaration......... 85
3.2.5 PUN instruction - Punch declaration................................................................ 87
3.2.6 PSB instruction - Declaration of alternative punches.................................... 106
3.3 Punching instructions................................................................................................ 107
3.3.1 XYP instruction - Single or multiple punching................................................ 108
3.3.2 RHO instruction - Square punching at a 45° angle........................................ 112
3.3.3 RAD instruction - External radiussing with a radiussing punch..................... 115
3.3.4 STR instruction - Punching at regular intervals along a straight line............. 115
3.3.5 GRI instruction - Punching at regular intervals on an orthogonal grid........... 116
3.3.6 POL instruction - Punching at regular intervals along an arc........................ 118
3.4 Nibbling instructions.................................................................................................. 121

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 3.4.1 REC instruction - Rectangular punching with destruction of the internal scrap....
122
3.4.2 REK instruction - Rectangular punching with preservation of the internal scrap
....................................................................................................................... 128
3.4.3 CWP instruction - Cutting with a punch......................................................... 132
3.4.4 RIC instruction - Internal circular nibbling...................................................... 133
3.4.5 NIK instruction - Internal circular nibbling with a lenticular punch and preserva-
tion of the scrap............................................................................................. 137
3.4.6 RIS instruction - Internal circular nibbling with a concave-convex punch and
preservation of the scrap............................................................................... 142
3.4.7 RES instruction - External circular nibbling with a concave-convex punch... 144
3.4.8 IST instruction - Nibbling a triangular figure.................................................. 146
3.4.9 COR instruction - Triangular notching........................................................... 151
3.5 Embossing instructions.............................................................................................. 153
3.5.1 Single embossing instructions....................................................................... 153
3.5.2 KKO instruction - Knock-outs........................................................................ 155
3.5.3 BBG, ARC, SEG and BND instructions - Continuous embossing................. 157
3.5.4 WRI instruction - Writing a string of characters............................................. 161
3.6 Defining the parts to be produced............................................................................. 163
3.6.1 PIE instruction - Defining a grid of rectangular parts..................................... 164
3.6.2 PPR instruction - Defining a non-rectangular part......................................... 167
3.6.3 BRS instruction - Nibbling the holding scrap................................................. 169
3.7 Trimming the sheet.................................................................................................... 171
3.7.1 TRI instruction - Trimming one or more sides of the sheet............................ 171
3.8 Composite instructions.............................................................................................. 172
3.8.1 BLC, EBL and CBL instructions - Managing blocks of instructions............... 172
3.8.2 NET and ENT instructions - Repeating a block of instructions on an orthogonal
grid................................................................................................................. 174
3.8.3 SIM and ESM instructions - Repeating a block of instructions symmetrically......
176
3.8.4 Specifying the order in which two or more instructions are performed.......... 182
3.8.5 REF instruction - Defining a new reference system...................................... 185
3.9 Parametric programming........................................................................................... 187
3.9.1 S4 functions................................................................................................... 187
3.9.2 Principles of master programming................................................................. 187
3.9.3 LET instruction - Defining parameters........................................................... 187
3.9.4 PAR instruction.............................................................................................. 188
3.9.5 Joining together composite strings................................................................ 191
3.9.6 Functions for rounding off and truncating...................................................... 192
3.9.7 SIM and ESM instructions - Repeating a block of instructions symmetrically......
193

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 3.9.8 IF THEN ELSEIF ELSE ENDIF instructions - Conditional parametric program-
ming............................................................................................................... 194
3.9.9 INC instruction - Including a file..................................................................... 198
3.9.10 Error management: stopping Sdex compilation in the event of an error....... 199
3.9.11 Diagnostics: how to stop Sdex even if logic and syntax are correct.............. 200
3.9.12 Parametric MetalNest.................................................................................... 200
3.9.13 OPS, MetalNest, parametric.......................................................................... 202
3.10 Special instructions.................................................................................................... 203
3.10.1 INK instruction - Managing printers............................................................... 203
3.10.2 RFO instruction - Managing the RF option.................................................... 204
3.10.3 MTI instruction - Modifying the punch descent and ascent times.................. 205
3.10.4 MPP instruction - Modifying the position in which the pincers hold the blank......
206
3.10.5 DWP instruction - Destroying shearing scrap with a punch........................... 208
3.10.6 VFY instruction - Broken punches check....................................................... 208
3.11 Zed programming...................................................................................................... 209
3.11.1 ZGL instruction - Program composed solely of Zed instructions................... 211
3.11.2 ZBG and ZND instruction - Defining a Zed block.......................................... 211
3.11.3 ZTG instruction - Elementary shearing.......................................................... 212
3.11.4 ZEX instruction - Information about a detached part..................................... 213
3.11.5 ZMV instruction - Moving the manipulator..................................................... 215
3.11.6 ZRT instruction - Rotating the sheet.............................................................. 217
3.11.7 ZRP instruction - Repositioning..................................................................... 218
3.11.8 Examples of Zed programming..................................................................... 219
3.12 Specifiers and options............................................................................................... 222
3.12.1 J index - PAC specifier.................................................................................. 222
3.12.2 Punching instruction specifiers...................................................................... 224
3.12.3 Part definition instruction specifiers............................................................... 229
3.12.4 VAR instruction - Compilation options........................................................... 233
4 Monitor............................................................................................................................... 255
5 Maintenance Manager...................................................................................................... 293
6 EasyData............................................................................................................................ 329
7 VisualStacker.................................................................................................................... 349
8 SimulX................................................................................................................................ 389
8.1 Preface...................................................................................................................... 389
8.1.1 What is SimulX?............................................................................................ 389
8.1.2 Who uses SimulX?........................................................................................ 389
8.2 User interface............................................................................................................ 390
8.2.1 General description....................................................................................... 390

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 8.2.2 Tool bar......................................................................................................... 392
8.2.3 View area....................................................................................................... 394
8.2.4 Head configuration........................................................................................ 399
8.2.5 Settings.......................................................................................................... 400
8.2.6 Printing a report............................................................................................. 400
9 Store Manager Shell......................................................................................................... 403
9.1 Preface...................................................................................................................... 403
9.1.1 Terminology................................................................................................... 403
9.1.2 What is Store Manager Shell?....................................................................... 403
9.1.3 Who uses Store Manager Shell?................................................................... 403
9.1.4 How to use the application?.......................................................................... 403
9.1.5 Typographical conventions............................................................................ 404
9.2 User interface............................................................................................................ 405
9.2.1 General description....................................................................................... 405
9.3 Menu bar................................................................................................................... 408
9.3.1 File menu....................................................................................................... 408
9.3.2 Packs menu................................................................................................... 409
9.3.3 View Menu..................................................................................................... 414
9.3.4 Options Menu................................................................................................ 415
9.3.5 Help Menu..................................................................................................... 417
9.4 Diagnostics................................................................................................................ 417
9.4.1 Messages...................................................................................................... 417
10 CTM Editor......................................................................................................................... 419

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 1. Salvagnini Console
1.1. Preface

1. Salvagnini Console

1.1. Preface

1.1.1. What Salvagnini Console is

It is a set of functions and applications that are integrated into the
control system and are used to graphically control and manage all the
information needed to run the system.
Salvagnini Console is used to:
• select several production programs and group them together;
• modify programs;
• select trouble-shooting functions for the whole system;
• command system cycles or movements useful for facilitating
production;
• dynamically plan different production batches;
• queue up and modify the sequence of programs without waiting for
the current program to end.

1.1.2. Typographical conventions

The images used in this manual show the English version of the
Salvagnini Console application.
In the descriptions, the exact English nomenclature is given in square
brackets after each reference to a parameter, command and/or button.
This is to help the reader identify the positions of the commands in the
images and thus in the application interface.

Example:

Figure 1: Salvagnini Console interface

The reference to the "Logged user" function is indicated as follows:

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1. Salvagnini Console
1.2. Work session

Current logged user [Current logged user]

1.2. Work session

1.2.1. Preliminary actions

Before turning the system on, please check that:
• no maintenance operations are in progress on the machine;
• the supply voltage to the cabinet is present;
• the user name and access password are available.

1.2.2. Connecting to the work session

The master switch on the power cabinet is in position 1 (power
enabled).

The user icons are present on the screen of the control unit.

1. Select the "syscon user" icon.

2. Enter the password.
3. If the data entered is correct, the start-up graphics will be followed
by the main interface window.
If not, press the "switch user” button to change user.

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 1. Salvagnini Console
1.2. Work session

Messages regarding the machine's readiness status may also appear

on the screen.
Follow the instructions given in the on-screen messages.

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1. Salvagnini Console
1.2. Work session

1.2.3. Exiting from the work session

1. Check that all the applications previously activated in Salvagnini
Console have been closed;
2. Check that the system is not running in production: if it is, click on

the button in the Salvagnini Console interface;

3. In the Control [Control] menu, select Exit [Exit].

4. Click on the Close application [Close Application] button.

1.2.4. Turning the system off

1. Make sure the machine is not running in production. If it is, press
the Stop [Stop] button.
2. For panel bending systems, activate the “Position machine for
turning off system” command.
3. Select the Exit [Exit] function in the Control [Control] menu.
4. In the Close window, click on the Shutdown [ShutDown] button
and wait for the control unit to shut down completely.
You can now use the master switch on the power cabinet to power
down the system.

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 1. Salvagnini Console
1.3. Graphical interface

1.3. Graphical interface

1 Menu bar 6 Status bar

2 Quick selection button bar 7 Production control
3 Value viewer 8 Program management
4 Toolbar 9 Sheet source
5 Line production 10 Production information

Figure 2: Salvagnini Console interface

1.3.1. Menu bar

All the functions of Salvagnini Console are grouped together in the
menu bar.
Some are a permanent feature, whilst others only appear depending on
what has been activated in the Toolbar.

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1. Salvagnini Console
1.3. Graphical interface

Some menu items may be enabled (in black) or disabled (in grey)
according to login privileges.

1.3.2. Quick selection button bar

The buttons in this area allow quick selection of the most common
functions. Some are always present, whilst others are added according
to what has been selected in the Toolbar.
1. Exit [Exit]: prompts you for confirmation and then stops the
system, closing the application or session.
2. Reset [Reset]: prompts you for confirmation and then stops the
system, resetting the software.
3. Stop production [Stop production]: prompts you for
confirmation and then suspends production. Progress status data is
stored so that the production list can be resumed and completed
later.
4. Show window for second monitor [Show the second
monitor window]: optional.
5. Print [Print]: sends the data to the printer; is only enabled when
there is data to print (otherwise is grey).
6. Info [About]: opens the “About Salvagnini Console” window.
7. Save [Save]: saves changes to the production lists.
8. Disable / enable line production [Disable / Enable line
production]: disables/enables combined operation with the
machine that follows or precedes it.
9. Disable / enable automatic data request [Disable / Enable
automatic job data request]: if the system is in line,
clicking on this button enables/disables the request for data from
the machine upstream.
10. Load / no-load mode [Select production with sheet /
Select empty production]: used to pass from load to no-load
work mode and vice versa.
11. Modify [Modify]: opens the text editor to modify the program
selected.
12. Compile [Compile]:starts to compile the program selected.

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 1. Salvagnini Console
1.3. Graphical interface

13. Simulation [Simulation]: launches the simulation application,

which shows the sheet machining positions and sequence. For
more detailed information, please refer to the appropriate manual.
14. Stacking [Stacking] (option): opens the application that
manages the stacking of parts on tables, pallet boxes or cages,
roller-surfaces and so on (depending on the configuration of the
system on which it is active). For more detailed information, please
refer to the appropriate manual.
15. Start production [Start production]: starts actual
production.
16. Stop production at end of sheet [Stop production after
sheet]: when the blank has been processed, the machine stops
and waits for a command from the operator.
17. Continue production [Continue production]: resumes the
production process.
18. Abandon production at end of sheet [Abort production]:
stops the production process should the operator decide to run
another one.
19. Operator absent [Absent operator]: indicates that the
machine is not attended by the operator. The control system may
take different decisions according to whether or not the operator is
present.
20. Settings [Settings]: opens the interface that handles general
production settings.
21. Info [About]: opens the “About Salvagnini Production Manager”
window.

1.3.3. Value viewer

This tracks a number of significant values over a period of time:
• main pressure of the hydraulic generator [bar];
• electrical power used by the system [kW];
• length of the last production cycle;
• temperature of the hydraulic oil [°C].
The values shown can be configured in different ways.

1.3.4. Toolbar
This contains the main functions (also available in the Applications
[Applications] and Tools [Tools] menus), split into three groups.

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1. Salvagnini Console
1.3. Graphical interface

1.3.5. Line production

If you click on the button, the machine will prepare to operate in

line with the machine placed up- or downstream of it. The button

changes to and the system's status indicator turns from grey to

green .

The P4-2725 system is not ready for production in line with the system upstream.

The P4-2725 system is ready for production in line with the system upstream.

For a more detailed description of line operation, please see Line

production [} 56].

1.3.6. Status bar

1. The F1 function button calls up this manual.

2. Shows the current feeding mode:
– LOAD [LOAD], with a sheet;
– NO-LOAD [VOID], without a sheet.
3. Shows the current operating mode:
– AUTOMATIC [AUTOMATIC]
– STEP-BY-STEP [STEP BY STEP]
– MANUAL [MANUAL]
– EMERGENCY [EMERGENCY]
if an emergency stop button has been pressed.

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 1. Salvagnini Console
1.3. Graphical interface

4. Shows the current status of the system and how long it has been in
this status:
– IDLE [IDLE]
– PRODUCTION [PRODUCTION]
– ERROR [ERROR]
5. Shows whether production is attended or not:
– OPERATOR [OPERATOR]
– NO OPERATOR [NO OPER.]
– SLAVE [SLAVE]
6. Indicates that a window with a message is waiting to be read and
acknowledged.
7. Semaphore that shows the status of communication between the
workstation and the control card:
– Green: the system is active, i.e. in the regular operating
condition.
– Amber: the system is temporarily off-line because internal
activities are in progress; on completion of these activities, the
system returns to normal operating status, with the green light
on.
– Red: there is a serious control system malfunction – more
specifically, a breakdown in communication between the
workstation and the control card. Depending on the type of
message displayed, consult the chapter on using the Connect
[Connect] function or contact the technical support
department.
8. Shows whether communication with the control card has been lost
(unplugged) or is correctly active (plugged in).

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1. Salvagnini Console
1.3. Graphical interface

1.3.7. Production control

Groups together information about production.

Layout View Shows the layout of the Salvagnini system and the progress
being made with the sheets in production.
List of jobs Shows a list of the jobs:
produced

in production

cancelled

File maintenance Shows a drawing of the panel, its dimensions and its
production data.
Production queues Lists the programs waiting to be produced.

1.3.8. Program management

The left-hand column lists the groups of programs.
The right-hand column lists the programs in the group selected.
Please refer to chapter Managing programs [} 44].

1.3.9. Sheet source

Shows how the sheet is fed (automatically or manually) and allows you
to choose whether to work with (load) or without (no-load) a sheet.

1.3.10. Production information

Area showing the status of the machine and its production phases.

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 1. Salvagnini Console
1.4. Descriptions of the menus

1.4. Descriptions of the menus

1.4.1. Control [Control]

Power user [Expert Logon]

Allows you to identify yourself to the system: as a result, certain
functions will be either enabled or disabled. The function is active when
there is a tick next to the command.

Slave mode [Slave Mode]

Allows you to activate or deactivate the automatic production manager,
if present. When the system is in manual mode, program loading and
production starting/stopping are decided by the operator; in automatic
mode, it is the automatic manager that decides these operations.

Connect [Connect]
Normally disabled, becomes active in the event of a communication
problem between the workstation and the RTCPU card. Used to restore
communication between the application and the control cabinet.

Reset [Reset]
Prompts you for confirmation and then immediately stops the system,
resetting the software of the cycles in progress (KILL). The automation
cycles return to the state they were in after the last reset (if there was
one). Axes and controls originating from output cards are also
deactivated.

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1. Salvagnini Console
1.4. Descriptions of the menus

Stop [Stop]
Prompts you for confirmation and then suspends production. Progress
status data is stored so that the production list can be resumed and
completed later.

Exit [Exit]
Prompts you for confirmation and then stops the system, closing the
application or the work session. See chapter Closing the application.

1.4.2. View [View]

Go to [Go To]

Logo
Displays the Salvagnini logo and opening image in the applications area.
Messages [Messages] / Events list [Events List] / PrdMgrPX
Activate the relevant windows in the applications area.
Applications [Applications] / Tools [Tools]
Open the relative graphic drop-down menus in the toolbar.

Toolbar [Toolbar]
Used to toggle between showing or hiding the quick selection button
bar.

Status bar [Status Bar]

Used to show or hide the status bar.

1.4.3. Applications [Applications]

Which applications appear in this menu depends on the configuration of
the system.

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 1. Salvagnini Console
1.4. Descriptions of the menus

The applications installed to manage the system can be activated from

the Applications [Applications] menu:

Application Description
EditP4 Application that allows you to modify the programs for the
P4 Panel Bender.
See the specific manual in volume 2 - Software
applications.
Statistics Application for analyzing in detail the activities that occur
on the machine.
See the specific manual in volume 2 - Software
applications.
Maintenance Manager Manages routine maintenance on Salvagnini systems.
See the specific manual in volume 2 - Software
applications.
Oil_temp See Oil temp [} 22]
Power Activating this utility allows you to view the power
consumption of the system.
Material database Application for interactively managing the database
containing all the technological information about the
materials and formats used by the various Salvagnini
elaboration applications.
See the specific manual in volume 2 - Software
applications.
Material Batch Editor Application for correcting the bend angles for given
materials.
RT Error This window displays full information about the message
that appeared on-screen.
EasyData Trouble-shooting software integrated with the numerical
control for interactively browsing the documentation using
web technology.
See the specific manual in volume 2 - Software
applications.

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1. Salvagnini Console
1.4. Descriptions of the menus

Application Description
Cmd_Screw Application for calibrating the Y manipulator's ball-bearing
screws.
LogMaker Creates a zip file containing all the log files for the
applications installed on the machine.
StackerStatus Application that manages the stacking of parts on tables,
pallet boxes or cages, roller-surfaces and so on
(according to which system it is active on).
See the specific manual in volume 2 - Software
applications.

Oil temp
Utility for viewing:
• Oil temperature [Oil temperature]: oil temperature detected
by the sensor on the hydraulic power pack;
• Cabinet temperature [Cabinet temperature]: temperature
detected by the sensor in the main power cabinet.

To view the pressures of the hydraulic pumps:

1. In the File menu, activate the Power user flag;
2. in the Options [Options] menu, select Configurations
[Configurations];

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 1. Salvagnini Console
1.4. Descriptions of the menus

3. in the Display tab, activate the Main pump pressure [Main

pump pressure] and Circulation pump pressure
[Circulation pump pressure] flags.

Do not modify the values of the interpolation parameters.

Automatic temperature check at given times

An electrical resistor inside the tank of the hydraulic generator keeps
the temperature of the hydraulic oil above the appropriate minimum
value defined (25°C). Normally, the automatic temperature check is
always active. However, if production is suspended for long periods,
energy can be saved by only performing the automatic minimum oil
temperature check at given times on each day of the week.

Activate the Use heating check [Use oil heat control] flag to
set the times at which the automatic check comes on and goes off.
Programmed heating management requires the master switch on the
main power cabinet to be on.

1.4.4. Tools [Tools]

Which applications appear in this menu depends on the configuration of
the system.

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1. Salvagnini Console
1.4. Descriptions of the menus

(*) Only present on punching machines

The items that are not enabled can only be accessed by Power users
[Expert Logon].
List of Applications/Utilities that can be activated from the Tools
[Tools] menu:

Application Description
Manual commands Displays service commands for activating special cycles
or moving the machine's axes.
See the chapter on "Manual commands" in volume 1 -
Operating manual.
CTM Used to manage the system's Machine Constants.
See the specific manual in volume 2 - Software
applications.
Monitor Used to view and directly command the states and actions
of the active parts of the machine: axes, regulators,
solenoid valves, sensors.
See the specific manual in volume 2 - Software
applications.
System Backup Makes an exact copy of all the software installed in the
hard disk on the removable one.
See the “Creating the backup” maintenance chart in
volume 1 - Operating manual.
Sachs See Sachs [} 28].
BatchCompiler Compiles, in sequence, all the programs in the folder
selected.

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 1. Salvagnini Console
1.4. Descriptions of the menus

Application Description
CheckTools See Check tools [} 28].
Dbht Used to manage the tools database of a Salvagnini
punching machine.
See the specific manual in volume 2 - Software
applications.
Check Material See Check material [} 29].

System [System] → Recycle bin

Opens the Windows recycle bin so that you can view its contents before
recovering or permanently deleting the files in it.

System [System] → Reload App configuration [Reload

Apps Configuration]
Used to make software changes effective immediately, without having
to completely relaunch Salvagnini Console.
Given the specific nature of the information shown, these functions are
only significant to software designers from Salvagnini's automation
division.

Security [Security] → User management [Users

Management]

There are three default access levels: Administrator, Expert (Power)

user, Standard user. There must be at least one Administrator (and this
must be a member of Salvagnini's staff) with access to everything.
Only the Administrator can change his own password and those of
people with lower levels of access, or add and remove users. The user
currently using Salvagnini Console can never be deleted.
The functions that can be accessed at each of the three levels
mentioned above are established by the Administrator.

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Users can only be managed by logging on as Administrator (the buttons

will be enabled), otherwise the window will open in read-only mode (with
the buttons disabled).

Language [Language]
Used to change the language in which the Salvagnini Console and
Salvagnini application messages are displayed.

To view the messages in the language chosen, close and restart the
Salvagnini Console application.

Options [Options]
(Expert user)
The Remote notification [Remote Notification] tab is used to
manage notifications of messages generated by the control system.

State [Status] • Disabled [Disabled]: messages are not notified.

• Enabled [Enabled]: messages are notified.

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• Time range enabled [Time range enable]: messages are

only notified within a given time range.
• Enabled on input signal [Enabled on input signal]:
messages are notified according to the value of a signal.
Type of event [Event type] Message notification according to the event selected can be enabled in
this area.
The Settings [Settings] button is used to notify messages outside
the control station.

Notify by SMS [Notify by SMS]

If you have the SMS machine software license, you can receive
message notifications by text to your mobile phone once you have set
the phone number (complete with international prefix).

Notify by email [Notify by E-MAIL] and Notify via network

[Notify by NETWORK]
These services are enabled if the SaRA software application license is
present.

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Sachs

Application used only by Power users to manage the system's axes and
the CAN-bus nodes.

Check tools
Used to check whether the tool configuration created with the DBHTSh
application on the punching head is compatible with the production
program you intend to run.
If the Hit Manager option is present, please consult the relative chapter
in the manual of the DBHTSh application.

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Check material
After you have selected the production program, you can use this
application to check the availability of sheets to be processed.

1.4.5. Help [Help]

Help topics [Help Topics]

Displays this manual.

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About Salvagnini Console [About Salvagnini Console]

Logged user [Logged User]: shows who is currently using Salvagnini Console.
Unit of measurement [Unit of measurement]: specifies whether the units of
measurement used when managing the system belong to the metric or imperial
systems.
Time worked [Working time]: shows the total number of hours worked by the
system's computer.
Disk usage [Disk usage]: shows the percentage of hard disk space used, both
numerically and graphically.
Memory available [Free memory]: shows the RAM available.
Disk space available [Free disk space]: shows how much space is still
available on the disk or in the partition where the Salvagnini environment is installed.
If you click on the More [More] button, a list of the Salvagnini programs installed will
appear, with information about their version.

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1.4.6. Production [Production]

Many of the functions listed in this menu can also be activated from the
button bar.

Enable line production [Enable line production]

Enables production to be run in sequence on systems placed in line.
Transforms all the processing required into a single production process,
from the system located upstream to that located downstream.
The machine line indicator lights up (see chapter Line production
[} 56]).

Enable automatic line data request [Enable automatic job

data request]
Allows the system located downstream to request data from the system
located upstream.
The system located downstream can have two states:
1. in line and enabled to receive data from the system located
upstream;
2. in line but not enabled to receive data from the system located
upstream.

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The second state allows the production of sheets arriving from the
system upstream to be interrupted for a given period of time, while
allowing the system downstream to continue its production.

Enable automatic list production [Enable automatic list

production]
Enables the management of production orders from a company OPS
(Order Processing System).

Enable absent operator mode [Enable absent operator

mode]
Stops the hydraulic generator at the end of production.

Enable power save timeout [Enable power save timeout]

After a period of inactivity, the Panel Bender is put into minimum energy
consumption conditions:
• the hydraulic unit is turned off;
• the electrical servo-drives are deactivated.
The period of inactivity can be configured from the “Production Manager
settings” tab.
A warning message appears on-screen before energy saving mode is
reached.

DANGER
With the movable guards closed, the Panel Bender’s bladeholder and
blankholder may move in order to reach the parking position.

Nobody must be in the vicinity of the machine.

While energy saving mode is enabled, the POWER status appears on a

green background in the interface status bar.
When energy saving mode is reached, the POWERSAVE flag on the
interface graphics turns green.
As soon as one of the following cycles is activated:
• panel production,
• machine resetting,
• hydraulic actuator movement,
the hydraulic unit and the electrical servo-drives are automatically
activated.

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Change tables [Change tables]

Optional function for forcing a table change at the end of production or
at the end of each production list.

Start/stop oil heating [Start/Stop oil heating]

Used to set the time at which oil heating starts and stops on each day of
the week. Useful for saving energy in the event of non-continuous
production cycles.

Work with sheet [Work with sheet]

Enables sheet pick-up during machine operation.

Work without sheet [Work without sheet]

Enables machine operation without sheet pick-up.

Start [Start]
Starts to run the selected program.

Stop after sheet [Stop after sheet]

Suspends the machining cycle at the end of the sheet.

Continue [Continue]
Resumes the production cycle after a pause.

Abort production [Abort production]

Stops the production process.

Stop after each piercing [Stop at each hole]

This function is only available for systems with integrated laser cutting.

Stop after each part [Stop after each part]

This function is only available for systems with integrated laser cutting.

Edit [Modify]
Opens the text editor so that the programs can be modified.

Compile [Compile]
Transforms the source program instructions into machine code.

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Simulation [Simulation]
Activates the program that previews the sheet processing phases.

Visual Stacker
Activates the program that manages the sheet unloading process.

Check sheet [Check sheet]

Checks the availability of the sheets required by the production
program.

Technological data [Technological data]

This function is only available for systems with integrated laser cutting.

Show unloading data [Show unload info]

Displays the main information about the last parts unloaded.

Settings [Settings]
This menu is used to configure the general operating settings.

Common settings

1 X dimension of panel.
2 Panel height.
3 Sheet thickness.
4 Default group.

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5 Time after which the pumps turn off automatically at the end of production
when in "operator absent" mode.
6 Enables the oil temperature to be checked during the given periods: define
these by pressing the Settings [Settings] button on the right.
7 Used to select the default source of the sheet that will be processed on the
machine.
8 Used to correct the pick-up position of the suction cups on the Destacking
Conveyor Surface.
9 Uses a text file to transfer the parameters to the compiler. Do not change the
default settings.
10 Label printing settings.

Production

11 Sets the compilation of each program and the management of the standard
compilation parameters. Do not change the default settings.
12 Where there is an OPS (Order Processing System), this allows the production
lists to be managed automatically. Do not change the default settings.
13 Settings configured where there is an OPS.

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View

14 The sheets processed are not counted.

15 Counts the sheets processed.
16 Counts the parts produced. On punching machines, the number of parts
produced is often greater than the number of sheets processed.
17 This is the maximum number of lines there can be in a production list (see
Managing production lists [} 46]).
18 Indicates the unit of measurement used to represent the dimensions of the
parts produced.
19 Displays the sheet data in the layout drawing during the current process (see
Production control [} 18]). In any case, the information is updated when you
move the mouse over it.
20 When working in no-load mode, this automatically deletes the sheets from the
layout drawing after production has been stopped immediately or the sheet
abandoned.

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Line production The tab below is used to set the various working parameters in "Line
production" mode. These are set during testing and must not be altered.

Figure 3: Tab only available to Power users

Unload info monitor The tab below allows you to configure the information on the second
monitor, which shows the parts arriving on the Panel Bender’s
unloading connection.

Figure 4: Tab only available to Power users

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About [About]
Shows information about the version and author of the Production
Manager application.

1.5. Functions for production

Figure 5: Salvagnini Console user interface area

From the toolbar, in addition to the functions present in the

Applications [Applications] and Tools [Tools] group, the
following functions can also be activated from the Main [Main] group:
1. Messages [Messages]
2. Events list [Events List]
3. File transfer [File transfer]
4. Production Manager [PrdMgrPX]

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1.5.1. Messages [Messages]

The control system communicates with the operator by means of the

messages that automatically appear on the screen. If there are one or
more messages to be read, the icon appears at the right-hand end
of the status bar.
Messages indicate what needs to be done to continue production, or
whether a fault is blocking the machine.
If the Info button in the message window is enabled, click on it for
further information (file and/or applications) about the message shown.
More than one message may be shown at the same time: once you
have done what the message asked you to do, click on the OK button to
see the next window.
Use the Ctrl + T key combination when a message window is active for
an immediate translation into one of the other languages installed.

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1.5.2. Events list [Events list]

All the messages are stored permanently in dedicated files; their

sequence can be seen in theEvents list [Events List] tab. It starts
with the first message since Salvagnini Console was last turned on and
ends with the last message reported.

Information that one of the automation cycles sends to the

operator.
One of the automation cycles has seen that an operation it
commanded has not been performed within the given time.
See Recovering a time-out error [} 62] for further information.
Non-recoverable error, usually requiring Salvagnini Console to
be restarted. See the chapter on Communication breakdown
[} 64].
Error information that the control system sends to the operator.

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1.5.3. File transfer [File transfer]

This function is used to transfer programs between workstations

connected to a local data network.
If the remote system is controlled by a PDP type workstation, programs
are transferred using a serial data line.
This is most frequently done to exchange programs between the
workstations that are used to develop programs and the workstations
that control the machine.
Programs are transferred from the resources in the Source [Source]
area towards the resources listed in the Target [Target] area.
Transfer is however bi-directional because the same computers are
found in both the Source and the Target areas.

The File Transfer function is set to transfer specific data and

programs: it cannot therefore be used to transfer generic files between
the workstations in the network. The commands provided by the
operating system should be used to do this.

Transfer type [Transfer Type]: indicates the type of transfer.

• Programs [Programs]: by default, this type of transfer is always
present; it is used to transfer source programs and/or production
lists.
• CTM: transfers the machine constants file.

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The Filter [Filter] group indicates which files will be shown as

available for transfer (only for Programs [Programs] type transfer):
• Programs [Programs]: displays the source programs.
• Production lists [Lists]: displays the production lists.
• AUTO-NEST files [AUTO-NEST files]: displays the nesting
lists.
• MAN-NEST files [MAN-NEST files]: displays the nesting lists.
• Toolset [Toolset]: displays the head set-ups.

The Options [Options] group indicates the transfer options (only for
Programs [Programs] type transfer):
• Expand lists [Expand lists]: when a production list is
transferred, all the source programs in the list will be transferred
too.
• Elaborated too [Elaborated too]: when one or more source
programs are transferred, all the files generated by the compiler will
be transferred too.

The toolbar for the Transfer user area is as follows:

1. Exits.
2. Stops.
3. Suspends production.
4. Starts the transfer (copies from source to target).
5. Starts the movement (moves from source to target). A message
appears asking the operator to confirm before proceeding:

6. Interrupts the transfer/movement operation.

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7. Opens a dialog box with full information about the transfer

operation made:

8. During the transfer operation (copy or movement), the following

dialog box appears if the target file already exists:

1.5.4. Production Manager [PrdMgrPX]

The functions that can be accessed from the PrdMgrPX - Production
Manager button and the sequences of operations that are required to
start production and check production progress are described in the
chapter on Managing production [} 43].

1.6. Managing production

1.6.1. Introduction
The chapter on Produzione [} 43] describes how to manage programs
or groups of programs, enable compilation and view production
simulation.
The operating sequences required to start production and monitor its
progress, shown here for a P4 system, are also valid for other
Salvagnini systems.

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1.6.2. Managing programs

1 Groups of programs
2 Programs
3 Program selection filter
4 Production information
5 Pop-up menu

The programs are organized into groups. Box (2) lists the programs
belonging to the group selected in box (1).
Control box (3) is used to filter the list of programs shown. The system
will only show programs with file names containing the string of
characters entered in the filter box (3).
Clicking the right-hand button on a program opens a menu (5). From
here, a series of actions can be taken:

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New [New] Creates a new program.

New list [New List] Creates a new list.
Open [Open] Opens the program in edit mode.
Copy [Copy] Creates a copy of the program selected.
Rename [Rename] Renames the program file.
Delete [Delete] Deletes the program selected.
Properties [Properties] Displays the properties of the file selected.
Refresh [Refresh] Updates the list of programs.

The actions New, Rename, Delete, Properties and Refresh can also
be applied to the groups in area (1).
Once you have selected a program, information about it can be found in
the File maintenance tab in area (4).
Three different viewing modes are available:
• Preview [Preview]: displays the production result;
• Source [Source]: displays the production program instructions;
• Mixed [Mixed]: displays the production layout and data.
For each program, a series of actions can be activated from the toolbar:

1. Edit the program (see Editing a program [} 59]);

2. Compile the program (see Compiling a program [} 60]);
3. Activate the production simulator (specific to the type of machine);
4. Activate the production simulator (specific to the type of machine);
5. Check that the material required for production is present.

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1.6.3. Managing production lists

The production list (file with the extension .PL) is a group of programs to
be executed in sequence.

The programs in the list are shown in the File maintenance tab on the
right, along with other information:

Job Icon describing the production status.

Source [Source] Machine feeding mode.
Quantity [Quantity] Number of times the program is repeated.
Done [Done] Number of times the program has been executed.
Group [Group] Group that the program belongs to.
Program [Program] Code of the program to be executed.
X, Z, S Dimensions of the panel.

A block of programs can be repeated by adding "repeat" instructions:

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In the case shown in the figure, the sequence of the two programs is
repeated 5 times.
Clicking the right-hand button on the production lists creates a new list
that will initially be empty.
To display the buttons that are used to edit a production list, double-
click on the name of the list you want to edit, or select the Edit icon

The buttons that appear in the area on the right are as follows:

Reset list.

Add item.

Delete selected item.

Move selected item.

Clicking on the Add item button displays the following production list
creation or modification window:

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The groups are listed in the left-hand column; the programs in the group
selected are listed in the right-hand column.
The Program data [Program data] section is used to enter further
data for parametric compilation (for bending systems).

How to add an item to the production list

1. Select the program in the Production list selection
[Production list selection] window;
2. Enter the number of parts to be processed;
3. Select machine feeding mode:

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AUTO Automatic feeding.

MANUAL Manual feeding.

PACK Feeding from pack.

STORE Feeding from store-tower.

LINE Feeding from line.

4. Click on the Add [Insert] button.

How to change the quantity of an item to be produced

1. Select the item in the "File maintenance" tab;
2. Change the number of parts in the Production list selection
[Production list selection] window;
3. Click on the Change [Change] button.

How to enter a repeat block

1. Select the REPEAT option in the Production list selection
[Production list selection] window;
2. Enter the number of times you want to repeat the block;
3. Click on the Add [Insert] button:

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4. Use the Move buttons to position the REPEAT command at the top
of the group of programs you want to repeat. In the same way,
enter the END REPEAT command at the end of the repeat block.
5. Click on Exit [Exit] to leave the Production list selection
[Production list selection] window and save the changes
made.

How to compile a production list

1. Select the production list;

2. Click on the Compile button in the toolbar;

3. Click on Compile all [Compile all] and wait for the items in the
list to be compiled.

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1.6.4. Starting production

Resetting the machine

1. Turn the system on as described in the chapter on Connecting to
the work session [} 10].
2. At the main console, press the START PUMPS [PUMPS ON]
button to activate the pressure in the hydraulic circuit.
3. Confirm the request for automatic machine resetting.
4. If an automatic store is present, this will require manual resetting:
press the RESET [RESET] button on the local console. Resetting
may take a few seconds.
5. After resetting, the system indicates in the status message bar that
the machine is ready for production or to carry out a manual
command.

Launching production from a program

1. Select "load" or "no-load" feeding mode (see Quick selection button
bar [} 14]).
2. Select "line operation" if available (see Line production [} 16]).
3. Select the production program.

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4. Click on the button in the button bar to display the following

window:

This interface allows you to:

- select a different program from that which has already been
selected;
- use the buttons at top right to edit the program selected;
- select the machine feeding mode;
- enter the number of parts that the machine is to produce.
When you have completed the modifications, click on OK to launch
production.
5. The production information bar contains the following information:

a Group and program being c Estimated production time

produced
b Number of parts produced d Speed adjustment cursor
and to be produced

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In the Layout view tab, you can graphically follow the flow of panels
being processed. If sheets that are thin or not flat enough are moved
too quickly, production may be suspended. It is therefore useful,
especially in the case of unattended production, to reduce the speed of
the machine by adjusting the cursor (d).
The sheets being processed are shown in blue. Positioning the mouse
above the sheets displays the main sheet information.

Launching production from a list

1. Select the production list from the PRODLIST group.

2. Click on the button in the button bar to display the following

window:

The window shows the situation of the last production for the list
selected: the number of parts not produced, the date on which the
list was interrupted (if it was) and any jobs that were interrupted.
For each item (job), the machine feeding mode can be reset if the
temporary feeding mode was selected when the item was added to
the list.
You can also:
- check how many sheets are available in the store (if there is one);
- use the Reset list [Reset list] button to reset the counters
for the sheets that were not produced when production was
previously launched from a list.
3. Click on the Start button to start production.

Stopping production
Production can be stopped, whether it has been started from a program
or from a production list, by clicking on the Stop production [Stop
production] button in the toolbar.

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The machine will stop when all the parts loaded in the machine and
visible in the drawing in the Layout [Layout view] tab are complete.
The “production suspended” message will be displayed in the status
bar. The Status [State] column in the List of jobs [List of
jobs] tab will also confirm that the job has been suspended.

1 Stop production at end of sheet [Stop production]

2 Continue production [Continue production]
3 Abandon production at end of sheet [Abort production]
4 Operator absent [Absent operator]

Click on button (2) to restart the production that has been suspended:
the number of parts that remain to be produced will be displayed.
Alternatively, click on button (3) if you want to start with a new
production job.
When the execution of a production list is stopped, the information
about the number of parts not completed is saved. As such, a
production list in progress can be abandoned and other lists or
programs executed, after which the abandoned production list can be
recalled and all the sheets not produced previously completed.

Stopping production immediately

Clicking on the Reset [Reset] button immediately stops production on
the machine (after confirmation from the operator) and the production in
progress is cancelled.

1 Stop production at end of sheet [Stop production]

2 Continue production [Continue production]
3 Abandon production at end of sheet [Abort production]
4 Operator absent [Absent operator]

After removing any sheets being processed, you can click on button (2).
Alternatively, click on button (3) if you want to start with a new
production job.

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If production is cancelled, the colour of the drawing of the part being

processed, as shown in the layout tab, changes from blue to red (sheet
abandoned).

Right-click the mouse on the sheet to access the following functions:

Modify panel data [Modify panel data]: changes the main production data.
Modify program [Modify program]: starts up the editor for changing the
program.
Compile [Compile]: Compiles the program.
Restart production [Mark panel as ready]:
restarts production after removing any incomplete panels.
Delete panel [Delete panel]: removes the panel from the layout drawing after
physically removing it from the machine too.

When the execution of a production list is stopped immediately, the

information about the number of parts not completed is saved. A
production list that was interrupted by an immediate stop can therefore
be recalled so as to complete the sheets that were not produced.

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1.6.5. Line production

Two machines working in line

The Salvagnini control system allows any machine to operate on its own
or be controlled automatically by another system with the same type of
control.
This status is called “SLAVE”. In this status, the machine receives and
executes the commands of the "MASTER" system.
"In-line" operation assumes that there is another control system
responsible for Starting, Suspending or Interrupting production. This
function of Salvagnini Console is used in the following cases:
• In the event of an S4+P4, the machine placed upstream acts as
Master and the one placed downstream acts as Slave: the
punching machine commands and the Panel Bender executes.
• Systems equipped with a production supervisor such as OPS
(Order Processing Systems). For instance, when the OPS
manages an S4 in line with a P4 followed by a Roboformer, the
OPS acts as Master with respect to the S4. The S4 acts as Master
with respect to the P4, which acts as Master for the Roboformer. In
other words, in the sheet machining flow, each system is Master for
the system that follows it and Slave for the system that precedes it.
This chain means that the OPS can be used to manage all the
machining phases in an extremely fast and flexible manner.

How to activate in-line production

1. In the Salvagnini Console toolbar for both machines, click on the

button to prepare the machine for integrated operation with

the machine placed before or after it.

2. The button changes to and the system's status indicator

turns from grey to green .

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The S4 system is not ready for production in line with the system
downstream.

The S4 system is ready for production in line with the system downstream.

3. On P4 Panel Benders, enable the data request button , which

changes to when it is enabled.

4. In the status bar of the Salvagnini Console interface for both
machines, check that communication with the control card is active
.
5. At this point, the Panel Bender is ready to receive commands from
the punching machine. When the sheet leaves the punching
machine and is positioned in the unloading station, the production
program is automatically loaded by the Panel Bender, which will
complete the processing of all the sheets arriving from the
punching machine.
6. If an S4 production program involves P4 parts, these are only
forwarded to the Panel Bender if the “machine in-line” statuses are
enabled. If the punching machine is not enabled for in-line
operation, the parts will be stacked on the punching machine’s
unloading station rather than being loaded by the Panel Bender.
The PIE instruction (see the programming manual) can be used to
define a part in an S4 program.

Example:

…
PIE: “gruppo\codice.p4” X0.000 Y517.000
U2195.000 V705.000 J1 PCT
…
Where “codice.p4” is the name of the P4 program within the P4 group. If
the program is not present in the P4 group, an error will be reported.

7. From the punching machine console, select the program to be

executed in line mode and press the Start production button .

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1. Salvagnini Console
1.7. PackModus mode

8. Select the sheet feeding mode and the quantity of sheets to be

processed, as described in Launching production from a program
[} 51]). At this point, once the punching phase has been
completed, the sheets will be transferred to the Panel Bender for
processing.

Settings

When two Salvagnini systems are managed in line, a number of

machine constants need to be modified on both systems: this can only
be done by Salvagnini staff.

1.7. PackModus mode

If, during line production, the punching time is longer than the bending
time, whilst the P4 waits for the S4 punching cycle to be completed, the
P4 can bend other panels present on the feeding station table. This
function is optional and is available as a license.
To add another bending batch to be processed during line production,
select the desired P4 program and press the Start production button

.
The P4 will alternate bending the sheets that were loaded by the local
feeding station with bending those that come from the S4 punching
cycle. This maximizes Panel Bender use time.

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 1. Salvagnini Console
1.8. Editing a program

In the list of jobs shown in the figure, we can see that the production of
the panel called "MULTIVISA0" (job W70) with manual feeding from the
P4 was added during the line production of a given number of panels
called "Mobile_uff_430_porte".

1.8. Editing a program

Selecting Modify [Modify] in the Production [Production] menu,
or pressing the relative button, activates the application for editing the
code of the program selected.
SEdit is the text editor developed by Salvagnini to modify the programs
used on Salvagnini systems.

Bookmarks
The lines in the program are numbered to make them easier to find.
Bookmarks can be inserted (line number highlighted in blue) so that the
corresponding line in the program can be found without delay.
The Edit [Edit] > Bookmarks [Bookmarks] menu is used to
manage bookmarks:

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1. Salvagnini Console
1.9. Compiling a program

Shortcuts:

Keys Function
Ctrl+F2 Sets/removes the bookmark from the line where the cursor is
positioned.
F2 Positions the cursor on the first bookmark found. Press F2 again to
go to the next bookmark.
Ctrl+Shift+F2 Removes all the bookmarks from the program.

Search in files
Activating Search in files [Find in files] in the Edit [Edit]
menu allows you to search a number of files at the same time.

1.9. Compiling a program

Selecting Compile [Compile] in the Production [Production]
menu or pressing the "Start ELABORATION” button, the system checks
that the syntax of the instructions in the program is formally correct
according to the programming language and interprets the program so
that it is executed.

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 1. Salvagnini Console
1.9. Compiling a program

1.9.1. The program is correct

If the user program is correct, the following window appears, with a
drawing of the workpiece and the significant program data.

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1. Salvagnini Console
1.10. Special situations

1.9.2. Errors in the program

If the program contains formal errors and/or inconsistent or missing
data, the compiler program generates error messages that are
displayed in the Errors [Errors] window:

a list of the errors detected, together with any warning messages,

appears in the foreground of the window. If there is even just one error,
the program will not be compiled; if only warning messages about
operations that could damage the system appear, the program will still
be compiled.
Double clicking directly on the error message opens the file in SEdit,
with the line that generated the error highlighted, so that you can edit
and save it.
Once you have dealt with the errors shown, you can recompile the
program.

1.10. Special situations

1.10.1. Recovering a time-out error

During the execution of a cycle, when a signal from the system does not
correspond to the signal that the cycle programmed is expecting, the
following window appears on-screen:

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 1. Salvagnini Console
1.10. Special situations

This window indicates that one of the system's automation programs

was expecting a condition that did not occur within the maximum time
limit. This may be due to a problem with the corresponding sensors,
which did not signal the expected change in condition; or it may be the
consequence of a situation upstream, which prevented the condition
expected from occurring.
The window shows the Timeout condition that caused the window to
appear: the condition expected in Line: 8 of the Cycle:
move_Z_pusher.P4 automation file did not occur.
The application was waiting for the following condition to occur:
“Component 7A1SQ213 was due to become ON”.

Component State Description

7A1SQ213 ON The right-hand Z pusher has performed the locking in
the advanced position.

Click on this button to enable the control unit to repeat the check for
the time-out condition.
Click on this button to reset the cycle.

If the problem's cause is eliminated, the Retry [Retry] button can be

pressed to resume the automation cycle from the exact point it left off,
and production can be restarted without a hitch.
If the problem has not been resolved, the window will reappear after
another wait, and so on after each subsequent wait: in this case, the
only operation possible is to request a machine reset using the Reset
[Reset] button. Then follow the instructions given in the operator
messages in order to restart the system.
If clicking on the Stop [Reset] button, or resetting the system, are not
successful, perform the Switching the control unit on and off procedure.

Click on this button to see a photo of the input sensor selected.

Click on this button to see the lower part of the window.

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1. Salvagnini Console
1.10. Special situations

The lines where the logical conditions expected did not occur are
highlighted in the area containing the procedure code.
This text is always in Italian and is only of interest to those who
developed the software.

Activates the Cycle Analyzer application which analyzes the cycle

automation files and the characteristic elements of the rack in the
central database and provides much information that is useful to the
software developer.
Activates a notepad where you can record the date and time at which
the problem occurred and what procedures were employed to solve it;
if the same problem reoccurs, you can immediately access these notes
and take much less time to solve it.
Allows an Expert User to force the automation software to read a
different sensor status from the real status, and thus continue the
cycle.
This manoeuvre is clearly hazardous and can only be performed
by trained Salvagnini staff.

1.10.2. Communication breakdown

An interruption in data transmission between the control system and the
control card in the cabinet may be caused by:
• faults in the transmission devices;
• external disturbances;
• network interruptions caused by cables being damaged or
connectors becoming detached.
If this happens:
• the semaphore in the Salvagnini Console status bar turns red;
• the system is no longer under control: all outputs and drives are
automatically reset and the system prepares to be reinitialized.

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 1. Salvagnini Console
1.10. Special situations

To reset production:
1. identify the cause of the network malfunction and eliminate it,
checking for example that none of the network connectors has
been disconnected;
2. close any applications that are active (SDE compiler, Monitor,
Maintenance Manager);
3. use Connect [Connect] in the Control [Control] menu to
restore the connection with the control card.
Should the problem persist, restart the system and, if this does not
work, contact Salvagnini's customer support service.

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1. Salvagnini Console
1.10. Special situations

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 2. Office Console
2.1. Preface

2. Office Console

2.1. Preface
This manual offers an overview of the commands and functions
available from the Office Console interface.
In order to simplify the use of this application, the part relating to the
functions common to Salvagnini Console has been kept unchanged,
whereas those parts not significantly important for use in the office have
been removed.

2.2. Functional areas

The Office Console window is logically divided into different functional
areas for easy use:

1. Menu bar
2. Fast selection buttons
3. Customization area
4. System selection area
5. User interface area
6. Status bar

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2. Office Console
2.2. Functional areas

2.2.1. Menu bar

This section contains all the items in the pull-down menus that appear in
area (1). Some options may be enabled (in black) or disabled (in grey),
depending on the items selected in area (5).

File menu

Edit menu [Edit]

Help menu [Help]

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 2. Office Console
2.2. Functional areas

2.2.2. Fast selection buttons

The buttons in this area allow fast selection of the most common
functions. They change according to the system selected in area (4).

EXIT: This function closes the application.

SHOW/HIDE SYSTEM TREE: This button allows you to view or hide the
system selection area (4).

SHOW TOOL FOR FILE TRANSFER: This activates the program transfer
window in area (5). It corresponds to the "File transfer" function described in
the Salvagnini Console manual.
EDIT SELECTED FILE: This corresponds to the "Edit" function described in
the Salvagnini Console manual.

EDIT SELECTED AUTOMATIC NEST FILE: Pressing this button launches

the MetalNest application for modifying the .mtn program selected.

EDIT SELECTED MANUAL NEST FILE: Pressing this button launches the
ManNest application for modifying the .mnt program selected.

ELABORATE SELECTED FILE: This corresponds to the "Compile" function

described in the Salvagnini Console manual.

SHOW SIMULATION OF SELECTED FILE: This corresponds to the

"Simulate" function described in the Salvagnini Console manual.

ELABORATE STACKING DATA FOR SELECTED FILE: This corresponds

to the "Stacking" function described in the Salvagnini Console manual.

SHOW TECHNOLOGICAL DATA FOR SELECTED FILE: This button only

appears when a laser system is selected. It is used to launch the Salvagnini
LaserToolManager application for managing the technological cutting tables.
PRINT: Sends the data to the printer; is only enabled when there is data to
print (otherwise is grey).

SHOW/HIDE PANEL DRAWING: This button allows you to view or hide the
drawing in the user interface area (5).

INFORMATION ABOUT: This opens the “Information about Office Console”

window.

ADD /REMOVE APPLICATIONS: This button only appears when

Applications is selected in the system tree structure in area (4).

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2. Office Console
2.2. Functional areas

File transfer

When you press the button, the fast selection button bar appears
as follows:

ADD/REMOVE COMPUTERS AND SYSTEMS

In this window, the user defines the connections between the office
workstation (the one he is working on) and other machine workstations with
which production programs and data are to be exchanged.
Computer name [Computer name]: localhost, the computer the user is
working on;
OS type [OS Type]: the operating system installed in it. Options possible:
• NT, for Windows NT, Windows 2000, Windows Xp and Windows 7
operating systems;
• UNIX, for workstations with this operating system;
• PDP, for Salvagnini systems with this computer.
%SYSCON%: \Usr2, the directory an independent computer accesses.
List of systems [Systems List]: List of the Salvagnini machines
configured to be controlled by the Host selected.
This function is preset to transfer specific data and programs: it cannot,
therefore, be used to transfer generic files between the workstations in the
network. The commands provided by the operating system should be used
for this purpose.

adds a new host.

deletes the host selected.

select the previous or the next host in the list.

For information on all transfer procedures, see the "File transfer" chapter in
the Salvagnini Console manual.

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 2. Office Console
2.2. Functional areas

FILE TRANSFER: The "File transfer” window appears:

adds a new group of files.

deletes the group of files selected.

moves the group selected upwards.

moves the group selected downwards.

Add [Add]: clicking on this button opens the Add files [Add Files]
window where you can set the path of the folder containing the files to be
copied (you can specify the extension of the files to be copied by indicating,
for example, *.mtn) and the target folder;
Delete [Delete]: allows you to cancel the “Files – Target folder”
combination selected;
Modify [Modify]: allows you to edit the “Files – Target folder” combination
selected;
Only copy between identical systems [Copy just towards same
system]: when copying files within the same system.
START TRANSFER: For further information, see the "File transfer"
paragraph in the Salvagnini Console manual.

STOP TRANSFER: For further information, see the "File transfer" paragraph
in the Salvagnini Console manual.

SHOW TRANSFER MESSAGES: Shows the transfer operations performed,

together with their outcome.

2.2.3. Customization area

This shows the customer’s name, followed by the machine's serial
number and the option selected in area (4): Applications or Production.

2.2.4. System selection area

This area contains a tree structure of all the systems loaded in the office
workstation computer.

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2. Office Console
2.2. Functional areas

For each system, you can select one of the following options:
• Applications: corresponds to the Applications [Applications]
menu described in the Salvagnini Console manual;
• Production: lists the programs in area (5). For further information,
see the "Production management" chapter in the Salvagnini
Console manual.

2.2.5. User interface area

This area contains dialog and information boxes, which vary according
to the item selected in area (4): Applications or Production.

2.2.6. Status bar

This highlights the main operating states of the Salvagnini system. For
further information, see the Salvagnini Console manual.

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 3. Programming the punching machine
3.1. Preface

3. Programming the punching machine

3.1. Preface
The architecture of the S4 punch - shear is original and has been
designed to achieve high performance in terms of flexibility of use,
speed of operation and productivity. Its distinguishing feature is the
large number of hydraulic presses, each associated with a tool, installed
in the operating head and able to operate simultaneously. The machine
is totally automatic both in handling the packs of sheets before they are
processed and in managing the machined parts: the programming
instructions give you full control of these operations.
The original programming language has been designed so that
programs can be written and elaborated quickly and easily, even while
the machine is running.
The optional software packages available for the S4 allow programming
to be partly automated and production optimized, yet the system
remains simple and easy to use.
The numerous options we offer for the machine further increase its
flexibility and widen the range of possible applications. In line with
Salvagnini S.p.A.’s P4 Panel Bender, the S4 becomes an integral part
of a complete flexible sheet metal manufacturing system (FMS), with
such a wide range of potential uses and applications that you who use
the machine are better placed than us to discover and employ them: we
shall, therefore, be grateful for any improvements or modifications you
may suggest and can then integrate them in our production.
Every effort has been made to make this manual as complete, accurate
and up-to-date as possible. We reserve the right to modify or improve it
at any time without prior notice.
This manual is structured so that, after a few hours’ study, you will be
able to write most of your programs.

3.1.1. Description of the S4 machine

The figure below gives a general view of the machine, indicating and
describing the main parts that we shall be referring to in this manual.

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3. Programming the punching machine
3.1. Preface

1 C-shaped machine structure 9 S4 machine control panel

2 Manipulator Y axis movement motor 10 Door giving access to worktable with brushes
3 Manipulator X axis movement motor 11 Sheet rotator
4 Worktable 12 Optional units
5 Manipulator 13 Operating head
6 Manipulator pincers 14 Conveyor
7 Control unit screen 15 Double sheet diverter
8 Control unit keyboard 16 S4 electrical control cabinet

Figure 6: Description of the main parts

Brief description of how the main parts work

The manipulator clamps the blank with its pincers and moves it in both
the x and y directions.
The y reference and the manipulator pushers center the blank fed on y.
The operating head contains the hydraulic presses that make the
punches needed to process the blank descend; more than one tool can
descend at the same time.

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 3. Programming the punching machine
3.1. Preface

The rotator rotates the blank in 90 degree steps (or multiples thereof),
thus increasing the y portion of the blank that the various tools can
reach. It also holds the sheet while it is being repositioned so as to
change the relative position along x between manipulator and blank and
allow the blank to make movements along x that are greater than the x
stroke of the manipulator.
The brush conveyor takes the processed parts away from the
worktable.
The sheet diverter positions the outgoing part on the correct y co-
ordinate for it to be unloaded.

1 Punching head 8 Worktable

2 Manipulator 9 Hatch for small parts
3 Rotator 10 Conveyor
4 Y references 11 Stacking line
5 Suction cups 12 Rear diverter
6 Pack retainer 13 Front diverter
7 Feeding table 14 Shear

Figure 7: Main parts

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3. Programming the punching machine
3.1. Preface

3.1.2. Description of the options for the S4 machine

P2R option - Continuous indexing punch

Up to three continuous indexing punches can be added to the S4 head.
These are called P2R3031, P2R3132, P2R3233, P2R3334, P2R3435
and P2R36 according to the position they occupy and the operating
head installed on the machine.
The punch and die are rotated under numerical control by two DC
motors.
For a punch to be installed in a P2R unit, its figure must fit inside a 60
mm diameter circle and it must require a maximum punching force of 12
tons. Indexing tools are given the following positions:
P30 and P31 for P2R3031
P31 and P32 for P2R3132
P32 and P33 for P2R3233
P33 and P34 for P2R3334
P34 and P35 for P2R3435
P36 and P37 for P2R36

Indexing punches are managed like any other punch i.e. they can be
used in all punching and nibbling instructions.

CC option - Shear
A right-angle shear can be installed next to the operating head; it is
used to make fast, accurate cuts of any length along the two orthogonal
axes without producing scrap or leaving a rough edge.
The shear has two independent blades at right-angles to each other.
These are classified according to how they work:

X blade - parallel to the X axis of the manipulator

Y blade - parallel to the Y axis of the manipulator

The two blades can work simultaneously.

The shear is used to sub-divide the workpiece into a number of parts
that can be unloaded in the following ways:
• small parts fall through a hatch and are sub-divided into scrap and
good parts; the good parts can then be sorted into bins;
• large parts are taken away from the worktable by the brush
conveyor and can be stacked downstream;
• if there is any holding scrap, it is automatically sub-divided and
unloaded by a special conveyor.
The CC option is managed by the instructions for Defining the parts to
be produced and Trimming.

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 3. Programming the punching machine
3.1. Preface

PU options
Punching units composed of a single-action hydraulic press with a max.
force of 12 tons can be installed in some of the positions in the S4 head.
These units will hold tools whose figures can fit inside a 60 mm square.
They are provided with adapters so that 7-ton tools whose figures can fit
inside a 33 mm diameter circle can be used.
These punches are programmed as normal 7-ton punches i.e. with the
P identifier followed by the number of the position of the PU in the head.

BU options
Double-action hydraulic presses with a max. force of 8 tons downwards
and 7 tons upwards can be installed in some of the positions in the S4
head. These units will hold tools whose figures can fit inside a 60 mm
diameter circle. They are used to make embossings or bends up to 16
mm high. Double-action presses can move a die above the blank and a
punch below it in sequence.
These tools are programmed as normal 7-ton punches i.e. with the P
identifier followed by the number of the position of the BU in the head,
by writing the DR1, DR2, DR3 and DR4 specifiers described in
Specifiers and options [} 222].

EI options
Hydraulic presses with a lower cylinder with a max. force of 6 tons
(instead of a die) can be installed in some of the 7-ton positions in the
S4 head. They are used to make embossings or bends up to 6.5 mm
high (including the thickness of the material) with tools whose figures
can fit inside a 20 mm diameter circle.
These tools are programmed as normal 7-ton punches i.e. with the P
identifier followed by the number of the position of the EI in the head, by
writing the DR1, DR2, DR3 and DR4 specifiers described in Specifiers
and options [} 222].

MA options
Units for cutting threads in preliminary holes in the workpiece can be
installed in positions 31, 33 and 35. The tapping tool works by plastic
deformation of the walls of the preliminary hole without producing scrap.
To obtain a preliminary hole for 65% of the height of the thread,
punches with a diameter equal to 92% of the diameter of the nut screw
are used. The male tool with its pitch adapter is interchangeable;
threads of M3, M3.5, M4 and M5 are available.

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3. Programming the punching machine
3.1. Preface

PP option - Poly-Punch
Punching units composed of 6 independent single-action hydraulic
presses with a force of 3 tons can be installed in positions 30, 31, 32,
33, 34 and 35. These will hold standard Salvagnini tools with
blankholders.
The 6 tools are arranged on a grid of three rows and two columns; their
figures must fit inside a 33 mm diameter circle. The pitch between the
tools is 44 mm in both directions.
The individual punches are programmed by writing the position of the
punch in the PP unit (1...6) after the number of the position of the PP
(30...35) in the head. For example, to program a punching by punch 2 in
PP30, indicate the punch in position 302.

PRINT option - Sheet printing

The PRINT option is used to write a part number or identification code
on the blank being processed, using a label or ink-jet printer.
This option is managed by the INK instruction.

RF option - Sheet repositioner

The RF option is used to reposition the blank after it has been rotated
but before it starts to be sheared. This is done to recover the error
caused by the internal stress that is released when the manipulator
pincers open.
The RF option consists of two push-rods with conical tips that are
inserted in a special pair of holes made near the edge of the sheet.
These holes, 1200 mm apart, are positioned and then chosen
automatically by the computer so that the RF push-rods do not interfere
with the manipulator.
This option is managed by the RFO instruction.

3.1.3. Description of the SDEX software package

SDEX is the optimization program that calculates the series of
operations that the machine must perform in order to make the
production required.
SDEX must calculate not only the punchings and shearings but also the
rotations and repositionings required. SDEX therefore sub-divides the
operations into "rotation blocks”, between which the sheet is rotated.
These, in turn, are sub-divided into "holding blocks", between which the
sheet is repositioned.

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 3. Programming the punching machine
3.1. Preface

The elaboration is performed in the following phases:

• Reading of the .S4 input file;
• Expansion of the program:
– Expansion of the instructions: each instruction in the program is
broken down into elementary options (single punchings);
– Calculation of the cuts needed to destroy the scrap: to reduce
the total number of cuts, adjoining scrap is consolidated before
the scrap is divided;
– Coverage check.
Unless you are programming a single sheet, you must define all
the parts (including scrap) into which the starting sheet is
divided: no portions of the sheet must remain unprogrammed;
– No-overlap check.
None of the parts programmed must interfere with the parts
adjoining them;
– Automatic holding scrap division;
– Opti-Notch: consolidation and optimization of rectangular
figures;
– Generation of any automatic hole-embossing sequences;
– Determination of the macrofigures (a macrofigure is a hole
produced by more than one punching);
– Determination of the tools used for each elementary punching
or embossing operation and of the position of the sheet with
respect to the head after each rotation of the sheet (by 0°, 90°,
180° and 270°), making sure that the sheet will not interfere
with the edges of the worktable.
SDEX considers the cutting figure of the punch and, if the
punch exchange option is enabled, may decide to use another
punch provided that this has the same cutting figure as the
punch programmed.
• Rotation blocks:
– Sub-division into rotation blocks;
– Translation of the elementary operations towards rotation
blocks downstream; this is done to delay their execution since it
is generally preferable to handle sheets when they have been
processed as little as possible;
– Calculation of the cuts; in this phase, SDEX determines the
constraints between punchings and cuts and on unloading the
various parts; it also calculates the effective cutting lengths and
the elementary shearing sequences needed to detach each
part. The cuts are calculated once the rotation blocks have
been generated, because the unloading and elementary
shearing sequences depend on how the sheet is rotated when
they are performed;

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3. Programming the punching machine
3.1. Preface

– "Static" scrap loss check; static scrap loss is caused by

programming errors rather than incorrect macrofigure execution
sequences; in this phase, SDEX attempts to recover any scrap
lost inside scrap that is due to be destroyed;
– Calculation of the centering and unloading positions for the last
part;
– Calculation of the intermediate rotation positions: an array of
possible rotation positions is calculated; the final position will be
decided once the various holding blocks have been determined.
• Holding blocks:
– Sub-division into holding blocks;
– Determination of the initial and final positions of the various
holding blocks;
– Translation of the elementary operations towards holding blocks
downstream that belong to the same rotation block; this is done
for the same reason that they are translated between rotation
blocks.
• Determination of the sequence in which the elementary operations
in each holding block will be performed;
• If any intermediate unloading operations onto the conveyor are due
to be performed, SDEX checks whether any punchings can be
made while the part is leaving;
• Final check; SDEX performs a final simulation, during which it
checks that there are no sheet holding problems or dynamic scrap
losses;
• Generation of the output file:
– data for sheet execution cycle programs;
– data for sheet execution simulation;
– report file.

3.1.4. Sheet orientation and punch positions

When programming the S4, you must imagine yourself in the place of
the S4 manipulator and consider the blank in the position in which the
manipulator holds it at the beginning of the punching cycle.
The figure below shows the layout of the S4 with the incoming sheet. An
arrow indicates the direction in which it is moving, or being fed.

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 3. Programming the punching machine
3.1. Preface

1 Y carriage
2 Manipulator
3 Direction of feeding

Figure 8: S4 machine layout

The two orthogonal axes, X and Y, which intersect at the bottom left-
hand corner of the sheet being fed, constitute the reference system of
the sheet to be punched.
To distinguish this reference system from all other possible reference
systems, from now on we shall call it the sheet reference system.
Since the REF instruction (see REF instruction - defining a new
reference system) can be used to change the reference system of the
programming co-ordinates, we shall use the term "current sheet
reference system" to indicate the sheet reference system defined last,
and the term "sheet reference system" to indicate the absolute sheet
reference system.
The co-ordinate measured along the X axis is called the abscissa or X-
co-ordinate, that measured along the Y axis the ordinate or Y-co-
ordinate.
You will also see the H2, H3, H4, H5 or H6 operating head (depending
on which type is installed on the S4) as in the enclosed figures, which
also show how the positions of the punches are numbered.

3.1.5. Head set-up tables

When writing programs, it is a good idea to refer to one of the tables
enclosed with this manual, containing a numbered layout of the S4
operating head.
This is because, before you start to write the program, you must
arrange all the punches required by the drawing of the blank to be
punched on the layout of the head.
In order to process certain panels, it is important that the punches be
installed in positions that allow the manipulator to reach the punching
positions programmed.

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3.2. Declaration instructions

Programs are composed of a certain number of instructions.
Each instruction occupies one or more lines and concentrates in a few
written characters a lot of information expressed in graphic and numeric
form on the drawing of the blank to be punched.
This chapter will describe all the instructions in the S4 programming
language.
Each instruction consists of a three-letter instruction code, usually
followed by a semi-colon (:) and a series of letters and numbers. Many
instructions can contain parameters. These generally comprise a letter
that identifies the parameter, followed by an expression that determines
its value.
The letter that identifies the parameter has two functions: identifier and
separator. It must be adjacent to its number i.e. there must be no blank
spaces between them. To make the program easier to read it can,
however, be separated by one or more blank spaces from the character
that precedes it.
For example, to write:
XYP:X525Y780
XYP: X525 Y780
is correct, whereas to write:

XYP:X 525Y780
XYP:X525 Y 780
is incorrect.
If the parameter identifier consists of two letters, it will have to be
followed by a space.
All lines are measured in millimetres and all angles in sexagesimal
degrees.
To express measurements in inches, write the E (English) identifier in
the DIM instruction (see Declaration instructions). Whole numbers and
decimals must be separated by full stops, not commas.
Fractions of a degree are expressed in decimals, not in minutes and
seconds. For example, a rotation of 30° 30' is expressed as 30.5.
All numbers can also be expressed in the form of algebraic expressions,
using round brackets [()] and plus [+], minus [-], multiplication [*],
division [/] and “raise to the power of” [**] signs. The sin, cos, tan and
atan trigonometric operators can also be used. You can therefore write:

XYP: X500+25 Y700+(150/2)+5 ;equivalent to X525 Y780

XYP: X1050/2 Y(373+20-3)*2 ;equivalent to X525 Y780

XYP: X125+20**2 Y625**(1/2)+500 ;equivalent to X525 Y525

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XYP: X1050*sin30 Y1050*cos60 ;equivalent to X525 Y525

XYP: X525*tan45 Y1050*cos(90-30) ;equivalent to X525 Y525

XYP: X200 Y(100**0.5) P33 ;equivalent to X200 Y10

For the sin, cos and tan functions, please see chapter S4 functions
[} 187].
Algebraic expressions are useful when the co-ordinate reference
systems of the drawings are different from that used on the S4,
whenever you want to avoid calculating the co-ordinates and when you
are using parametric programs (see Parametric programming [} 187]).
The S4 language instructions described in the following paragraphs
contain numerical data by way of example to make them easier to
understand. Generally speaking, one line of program is used for each
instruction; if an instruction requires more than one line, you can
continue on the next line by writing "&" at the beginning of the line.
When writing programs, you need not worry about considering the
punchings in the order that minimizes the distance covered by the
manipulator and, therefore, the punching time. You can write the
instructions in any order: SDEX will then optimize the sheet movement
sequence so as to minimize the distance covered by the manipulator.
Exceptionally, you may find that you have to impose the order in which
sheet movements are made. There are special instructions for doing
this (SEQ and ESQ instructions - Composite instructions - Zed
programming).

3.2.1. COD instruction - Program identification

The COD instruction identifies the program among all those present in
the memory of the control unit.
The COD instruction has the following syntax:
COD:"XXXXXXX"
where:

"XXXXXXX" is an alphanumeric code that allows the program to be identified

without ambiguity.
It is a good rule to include the name of the program and the
number of the drawing it refers to in the identification code.

The COD instruction is compulsory and must be written in the first line
of the program.

3.2.2. END instruction - End of program

In the last line of each program, you must write:
END
This instruction is compulsory; if it is not present, the program cannot be
elaborated.

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3.2.3. DIM instruction - Blank size declaration

The DIM instruction contains information about the sheet to be
processed.
The instruction has the following syntax:
DIM: E X1250 Y720.5 S1.5 P2.6 F2.5 K35 M37 DB "FePOL"
where:

E (English) indicates that the measurements given in the program are

expressed in inches.
If this identifier is not present, all the measurements will be
understood to be in mm.
X1250 are the identifier and value of the length of the side of the sheet
parallel to the X axis.
Y720.5 are the identifier and value of the length of the side of the sheet
parallel to the Y axis.
S1.5 are the identifier and value of the thickness.

P2.6 are the identifier and value of the specific weight (kg/dm3) of the
material. This is indicated in order to obtain the correct pressure for
the pincers of the manipulator and feeder. It is omitted if the material
is steel (7.8 kg/dm3).
N.B. Even if the measurements are expressed in inches, the specific
weight must always be given in kg/dm3.
F2.5 are the identifier and value of the specific pressure (kg/mm2) that the
material can bear. If omitted, it will be assumed to have a value of 3
kg/mm2.
N.B. Even if the measurements are expressed in inches, the specific
pressure must always be given in kg/mm2.
K35 are the identifier and value of the ultimate tensile stress (kg/mm2) of
the material. If omitted, it will be assumed to have a value of 40
kg/mm2.
N.B. Even if the measurements are expressed in inches, the ultimate
tensile stress must always be given in kg/mm2.
M37 are the identifier and code for selecting the material from the store.
The code can have any value between 1 and 32767. It is used when
the S4 has an automatic connection to a sheet metal store, otherwise
it is omitted.
DB are the identifier and code of the request for acquiring the material
data from the material database, if present, using the material code. If
omitted, the database will not be interrogated.
"FePOL" is the code of the material or blank (max. 16 characters).

To make it easier to write programs with measurements in inches, you

can use fractional notation. You should, however, be careful not to
make errors like this:
To indicate an X measurement of 3 5/16”, you can write:
X3.3125
or
X3+5/16

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but not:
X3.5/16
which corresponds to X0.21875.
The DIM instruction is compulsory.

3.2.4. BFF, AFG, SFG and EFF instructions - Pre-punched blank

declaration
A pre-punched blank is a rectangular starting sheet that has already
been processed (cut, punched or embossed).
You can define the outlines of the holes inside the sheet as well as the
outline of the sheet itself (if it is not rectangular) or the holes made to
give it its shape.
The following instructions are used to describe a pre-punched blank:

Beginning of the description of the figure

BFF: X0 Y1000 T1
where:

X0 are the identifier and value of the X co-ordinate of the beginning of the
figure in the current sheet reference system;
Y1000 are the identifier and value of the Y co-ordinate of the beginning of the
figure in the current sheet reference system;
T1 are the identifier and code of the type of figure (0=outline of the sheet,
1=hole, 2=embossing, 3=hole on trimmed sheet, 4=embossing on
trimmed sheet).

Description of a straight section

SFG: X100 Y300
where:

X100 are the identifier and value of the X co-ordinate of the end of the
segment in the current sheet reference system;
Y300 are the identifier and value of the Y co-ordinate of the end of the
segment in the current sheet reference system.

Description of a circular section

AFG: X300 Y400 I200 J200 S1
where:

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X300 are the identifier and value of the X co-ordinate of the end of the arc in
the current sheet reference system
Y400 are the identifier and value of the Y co-ordinate of the end of the arc in
the current sheet reference system
I200 are the identifier and value of the X co-ordinate of the center of the circle
that the arc is part of in the current sheet reference system
J200 are the identifier and value of the Y co-ordinate of the center of the circle
that the arc is part of in the current sheet reference system
S1 are the identifier and code of the direction in which the arc is described
(=1 clockwise, =0 anti-clockwise)

End of the figure

EFF
The outline must be continuous but it does not matter in which direction
it is described.
N.B. It is up to you to check that the machine will be able to feed and
center the blank you have defined.

Example of a pre-punched blank

DESCRIPTION OF THE PRE-PUNCHED BLANK

BFF: X150 Y0 T0
SFG: X1250 Y0
SFG: X1250 Y400
SFG: X1500 Y400
SFG: X1500 Y1000
SFG: X0 Y1000
SFG: X150 Y0
EFF
BFF: X460 Y550 T1
AFG: X460 Y550 I600 J550 S0
EFF

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3.2.5. PUN instruction - Punch declaration

The PUN instruction describes the form, position and dimensions of the
punches in the S4 operating head. It must appear before the punching
instructions so that they can use the parameters it provides.
If the PUN instruction refers to an indexing punch, you must define the
punch at 0 degrees.
The PUN instruction has the following syntax:
PUN: 2 P5 F5 G10 H10 I15 R0.5 S10 T60 Cc A90 X1 Y2 E3
U50 V30 VB VH Lnn “aa”
where:

2 is the distinctive code of the punch family. These are defined in the
following paragraphs.
P5 are the identifier and number of the position of the punch in the
operating head.
F5 G10 H10 I15 R0.5 T60 Cc
are the identifiers and values of the parameters that describe the
geometric form of a given punch. The paragraphs describing the various
punch families explain how the different parameters are used.
S10 are the identifier and value of the angle between the axis of symmetry of
the punch and the positive X axis. Anti-clockwise rotation is considered
positive.
If omitted, S will be assumed to have a value of 0.
A90 are the identifier and value of the angle at which the punch is installed in
the head. While S is taken from the drawing, A describes how the punch
is actually installed. When calculating the angle of a punch, S and A are
added together.
If omitted, A will be assumed to have a value of 0.
X1 are the identifier and value of the X co-ordinate of the point of
programming with respect to the actual center of the punch (except for
family 14: knock-outs) as shown in the following figure.
If omitted, X will be assumed to have a value of 0.
Y2 are the identifier and value of the Y co-ordinate of the point of
programming with respect to the actual center of the punch (except for
family 14: knock-outs) as shown in the following figure.
If omitted, Y will be assumed to have a value of 0.

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E3 are the identifier and code of the type of tool, regardless of what is
defined in the machine constants. The following codes are used:
-2 fast punch
-1 punch
1 tool for making low downward embossings
2 tool for making low upward embossings
3 tool for making high downward embossings
4 tool for making high upward embossings
5 tool for making embossings that do not require the anti-flattening
check (marking tools)
6 tool for making upward embossings that do not require the anti-
flattening check (marking tools)
7 blind punch
8 "continuous embossing" tool for ribbing
9 "continuous embossing" tool for offsetting
10 "continuous embossing" tool for engraving
11 "tapping" tool
If the value of E is above 100, this means that a special type of
embossing tool is installed in the position specified.
If the value of E is below -100, this means that a special type of
punching tool is installed in the position specified.
If the E parameter is omitted, or has a value of 0, the type of tool will be
taken from the machine constants.
U50 are the identifier and value of the first dimension of the punch
blankholder; U # 0 indicates that the blankholder is present.
With U # 0 and V = 0, the outline of the blankholder is considered to be
a circle with a radius of U; with U # 0 and V # 0, the outline of the
blankholder is considered to be a rectangle with side x of U and side y
of V.
The U and V parameters refer to the punch reference system.
If omitted, U will be assumed to have a value of 0.
V30 are the identifier and value of the second dimension of the blankholder;
this will only be considered if U # 0.
If omitted, V will be assumed to have a value of 0.
VB for further information, please consult the paragraph on VAR instruction -
Compilation options [} 233].
VH for further information, please consult the paragraph on VAR instruction -
Compilation options [} 233].
Lnn indicates the number of the lubricator to be used and may be followed
by the number of strokes to be performed between one lubrication and
the next. For example, L123 means lubricator 1 will be used every 23
strokes.
“aa” is the punch code.

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Example of a punch that is centered with Example of a punch that is offset with
reference to its seat: the point of reference to its seat: the point of
programming coincides with the center of programming does not coincide with the
the punch (X0 Y0) center of the punch (X-10 Y0)

Several punches can be described in a single line of PUN instruction,

provided that they all belong to the same family.
For example:
PUN: 1 P3 F5 P6 F7 P8 F12 P10 F3
The punch families that can be used in S4 programs are described
below.

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Circular punches
PUN: 1 P1 F5

F5 are the identifier and value of the length of the radius of the punch.

The RIC instruction can use a circular punch.

Rectangular punches
PUN: 2 P1 F20 G10 S30

F20 are the identifier and value of the length of the side parallel to the X axis
when S has a value of 0.
G10 are the identifier and value of the length of the side parallel to the Y axis
when S has a value of 0.
If omitted, G will be assumed to have the same value as F.
S30 are the identifier and value of the angle between side F and the X axis.
If omitted, S will be assumed to have a value of 0.

The REC instruction requires a rectangular punch.

The CWP instruction may use a rectangular punch.

Rectangular radiussed punches

PUN: 43 P1 F20 G10 S30 R0.5

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F20 are the identifier and value of the length of the side parallel to the X axis
when S has a value of 0.
G10 are the identifier and value of the length of the side parallel to the Y axis
when S has a value of 0.
If omitted, G will be assumed to have the same value as F.
R0.5 is the identifier and value of the radius at the vertexes.

S30 are the identifier and value of the angle between side F and the X axis.
If omitted, S will be assumed to have a value of 0.

The rectangular radiussed punch can be used with the REC or XYP
instructions.

Lenticular punches
PUN: 5 P1 F33 G0.4 S22.5

F33 are the identifier and value of the diameter of the circle that circumscribes
the figure.
G0.4 are the identifier and value of the radius of rounding.

S22.5 are the identifier and value of the angle between the axis of symmetry of
the punch and the positive X axis.
The standard values for fixed punches are: 22.5, 67.5, 112.5, 157.5.
If omitted, S will be assumed to have a value of 0.

The NIK instruction requires a lenticular punch.

Radiussing punches
PUN: 6 P1 F3 G5 H2.54 I0.68

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F3 are the identifier and value of the length of the straight side.

G5 are the identifier and value of the length of the radius of rounding.

H2.54 are the identifier and value of the dimension of the oblique side measured
perpendicular to the straight side (see the figure below).
If omitted, H will be assumed to have a value of 0.
I0.68 are the identifier and value of the dimension of the oblique side measured
parallel to the straight side (see the figure below).
If omitted, I will be assumed to have a value of 0; if present, the F
parameter will indicate the length of the straight side plus I.

The RAD instruction requires a radiussing punch.

H is the Y dimension of the

oblique side
I is the X dimension of the
oblique side
G is the radius of nibbling
F is the sum of the horizontal
side plus I

The arc of nibbling is at a tangent to the oblique side.

Tricuspid punches
PUN: 7 P1 F30 R0.2

F30 are the identifier and value of the radius of curvature of the tool.
Holes with a radius greater than, or equal to, 28.35 can be made.
R0.2 are the identifier and value of the radius of rounding.
If omitted, the radius of rounding will not be considered.

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The RIC instruction may use a tricuspid punch.

Obround punches
PUN: 8 P1 F30 G10 S30

F30 are the identifier and value of the outside length of the side parallel to the X
axis when S has a value of 0.
G10 are the identifier and value of the outside length of the side parallel to the Y
axis when S has a value of 0.
S30 are the identifier and value of the angle between side F and the X axis.
If omitted, S will be assumed to have a value of 0.

The CWP instruction may use an obround punch.

Triangular punches
PUN: 9 P1 F18 G23 R0.4 S30

F18 are the identifier and value of the length of the base of the isosceles triangle.

G23 are the identifier and value of the length of the congruent sides of the
isosceles triangle.
R0.4 are the identifier and value of the radius of rounding at the vertex (opposite
the base).
If omitted, the radius of rounding will not be considered.
S30 are the identifier and value of the angle between the axis of symmetry of the
punch and the positive X axis.
If omitted, S will be assumed to have a value of 0.

The IST instruction requires a triangular punch.

Bi-trapezoidal punches
PUN: 11 P1 F32 G5 S90

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F32 are the identifier and value of the length of the side parallel to the X axis
when S has a value of 0.
G5 are the identifier and value of the length of the side parallel to the Y axis
when S has a value of 0.
S90 are the identifier and value of the angle between side F and the X axis; it can
only have a value of 0 or 90°.
If omitted, S will be assumed to have a value of 0.

The REK and CWP instructions may use a bi-trapezoidal punch.

Trapezoidal punches
PUN: 12 P1 F32 G5 S90

F32 are the identifier and value of the length of the side parallel to the X axis
when S has a value of 0.
G5 are the identifier and value of the length of the side parallel to the Y axis
when S has a value of 0.
S90 are the identifier and value of the angle between side F and the X axis; it can
only have a value of 0, 90, 180 or 270°.
If omitted, S will be assumed to have a value of 0.

The REK and CWP instructions may use a trapezoidal punch.

Multiple radiussing punches

PUN: 13 P35 F30.48 G53.34 H38.1 I45.72 R21

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F30.48 are the identifier and value of the radius of nibbling in quadrant 1.

G53.34 are the identifier and value of the radius of nibbling in quadrant 2.

H38.1 are the identifier and value of the radius of nibbling in quadrant 3.

I45.72 are the identifier and value of the radius of nibbling in quadrant 4.

R21 are the identifier and value of the radius of the circle that circumscribes
the punch.

The RIC instruction may use a multiple radiussing punch.

Multiple radiussing punches with 8 radii

PUN: 20 P35 F30.48 G53.34 H38.1 I45.72 R21 K95 Q100
W88 Z98

F30.48 are the identifier and value of the radius of nibbling in quadrant 1.

G53.34 are the identifier and value of the radius of nibbling in quadrant 2.

H38.1 are the identifier and value of the radius of nibbling in quadrant 3.

I45.72 are the identifier and value of the radius of nibbling in quadrant 4.

R21 are the identifier and value of the radius of the circle that circumscribes
the punch.
K95 are the identifier and value of the radius of nibbling in quadrant 5.

Q100 are the identifier and value of the radius of nibbling in quadrant 6.

W88 are the identifier and value of the radius of nibbling in quadrant 7.

Z98 are the identifier and value of the radius of nibbling in quadrant 8.

The RIC instruction may use a multiple radiussing punch.

Knock-out tools
Circular tool
PUN: 14 P78 F14.08 G17.46 H22.02

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F14.08 are the identifier and value of the inside radius.

G17.46 are the identifier and value of the intermediate radius.

If omitted, G will be assumed to have the same value as F.
H22.02 are the identifier and value of the outside radius.
If omitted, H will be assumed to have the same value as G.

Arc-shaped tool
PUN: 14 P21 F45.65 G49 H53.24 S-30 T150 X26.18 Y10.41

F45.65 are the identifier and value of the inside radius.

G49 are the identifier and value of the intermediate radius.

H53.24 are the identifier and value of the outside radius.

If omitted, H will be assumed to have the same value as G.
S-30 are the identifier and value of the angle between the beginning of the
arc and the positive X axis.
T150 are the identifier and value of the size of the angle covered by the arc.

X26.18 are the identifier and value of the X co-ordinate of the center of the
punch with reference to the point of programming (the center of the
circles with radii of F, G and H).
Y10.41 are the identifier and value of the Y co-ordinate of the center of the
punch with reference to the point of programming.

The KKO instruction requires a knock-out tool.

Marking punches
PUN: 15 P1 F0.8 G1.2 C1

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F0.8 are the identifier and value of the width of the character.

G1.2 are the identifier and value of the height of the character.

C1 are the identifier and character printed.

The WRI instruction may use a marking punch.

Continuous embossing tools

PUN: 16 P36 F10 G3 R100 S90 E8

A Punch D Ribbing tool

B Die E Offsetting tool
C Forming produced F Engraving tool

F10 are the identifier and value of the size of the forming made along X when S
= 0.
G3 are the identifier and value of the size of the forming made along Y when S
= 0.
R100 are the identifier and value of the minimum radius of the circular trajectory
that the tool can make.
S90 are the identifier and value of the angle between side F and the X axis.
If omitted, S will be assumed to have a value of 0.
E8 are the identifier and code of the type of tool; this punch family will accept
E8 (ribbing), E9 (offsetting) and E10 (engraving).
If omitted, E will be assumed to have a value of 8.

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The continuous embossing instructions (BBG, SEG, ARC and BND)

require a punch from this family.

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Bi-concave, bi-convex and concave-convex punches

PUN: 17 P36 F14 G21 H150 I200 R0.5 T0 PUN: 17 P36 F14 G21 H-254 I200 R0.5 T-20

Examples of a concave-convex punch

F14 are the identifier and value of the length of the base of the punch.

G21 are the identifier and value of the radius of the circle that circumscribes the
punch.
h-254 are the identifier and value of the lower nibbling radius: negative for a
concave side, positive for a convex side.
I200 are the identifier and value of the upper nibbling radius: negative for a
concave side, positive for a convex side.
R0.5 are the identifier and value of the radius of rounding at the vertex (opposite
the base).
T-20 are the identifier and value of the angle between a straight line drawn
through the center of the punch and the center of the rounded end and the
X axis in the punch reference system.
If omitted, T will be assumed to have a value of 0.

H and I will be negative for a bi-concave punch and positive for a bi-
convex punch. H will be positive and I negative (or vice-versa) for a
concave-convex punch.
The RIS and RES instructions require a concave-convex punch.

Concave multiple radiussing punch

PUN: 18 P35 F208.6 G865.05 H51 I1570 J0.5 R21

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F208.6 are the identifier and value of the radius of nibbling in quadrant 1.

G865.0 are the identifier and value of the radius of nibbling in quadrant 2.
5
H51 are the identifier and value of the radius of nibbling in quadrant 3.

I1570 are the identifier and value of the radius of nibbling in quadrant 4.

J0.5 are the identifier and value of the radius of rounding between two
consecutive arcs.
R21 are the identifier and value of the radius of the circle that circumscribes
the punch.

The RES instruction can use a concave multiple radiussing punch.

Tapping tool
PUN: 19 P33 F4 G1.25 H77 I4 T8.33 E11

19 is the code of the punch family.

P33 are the identifier and number of the position of the punch in the
operating head.
F4 are the identifier and value of the radius of the circle that inscribes the
tapping (value M/2 of the tap).
They are used when checking for interference with embosses and/or
punchings and for graphic representation.
G1.25 are the identifier and value of the pitch of the tool (lead screw).

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H77 are the identifier and value of the length of the tool.
(outside the chuck and including the end to facilitate measurement).
I4 are the identifier and value of the length of the tip of the tool.

T8.33 are the identifier and value of the speed of tapping, in revolutions per
second.
E11 are the identifier and value of the type of tapping tool.
E11 defines an electrical tapping tool.

Curved trapezoidal punch

A curved trapezoidal punch is used for circular nibbling inside the sheet,
keeping the internal scrap. The punch profile consists of two concentric
arcs and two sloping sides. To define its geometric parameters, we use
the outer radius (H) which characterizes the processing required, and
the thickness of the tool at the centre (G) which is easy to measure with
a caliper.

G thickness at the centre of the J chord of the lower arc of the

tool punch
H radius of the outer arc R radius of the circle that
circumscribes the punch

PUN: 21 P34 G5 H138 J36.58 R41.96/2

Writing punch
The punches in this family have been created to write numbers and/or
letters (S4 WRI instruction) using far fewer punching strokes than a pair
of rectangles would require. An obround punch is installed at S0 and
S90 and an L-shaped punch is installed at S0/S90/S180/S270. 6
punches are therefore required on 6 punching stations (typically a
polypunch). Whether or not the G parameter is present in the
declaration defines whether the writing punch is L-shaped or obround.

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It is possible to install and program just one L-shaped punch and one
obround punch (i.e. one pair) on the head: writing can still be done with
extra rotations as long as the point on the sheet can be reached.
Installing 6 punches does, however, make writing much easier.

F Width
G Height
H Profile thickness

PUN: 22 P34 F5 G5 H1.5

F Width
H Profile thickness

PUN: 22 Pnn F5 H1.5

Characters that can be obtained

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 3. Programming the punching machine
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Hexagonal punch
A new punch family (45) has been introduced. This new family defines
hexagonal tools via the F and S parameters rather than define them as
special tools.

Special punches
If a punch will not fit into any of the families listed above, you must
classify it yourself with your own rules, using family identification codes
from 100 to 1000 and bearing in mind that the same code must be used
throughout the S4 program.
For example, a hexagonal punch with sides 10 mm long could be
defined as belonging to family 100, an embossing punch as belonging
to family 101, or above, and so on.
The figures generated by these punches can be divided into three
categories:
• “centrally symmetrical” figures which do not change when the sheet
is rotated by 90°, 180° or 270°;
• “orthogonally symmetrical” figures which do not change when the
sheet is rotated by 180°;
• “asymmetrical” figures.
When using orthogonally symmetrical and asymmetrical punches, you
must pay attention to the figure you require on the sheet. To do this, you
will find it helpful to program the angle or use the LEF, RIG, HIG and
LOW specifiers (see Specifiers and options [} 222]).

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Examples of centrally symmetrical figures

The broken lines represent the axes of the punch.

Examples of orthogonally symmetrical figures

Examples of asymmetrical figures

The PUN instruction has the following syntax:

PUN: 100 P1 F20 G10 S30 T180

F20 are the identifier and value of the dimension along X when S has a value
of 0 (as though the tool were rectangular).
If omitted, F will be assumed to have a value of 33.
G10 are the identifier and value of the dimension along Y when S has a value
of 0 (as though the tool were rectangular).
If omitted, G will be assumed to have the same value as F.
S30 are the identifier and value of the angle between side F and the X axis.
If omitted, S will be assumed to have a value of 0.
T180 are the identifier and value of the angle of symmetry of the punch i.e. the
minimum amount (in 90° steps) by which the tool needs to be rotated in
order to obtain the same figure as that made at 0°.
Centrally symmetrical figures must have T90; orthogonally symmetrical
ones must have T180. If omitted, T will be assumed to have a value of
360 (asymmetrical figure).

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Special multiple punch with a cutting figure composed of 3 holes with a

radius of 5 mm and a pitch of 20 mm.
PUN: 100 P20 F50 G10 T180

Special multiple punch with a cutting figure composed of 3 holes with a

radius of 5 mm positioned on the vertexes of a 20 mm equilateral triangle.
PUN: 101 P20 F30 G27.3

Special multiple punch with a cutting figure composed of 4 holes positioned

on the vertexes of a 20 mm square.
PUN: 102 P20 F30 T90

Special punches must be defined correctly if they are to be used in

symmetry operations.
A figure can be used symmetrically if there is an axis that divides it into
two identical parts. If there is no such axis, the punch cannot be used in
symmetry operations.

Figure 9: Example of a punch with a cutting figure that cannot be used symmetrically

SDEX considers the axis of symmetry that coincides with the X axis of
the punch reference system. It may therefore be useful to modify the S
parameter in such a way as to obtain this condition.

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The axis of symmetry of punch A is 90° in the punch reference system.

If, therefore, you define it as though it were B rotated by 90°, it will not
cause any problems when used in symmetry operations. You should
write:
PUN: 103 F50 G40 S90

3.2.6. PSB instruction - Declaration of alternative punches

The PSB instruction is used to define punches that can be employed as
an alternative.
The PSB instruction has the following syntax:

PSB: P1 A90 lista_punzoni_alternativi

where:

P1 are the identifier and number of the position of the

main punch in the head.
A90 are the identifier and value of the angle of the main
punch.
If omitted, A will be assumed to have a value of 0.
Lista_punzoni_ is the list of the punchings that can replace a
alternativi punching by the main punch, e.g.:
X-10 Y0 P2 A90
X-10 are the identifier and value of the X co-ordinate of
the punching center of the alternative punch (P2) in
the reference system of the main punch.
Y0 are the identifier and value of the Y co-ordinate of
the punching center of the alternative punch (P2) in
the reference system of the main punch.
P2 are the identifier and number of the position of the
alternative punch in the head.
A90 are the identifier and value of the angle of the
alternative punch.
If omitted, A will be assumed to have a value of 0.

The PSB instruction is useful for declaring the alternative to special (and
generally multiple) punches that can be used when the main punch
cannot reach the punching position programmed.

Example of the PSB instruction

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The main punch (P20) is a multiple punch with a

cutting figure composed of 3 holes with a radius of 5
mm and a pitch of 20 mm.

The alternative punch (P1) is a circular punch with a

radius of 5 mm.

The PSB instruction has the following syntax:

PSB: P20 X-20 Y0 P1 X0 Y0 P1 X20 Y0 P1

3.3. Punching instructions

All punching instructions program a tool to be used. However, this tool
is only viewed as “the punching figure to be used” and SDEX may well
decide to use other tools with the same punching figure. If you want the
punch you have programmed to be used at all costs, you must add the
NSB specifier to the punching instruction.
All the instructions given below can use either fixed punches or indexing
tools. To program the rotation of an indexing tool, add the A identifier
and the value of the rotation (in degrees) to the number of the position
of the punch. The positive direction of rotation is anti-clockwise (as
viewed from above); indexing tools can be rotated by between 0 and
360°.
To program a punching with the punch rotated as in the figure below,
write:
P31 A30
in the instruction.
You can program angle A for fixed punches too, but only values of 90,
180 and 270 - which correspond to one of the possible rotations of the
sheet - will have any sense. (If omitted, A will be assumed to have a
value of 0).
To find which value to give to the A identifier, study the figure you want
to obtain over the blank, considering the arc oriented as shown below.

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Figure 10: Defining the angle of rotation for the P2R indexing tool

Figure 11: Defining the angle of rotation over the blank

3.3.1. XYP instruction - Single or multiple punching

Single punching
If it were always easy to find the Cartesian co-ordinates of the punching
centres, all punching programs could be written using single punching
instructions.

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The programming language, with its specific instructions, relieves you of

most of the work involved in finding the punching centres.
The fewer the calculations needed to write a program, the better the
programming language.
The elementary punching instruction is, however, the only way of
programming a punching that is not connected geometrically (by
alignment, symmetry or grouping) with other punchings.
The elementary single punching instruction has the following form:
XYP: X50 Y100 P12 A90
where:

X50 are the identifier and value of the X co-ordinate of the center of
punching in the current sheet reference system.
Y100 are the identifier and value of the Y co-ordinate of the center of
punching in the current sheet reference system.
P12 are the identifier and distinctive number of the position of the punch in
the operating head.
A90 are the identifier and value of the punch angle.
If omitted, A will be assumed to have a value of 0.

To indicate a positive or negative incremental deviation from the co-

ordinates given in the preceding instruction, you can write the I
incremental identifiers in front of the X and Y identifiers. These
identifiers are particularly useful if the drawing of the sheet to be
punched only gives the distances between the punching centres.
For example, these two consecutive single punching instructions:
XYP: X50 Y100 P12
XYP: IX150 IY-55 P1
mean that the punch installed in position 12 of the head will go to punch
at the point with co-ordinates of (50, 100) and the punch in position 1
will go to punch at the point with co-ordinates of (200, 45), since
200=50+150 and 45=100-55.
If the increment is zero, you can omit the identifier and the value of the
co-ordinate. For example, these two consecutive single punching
instructions:
XYP: X50 Y100 P12
XYP: IY-50 P1
mean that punch P1 will go to punch at the point with co-ordinates of
(50,50).
If two consecutive single instructions refer to the same punch, you do
not have to indicate it in the second instruction.
For instance:
XYP: X50 Y100 P12
XYP: X200 Y20

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In addition to the parameters described above, the XYP instruction will

also accept the J index and a number of specifiers (see Specifiers and
options [} 222]).

Multiple punching
If the position of the main punch (due to act at the point with co-
ordinates of X, Y) is followed in the same line by the positions of other
punches, these punches will act at the same time as the main punch.
This is known as simultaneous multiple punching and is an exclusive
feature of the S4.
The multiple elementary punching instruction has the following form:
XYP: X125 Y300 P5 P1 P9
where:

X125 are the identifier and value of the X co-ordinate of the center of
punching.
Y300 are the identifier and value of the Y co-ordinate of the center of
punching.
P5 are the identifier and distinctive number of the position of the punch that
will act at the point with co-ordinates of X125, Y300 (the main punch).
P1 P9 are the identifiers and distinctive numbers of the positions of the
punches that will act at the same time as the punch in position 5.

This instruction is very useful for making rows of equidistant (and almost
always identical) holes very quickly.
You might at first think that this instruction can only be used for rows of
equidistant holes where the pitch is either equal to, or a multiple or sub-
multiple of, 80 mm (the distance between the centres of the seats of 7-
ton punches). This is not, however, the case.
It can in fact be used with different pitches, as long as the cutting figure
of the punch is offset from the center of the seat. Below is an example
in which the main punch is in position 5. To reduce the number of
calculations you need to make, it is a good idea to choose as the main
punch a punch whose center coincides with the center of the position.
Of the three punches in the following example, only P5 is centered.
The STR instruction should be used when the row consists of a large
number of holes set along a sloping straight line.
If the multiple punching operation is performed by an even number of
punches, or if the secondary punches are not arranged symmetrically
with reference to the main punch, the main and auxiliary punches must
be considered together as an "asymmetrical" punch and the
corresponding instruction may require the HIG, LOW, LEF, RIG and
SQR specifiers (see Specifiers and options [} 222]).

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Example of multiple punching:

Please note that, in the above example, the punches must be defined
as follows:
PUN: 1 P5 F3
PUN: 1 P9 F3 X-12
PUN: 1 P1 F3 X12

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In addition to the parameters described above, the XYP instruction will

also accept the J index and a number of specifiers (see Specifiers and
options [} 222]).

3.3.2. RHO instruction - Square punching at a 45° angle

The figure below shows all the possible ways of punching with a square
punch at a 45° angle; each is given one of the following codes: R1,
R2, ..., R12.

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The RHO instruction has the following syntax:

RHO: X100 Y200 P21 R1
where:

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X100 are the identifier and value of the X co-ordinate of point P in the
current sheet reference system.
Y200 are the identifier and value of the Y co-ordinate of point P in the
current sheet reference system.
P21 are the identifier and number of the position of the square punch at a
45 angle. The form and dimensions of the punch must be declared in
the PUN instruction as belonging to family 2.
R1 are the identifier and characteristic number of the type of punching.

The number associated with the R identifier represents one hour on the
face of a clock. To remember this rule, imagine that the center of the
punch is the center of the clock and the line joining it to point P is the
corresponding hour hand. The value of a is 3 mm.
If the side of the punch at 45° is shorter than the side to be punched,
the other punchings can easily be programmed by writing other RHO
instructions with just the increments of the X and Y co-ordinates. These
increments must all have the same absolute value and must be no more
than 70% of the side of the punch. For example:

PUN: 2 P7 F23 S45

RHO: X25 Y0 P7 R2 ; point no. 1
RHO: IX-12 IY12 P7 R2 ; point no. 2

When programming large notches at 45°, it is easier to use the COR

instruction to automatically nibble the triangle that is to be removed,
plus an auxiliary rough-shaping punch (if necessary).
In addition to the parameters described above, the RHO instruction will
also accept the J index and a number of specifiers (see Specifiers and
options [} 222]).

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3.3.3. RAD instruction - External radiussing with a radiussing

punch
The corner of the blank can be rounded using a radiussing punch. The
co-ordinates of the center of the radiussing punch (in terms of the
current sheet reference system) are given by the RAD instruction. This
has the following syntax:
RAD: X100 Y50 P3 Q1
where:

X100 are the identifier and value of the X co-ordinate of the corner to be
rounded (in the current sheet reference system).
Y50 are the identifier and value of the Y co-ordinate of the corner to be
rounded (in the current sheet reference system).
P3 are the identifier and number of the position of the radiussing punch.
Q1 are the identifier and number of the corner punched, as shown
below.

Figure 12: Radiussing

In addition to the parameters described above, the RAD instruction will

also accept the J index and a number of specifiers (see Specifiers and
options [} 222]).

3.3.4. STR instruction - Punching at regular intervals along a

straight line
A series of identical punchings at regular intervals along a straight line
at any angle can be programmed as follows:
STR: X100 Y50 P6 P2 P10 A90 S30 U20 W10
where:

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X100 are the identifier and value of the X co-ordinate of the center of the
first punching in the current sheet reference system.
Y50 are the identifier and value of the Y co-ordinate of the center of the
first punching in the current sheet reference system.
P6 are the identifier and number of the position of the main punch.
P2 P10 are the identifiers and numbers of the positions of the punches that
act at the same time as the main punch in a multiple punching
operation.
They are omitted in the case of a single punching operation.
A90 are the identifier and value of the punch angle.
If omitted, A will be assumed to have a value of 0.
S30 are the identifier and width in degrees of the angle between the
positive X axis and a straight line that passes through the centres
of the punchings. Anti-clockwise rotation is considered positive. For
example, you can write S-30 instead of S330. If omitted, S will be
assumed to have a value of 0.
U20 are the identifier and length of the center-to-center distance
between the single punchings or between the main punchings in
multiple punching operations.
W10 are the identifier and number of single or multiple punchings.

If you use a multiple punching operation, you should follow the

indications given in the paragraph on the XYP instruction.

In addition to the parameters described above, the STR instruction will

also accept the J index and a number of specifiers (see Specifiers and
options [} 222]).

3.3.5. GRI instruction - Punching at regular intervals on an

orthogonal grid
The GRI instruction has the following syntax (see the figure below for
the definition of side AB):

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GRI: X100 Y50 P3 P2 P4 A90 Q1 S30 U20 V40 W4 Z6 H10

K-20 Tn SQM
where:

X100 are the identifier and value of the X co-ordinate of corner A in the
current sheet reference system.
Y50 are the identifier and value of the Y co-ordinate of corner A in the
current sheet reference system.
P3 are the identifier and number of the position of the main punch.
P2 P4 are the identifiers and numbers of the positions of the punches that act
at the same time as the main punch in a multiple punching operation.
They are omitted in the case of a single punching operation.
A90 are the identifier and value of the punch angle.
If omitted, A will be assumed to have a value of 0.
Q1 are the identifier and code of the “quadrant” used for programming; Q
can have one of the following values:
1 – irrelevant;
2 - the sign will change at each step along X;
3 - the sign will change at each step along X and Y;
4 - the sign will change at each step along Y;
If omitted, Q will be assumed to have a value of 1.
Example
The following instructions all have the same effect:
GRI: X100 Y150 P3 Q1 U20 V40 W4 Z6
GRI: X100+60 Y150 P3 Q2 U20 V40 W4 Z6
GRI: X100+60 Y150+200 P3 Q3 U20 V40 W4 Z6
GRI: X100 Y150+200 P3 Q4 U20 V40 W4 Z6
GRI: X100 Y150 P3 Q2 U-20 V40 W4 Z6
GRI: X100 Y150 P3 Q3 U-20 V-40 W4 Z6
GRI: X100 Y150 P3 Q4 U20 V-40 W4 Z6
S30 are the identifier and width in degrees of the angle between the
positive X axis and side AB oriented from A to B. Anti-clockwise
rotation is considered positive. For example, you can write S-30
instead of S330. If omitted, S will be assumed to have a value of 0.
U20 are the identifier and length of the center-to-center distance between
the single punchings or between the main punchings in multiple
punching operations on the side parallel to side AB.
V40 are the identifier and length of the center-to-center distance between
the single punchings and between the main punchings in multiple
punching operations on the side at right-angles to side AB.
W4 are the identifier and number of single or multiple punchings on side
AB.
Z6 are the identifier and number of single or multiple punchings on the
side at right-angles to side AB.

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In addition to the parameters described above, the GRI instruction will

also accept the J index and a number of specifiers (see the SQM
instruction in Punching instruction specifiers [} 224]).

H10 This is the movement for disengagement on X (positive or negative) to

be made after each punching/embossing generated by the GRI
instruction;
K-20 This is the movement for disengagement on Y (positive or negative) to
be made after each punching/embossing generated by the GRI
instruction.
Tn T0 = slow simultaneous axis movement (default);
T1 = X movement then Y movement (slow);
T2 = Y movement then X movement (slow);
T3 = fast simultaneous axis movement (default);
T4 = X movement then Y movement (fast);
T5 = Y movement then X movement (fast).

These automatic disengagement movements are useful when

embossings must be followed by a movement of the manipulator so as
not to get stuck (this is typically done by programming a false NOP
punching). Remember that the GRI instruction can also be used for
single strokes by programming the W1 and Z1 parameters.

3.3.6. POL instruction - Punching at regular intervals along an

arc
This instruction has the code POL because the punchings are on the
corners of a polygon drawn inside a circle (see the figure below).
The instruction has the following form:
POL: X100 Y50 P5 S30 T60 U100 W6
where:

X100 are the identifier and value of the X co-ordinate of the center (P) of the
circle in the current sheet reference system.
Y50 are the identifier and value of the Y co-ordinate of the center (P) of the
circle in the current sheet reference system.
P5 are the identifier and number of the position of the punch.

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S30 are the identifier and width in degrees of the angle between the positive X
axis and the first punching encountered when moving anti-clockwise
along the arc on which the punchings are arranged at regular intervals. If
the punchings are arranged at regular intervals around a complete circle,
any one of them can be the first punching.
T60 are the identifier and width in degrees of the angle between two adjacent
punchings.
U100 are the identifier and radius of the circle around which the punchings are
arranged.
W6 are the identifier and number of punchings; can be omitted if the
punchings are arranged around a complete circle.

The POL instruction can be used with the indexing tool to make
punchings on the corners of a polygon drawn inside a circle. The axes
of the figures punched will be distributed on the radii of the circle and
the angle given will be maintained for each punching (see the figures
below).
When used with the indexing tool, the POL instruction has the following
form:
POL: X200 Y150 P31 A60 S45 T45 U100 W8
where:

A60 are the identifier and width of the angle between the X axis and the axis
of the punch.

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Figure 13: Punchings on a circle with A ≠ 0

Figure 14: Punchings on a circle with A = 0

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Special specifiers for the POL instruction

In addition to the usual specifiers (see Specifiers and options [} 222]),
the POL instruction will also accept the special CEH specifier.
Adding the CEH specifier (exclusive to the indexing tool) to the POL
instruction rotates the punching figures.
The instructions for the figures below have the following forms,
respectively:

In addition to the parameters described above, the POL instruction will

also accept the J index and a number of specifiers (see the SQM
instruction in Punching instruction specifiers [} 224]).

3.4. Nibbling instructions

Nibbling instructions are used to define geometrically the portion of the
sheet that is to be punched.
By “finishing” we mean machining on the perimeter the figure required
whereas by “rough punching” we mean machining inside this figure.
Rough punching can, of course, only be performed if the scrap inside
the hole is to be destroyed.

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Figure required

Punchings made to obtain the figure required

Rough punchings

Finishing punchings

3.4.1. REC instruction - Rectangular punching with

destruction of the internal scrap
Rectangular punching may be required on a corner of the blank (notch),
on the edge of the blank (trim-cut) or inside the blank (window). The
instruction for rectangular punching is “REC”.

The syntax of the instruction for the above figure is:

REC: X100 Y200 P12 Q1 S30 R1 U40 V20 L50 W100
where:

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X100 are the identifier and value of the X co-ordinate of corner A in the
current sheet reference system.
Y200 are the identifier and value of the Y co-ordinate of corner A in the
current sheet reference system.
P12 are the identifier and number of the position of the rectangular punch
that is to make the punching.
If an indexing tool is used, the angle at which it must be positioned for
nibbling will be calculated automatically.
Can be omitted if the Opti-Notch software option is present.
Q1 are the identifier and code of the “quadrant” that contains the corner
being programmed. It can have values from 1 to 4.
If omitted, Q will be assumed to have a value of 1.

S30 are the identifier and width in degrees of the angle between side AB of
the rectangular figure to be punched and the positive X axis.
If omitted, S will be assumed to have a value of 0.
R1 are the identifier and distinctive number of the nibbling sequence. If
omitted, R will be assumed to have a value of 0.
The nibbling sequence will only be respected if the instruction has the
SQM specifier or is part of a Zed block (see Zed programming
[} 209]); otherwise, SDEX will automatically choose a sequence that
does not lose any scrap.
U40 are the identifier and length of side AB of the punching; if omitted, it
will be assumed to be the same length as side U of the punch.
V20 are the identifier and length of the side of the punching perpendicular
to side AB; if omitted, it will be assumed to be the same length as side
V of the punch.
L50 are the identifier and value of the amount by which the notch can
extend along X beyond the distance actually required (side U in the
REC reference system); this value will be negative if the notch can
extend along X in the negative direction.
If omitted, L will be assumed to have a value of 0.
W100 are the identifier and value of the amount by which the notch can
extend along Y beyond the distance actually required (side V in the
REC reference system); this value will be negative if the notch can
extend along Y in the negative direction.
If omitted, W will be assumed to have a value of 0.

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Figure 15: Sequence for nibbling in rows

Figure 16: Sequences for nibbling in columns

The U identifier is given to the side of the figure that would overlap the X
axis if the S identifier had a value of 0. Below is an example of a figure
that lies at an angle. This shows how the names of the S, U and V
identifiers change according to which corner is chosen to be corner A.

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Figure 17: Defining the sides and the angle of rotation of the rectangular window ac-
cording to which corner is taken to be corner A

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3.4. Nibbling instructions

This figure gives examples of REC instructions for notches, trim-cuts

and windows made by a 90 mm square punch in position 21.
It is a good idea to avoid using punches that are only a little bit smaller
than the figure to be nibbled, because the strip sheared would be too
thin and could damage the punch and/or the dies. As a general rule, the
minimum width of the strip that can be sheared is twice the thickness of
the material.

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Special specifiers for the REC instruction

In addition to the usual nibbling instruction specifiers (see Specifiers and
options [} 222]), the REC instruction will also accept the special SFR
and SFP specifiers (that will be described in the paragraph on the PPR
instruction).
Both these specifiers consider the rectangle defined in the REC
instruction as a piece of scrap that is destroyed using a punch. This part
will be taken into consideration for the starting sheet coverage check
(see Description of the SDEX software package).
The overlap check, however, will not be performed on these particular
parts, because the punchings usually have to extend slightly over the
adjoining part.
The SFR specifier simply indicates that the rectangle defined in the
REC instruction must be considered by the coverage check. The SFP
specifier, on the other hand, states that the punchings must be
considered feasible if the part defined in the REC instruction could be
unloaded were it to be made by the shear (see the figure below).
The SFP specifier has the same effect as the SFR specifier if the
punchings in the REC instruction are not made in the same rotation
block as the final cuts.

1 X blade 4 Part 1
2 Y blade 5 Part 2
3 Shear

If the REC instruction has the SFR specifier, part 1 will be cut after the
REC is made. It will be difficult to remove, because when it is detached
from the blank it will not be completely on top of the conveyor since its
right-hand edge will be above the Y blade. As a result, the attrition
between the part and the blade will oppose the action of the conveyor
during the unloading phase. If the REC instruction has the SFP
specifier, part 1 will be cut before the REC is made and it will not be
difficult to remove.
N.B. In addition to the parameters described above, the REC instruction
will also accept the J index and a number of specifiers (see Specifiers
and options [} 222]).

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3.4.2. REK instruction - Rectangular punching with

preservation of the internal scrap
If the window to be nibbled is large, it may take too long to destroy the
internal scrap. Sometimes, too, it may be possible to re-use the scrap,
possibly by punching it in the same cycle. Even if the window is small,
but lies in the center of the sheet, and the sheet is going to be bent on
the P4, the scrap must remain attached to the rest of the blank or the
manipulator of the bending machine will be unable to grip the sheet.
This is why the REK instruction was introduced. It uses trapezoidal or
bi-trapezoidal punches to punch the outline of the window, leaving the
scrap joined to the rest of the sheet by a number of micro-joints. The
REK instruction produces the punchings shown in the figures below: the
first using trapezoidal punches, the second using bi-trapezoidal ones.

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You might think that you could always use bi-trapezoidal punches
because they leave a rectangular piece of scrap without tacks that is
easier to re-use. However, they also produce small diamond-shaped
connection tabs between the scrap and the sheet. These often remain
attached to the sheet when the scrap is detached and further manual
work is required. If, instead, you use trapezoidal punches, not only does
this problem not arise but the micro-joints are also more resistant when
the parts slide over the worktable.
A greater number of phases will, however, be required to make the
windows (or a greater number of units installed).

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With punch c), the window is made in four phases and the sheet is
automatically rotated by 90° between each phase.
With the pair of punches d), the window is made in just two phases and
the sheet is automatically rotated by 180° between them. Reducing the
number of rotations reduces the punching time too.

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Sometimes, however, it may not be possible to make the window that

has been programmed because its size or position in the sheet are such
that the manipulator is unable to reach the correct position. In this case,
the set of four punches e) are used. These can make all types of
window, even without rotating the sheet. Windows or cuts whose
outlines lie very close to the edge of the sheet can be made in no more
than two phases (0°, or 0° and 180°). This would not be possible with
only the pair of punches d).
Only one punch is written in the instruction to indicate the punching
figure that is to be used but, to reduce the number of rotations, it helps
to have a number of identical tools at different orientations (90° steps):
two in the case of bi-trapezoidal punches, since they are orthogonally
symmetrical; up to four in the case of trapezoidal punches, since they
are asymmetrical. These tools must, of course, be declared in the PUN
instructions.
The REK instruction for the figure below has the following syntax:
REK: X100 Y200 P1 Q1 S0 R0 T0.5 U500 V200 W4 Z1
where:

X100 are the identifier and value of the X co-ordinate of corner A of the
window in the current sheet reference system.
Y200 are the identifier and value of the Y co-ordinate of corner A of the
window in the current sheet reference system.
P1 are the identifier and number of the position of the punch which
identifies the cutting figure that is to be used.
Q1 are the identifier and code of the “quadrant” that contains the corner
being programmed. It can have values from 1 to 4.
If omitted, Q will be assumed to have a value of 1.

S0 are the identifier and value of the angle between side U of the window
and the X axis.
If omitted, S will be assumed to have a value of 0.
R0 are the punch rotation identifier and code.
If R = 0, irrelevant;
If R = 1, all the punchings generated will be rotated by 180°.
If omitted, R will be assumed to have a value of 0.
T0.5 are the identifier and width of the micro-joint attaching the scrap to the
rest of the sheet.
U500 are the identifier and value of the length of the side of the window that is
parallel to the X axis when S = 0.

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V200 are the identifier and value of the length of the side of the window that is
parallel to the Y axis when S = 0.
W4 are the identifier and number of micro-joints between the scrap and the
sheet along the side of the window that is parallel to the X axis when S =
0.
If omitted, it will be assumed that there are no micro-joints along X.
Z1 are the identifier and number of micro-joints between the scrap and the
sheet along the side of the window that is parallel to the Y axis when S =
0.
If omitted, it will be assumed that there are no micro-joints along Y.

In addition to the parameters described above, the REK instruction will

also accept the J index and a number of specifiers (see Specifiers and
options [} 222]).

3.4.3. CWP instruction - Cutting with a punch

The CWP instruction is used to make cuts with a punch. Rectangular,
obround, trapezoidal and bi-trapezoidal punches can be used.
It has the following syntax:
CWP: X100 Y50 P5 R1 S30 U300 B-1 E10 W1 Z3
where:

X100 are the identifier and value of the X co-ordinate of the beginning of
the cut in the current sheet reference system.
Y50 are the identifier and value of the Y co-ordinate of the beginning of
the cut in the current sheet reference system.
P5 are the identifier and number of the position of the punch that
indicates the punching figure to be used for the cut.
R1 are the identifier and code of where the punch must be positioned
with reference to the cut; for a horizontal cut at 0° (S0), R0 means
that the punch must be positioned above the cut and R1 below it.
If omitted, R will be assumed to have a value of 0.
S30 are the identifier and width in degrees of the angle between the line
giving the start and direction of the cut and the positive X axis.
If omitted, S will be assumed to have a value of 0.
U300 are the identifier and value of the length of the cut.
B-1 are the identifier and value of the overhang allowed before the
beginning of the cut; a negative value indicates that there must be a
micro-joint at the beginning of the cut.
If omitted, B will be assumed to have a value of 0.
E10 are the identifier and value of the overhang allowed after the end of
the cut; a negative value indicates that there must be a micro-joint at
the end of the cut.
If omitted, E will be assumed to have a value of 0.
W1 are the identifier and width of micro-joint.
Z3 are the identifier and number of micro-joints required inside the cut,
excluding any micro-joints at either end of the cut (B and/or E with a
negative value).

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Examples of cuts made with the CWP instruction using 4 different types
of punch. For each punch, we have shown 3 ways of cutting the same
segment horizontally. They all start on the left, but the ends are
attached in different ways: those in the first row are attached at both
ends, those in the second are only attached at the beginning and those
in the third are not attached at all. We have also shown what happens
when 2 segments are cut with a 60° angle between them.
In addition to the parameters described above, the CWP instruction will
also accept the J index and a number of specifiers (see Specifiers and
options [} 222]).

3.4.4. RIC instruction - Internal circular nibbling

The RIC instruction can be used to nibble circular holes using a circular,
tricuspid or multiple radiussing punch for finishing and a circular or
rectangular punch for any rough punching.
The tricuspid punch can be installed in either a fixed or an indexing
station.
The multiple radiussing punch must be installed in an indexing station. It
is used to nibble four different circles (with each of the four nibbling radii
available) without any rough edges.

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Figure 18: Internal circular nibbling

The instruction has the following syntax:

RIC: X100 Y50 P5 P6 M1 S20 T300 U100 V0.5
where:

X100 are the identifier and value of the X co-ordinate of the center (P) of the
circle to be nibbled in the current sheet reference system.
Y50 are the identifier and value of the Y co-ordinate of the center (P) of the
circle to be nibbled in the current sheet reference system.
P5 are the identifier and number of the position of the nibbling punch used for
the finishing operation: circular, tricuspid or multiple radiussing punches
can be used.
P6 are the identifier and number of the position of the auxiliary punch chosen
to destroy the scrap inside the circular nibbling. The form of the auxiliary
punch can be circular or rectangular. If the finishing punch is a multiple
radiussing punch, the tool used for the rough punching operation can also
be a multiple radiussing punch. The auxiliary punch will only be taken into
consideration if a complete circle is to be nibbled (T = 360°).
If omitted, the internal scrap will not be destroyed.
M1 The meaning of this identifier depends on the cutting figure of the
finishing punch.

Circular finishing punch

The identifier and value of the M parameter are ignored and can be
omitted.
Tricuspid finishing punch
Are the identifier and code of the saw-tooth edge considered
acceptable. Only valid if the radius of rounding at the corners of the
tricuspid punch has been defined (R parameter in the PUN instruction)
and the tricuspid punch is not installed in an indexing station. The saw-

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tooth edge will be found towards the ends of the 60° arc, since the
nibbling punch works “head-on” in this area and the outline of the figure
generated therefore depends not only on the radius of nibbling but also
on the punch’s radius of rounding. The figure below shows how the
intersection between two punchings close together changes as the M
parameter changes.
If omitted, M will be assumed to have a value of 1.
If M = 0, no punchings will be made closer together than the minimum
interval for circular nibbling given by the TRAMIN machine constant (no.
1093).

a nibbling side of the tricuspid 2 point at which nibbling starts

punch with M=2
1 point at which nibbling starts 3 point at which nibbling starts
with M=1 with M=3

Figure 19: Saw tooth edge produced with M=3

Multiple radius finishing punch

Are the identifier and code of the nibbling radius to be used; M1
indicates the radius identified by the F parameter in the PUN instruction,
M2 that identified by G, M3 that identified by H and M4 that identified by
I.
If omitted, the largest nibbling radius from among all those smaller than
the radius of the circle to be nibbled will be chosen.

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S20 are the identifier and width in degrees of the angle between the point at
which the nibbling starts (i.e. the end of the arc of nibbling encountered
first when moving anti-clockwise along the arc) and the positive X axis.
If the finishing punch is tricuspid, the RIC instruction will work in 60°
steps: if the value of S is not 0 or a multiple of 60, it will be approximated
to the nearest value.
If omitted, S will be assumed to have a value of 0.
T300 are the identifier and width in degrees of the angle of nibbling.
If the finishing punch is tricuspid, the RIC instruction will work in 60°
steps: if the value of T+S is not a multiple of 60, it will be approximated to
the nearest value.
If omitted, T will be assumed to have a value of 360.
U100 are the identifier and length of the radius of the circumference of the
figure to be nibbled.
V0.5 are the identifier and width of the rough edge.

To reduce the nibbling time, choose the punch with the largest nibbling
radius from among all those that are smaller than the radius of the circle
to be nibbled. This allows you to obtain the rough edge programmed
with punchings that are further “apart” and therefore require fewer
punchings. You should, however, be careful not to use a circular punch
with a radius that is very close to that of the circle to be nibbled, as this
would have the effect of cutting a very thin strip of material that could
damage the punch.
The auxiliary punch must be inside the circle with a radius of U minus V,
otherwise it will extend beyond the finishing.

Figure 20: Circular punching with a tricuspid punch

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Examples of circular nibbling with the multiple radiussing punch shown

at the bottom. The nibbling at the top also contains rough punching by a
circular punch.
In addition to the parameters described above, the RIC instruction will
also accept the J index and a number of specifiers (see Specifiers and
options [} 222]).

3.4.5. NIK instruction - Internal circular nibbling with a

lenticular punch and preservation of the scrap
The NIK instruction is used to perform circular nibbling operations
where the scrap in the middle is connected to the rest of the sheet by
thin micro-joints.

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If you have a pair of lenticular punches, the sheet must be held at 90° or
270°.

If you have four lenticular punches, the sheet does not have to be held
at 90° or 270°. This reduces the nibbling time.
The above is true if the lenticular punches are installed in fixed stations.
Otherwise, a single lenticular punch installed in an indexing station is
sufficient.

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Since these punches have a large nibbling radius, the same degree of
roughness can be obtained when punching at greater intervals than
would be possible if a punch with a smaller diameter were being used.
This greatly reduces the nibbling time.
The NIK instruction has the following form:
NIK: X100 Y50 P1 M1 S45 T90 U100 V0.5 W0.5 Z4
where:

X100 are the identifier and value of the X co-ordinate of the center of the circle
to be nibbled in the current sheet reference system.
Y50 are the identifier and value of the Y co-ordinate of the center of the circle
to be nibbled in the current sheet reference system.
P1 are the identifier and number of the position of the punch indicating the
cutting figure to be used.
M1 are the identifier and code of the saw-tooth edge considered acceptable.
Only valid if the lenticular punch is not installed in an indexing station.
The saw-tooth edge will be found towards the ends of the 45° arc, since
the nibbling punch works “head-on” in this area and the outline of the
figure generated therefore depends not only on the radius of nibbling but
also on the punch’s radius of rounding. The figure below shows how the
intersection between two punchings close together changes as the M
parameter changes.
If omitted, M will be assumed to have a value of 2.
If M = 0, no punchings will be made closer together than the minimum
interval for circular nibbling given by the TRAMIN machine constant (no.
1093).

___ nibbling side of the lenticular 2 point at which nibbling starts

punch with M=2
1 point at which nibbling starts 3 point at which nibbling starts
with M=1 with M=3

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Figure 21: Saw-tooth edge produced with M=3

S45 are the identifier and width in degrees of the angle between the point at
which the nibbling starts (i.e. the end of the arc of nibbling encountered
first when moving anti-clockwise along the arc) and the positive X axis.
The NIK instruction works in 45° steps: if the value of S is not 0 or a
multiple of 45, it will be approximated to the nearest value.
If omitted, S will be assumed to have a value of 0.
T90 are the identifier and width in degrees of the angle of nibbling.
The NIK instruction works in 45° steps: if the value of T+S is not a
multiple of 45, it will be approximated to the nearest value.
If omitted, T will be assumed to have a value of 360.
U100 are the identifier and length of the radius of the circumference to be
nibbled.
V0.5 are the identifier and width of the rough edge considered acceptable.
W0.5 are the identifier and width of the micro-joint attaching the scrap to the
rest of the sheet.
Z4 are the identifier and distinctive number (4 or 8) of the angles at which
the micro-joints are distributed. 4 indicates that they are distributed at
90° intervals (in positions corresponding to 0°, 90°, 180° and 270°); 8
that they are distributed at 45° intervals (i.e. in these four positions plus
the four intermediate ones).

Figure 22: Circular nibbling with four micro-joints attaching the scrap

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Figure 23: Circular nibbling with eight micro-joints attaching the scrap

Figure 24: Examples of NIK instructions with fixed punches and different values of the M
parameter

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You will see that the number of punchings required with M1 is greater
than (or equal to) the number of punchings required with M2. The same
is true of M2 compared with M3.
M0 guarantees that no punchings will be made at less than the
minimum recommended interval. The number of punchings required
with M0 is smaller than (or equal to) the number of punchings required
with M1.

Figure 25: Example of a NIK instruction with an indexing punch

Compared with fixed punches, this offers the same degree of roughness
but requires fewer punchings.
In addition to the parameters described above, the NIK instruction will
also accept the J index and a number of specifiers (see Specifiers and
options [} 222]).

3.4.6. RIS instruction - Internal circular nibbling with a

concave-convex punch and preservation of the scrap
The RIS instruction is used to nibble the inside of an arc of any length,
leaving any number of micro-joints.
It requires a concave-convex punch that has at least one convex
nibbling side and is installed in an indexing station.
The RIS instruction has the following form:
RIS: X100 Y50 P1 R1 S45 T90 B-1 E10 U100 V0.5 W0.5 Z4
D1
where:

X100 are the identifier and value of the X co-ordinate of the center of the
circle to be nibbled in the current sheet reference system.
Y50 are the identifier and value of the Y co-ordinate of the center of the
circle to be nibbled in the current sheet reference system.
P1 are the identifier and number of the position of the punch indicating
the cutting figure to be used.

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R1 are the identifier and code of the radius to be used; R1 indicates the
side defined by the H parameter in the PUN instruction; R2 that
defined by the I parameter.
The side indicated must be convex.
If omitted, the side with the better radius will be chosen.
S45 are the identifier and width in degrees of the angle between the point
at which the nibbling starts (i.e. the end of the arc of nibbling
encountered first when moving anti-clockwise along the arc) and the
positive X axis.
If omitted, S will be assumed to have a value of 0.
T90 are the identifier and width in degrees of the angle of nibbling.
If omitted, T will be assumed to have a value of 360.
B-1 are the identifier and value of the angular overhang allowed before
the beginning of the nibbling (angle S). If this value is negative, there
must be a micro-joint at the beginning of the nibbling. The width of
this micro-joint will be given by the W parameter (see below).
If omitted, B will be assumed to have a value of 0.
E10 are the identifier and value of the angular overhang allowed after the
end of the nibbling (angle S+T). If this value is negative, there must
be a micro-joint at the end of the nibbling. The width of this micro-
joint will be given by the W parameter (see below).
If omitted, E will be assumed to have a value of 0.
U100 are the identifier and length of the radius of the circumference to be
nibbled.
V0.5 are the identifier and width of the rough edge considered acceptable.
W0.5 are the identifier and width of a micro-joint.
Z4 are the identifier and number of micro-joints inside the nibbling,
excluding any micro-joints at either end of the nibbling (B and/or E
with a negative value).
D1 are the identifier and code of the type of nibbling required; with D1,
the end of the nibbling will lie at a tangent to the circumference to be
nibbled and, as a result, there will be no rough edges at the ends;
with D0, the end of the nibbling will lie inside the circumference to be
nibbled.
If omitted, D will be assumed to have a value of 0.

Figure 26: Example of a RIS instruction for nibbling a complete circle

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Figure 27: Example of a RIS instruction with D0

Figure 28: Example of a RIS instruction with D1

In addition to the parameters described above, the RIS instruction will

also accept the J index and a number of specifiers (see Specifiers and
options [} 222]).

3.4.7. RES instruction - External circular nibbling with a

concave-convex punch
The RES instruction is used to nibble the outside of an arc of any
length, leaving any number of micro-joints.
It requires a concave-convex punch with at least one concave nibbling
side or a concave multiple radiussing punch or a rectangular,
trapezoidal or bi-trapezoidal punch; the punch must be installed in an
indexing station.
The RES instruction has the following form:
RES: X100 Y50 P1 R1 S45 T90 B-1 E10 U100 V0.5 W0.5 Z4
D1
where:

X100 are the identifier and value of the X co-ordinate of the center of the circle
to be nibbled in the current sheet reference system.
Y50 are the identifier and value of the Y co-ordinate of the center of the circle
to be nibbled in the current sheet reference system.
P1 are the identifier and number of the position of the punch indicating the
cutting figure to be used.

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R1 are the identifier and code of the nibbling radius to be used. If a

concave-convex punch is used, R1 will indicate the side defined by the
H parameter in the PUN instruction and R2 that defined by the I
parameter (the side indicated must be concave). If a multiple radiussing
punch is used, R1 will indicate the side defined by the F parameter, R2
that defined by the G parameter, R3 that defined by the H parameter
and R4 that defined by the I parameter. If a rectangular, trapezoidal or
bi-trapezoidal punch is used, the R parameter will be ignored.
If the R parameter is omitted, and a concave-convex or multiple
radiussing punch is used, the side with the best radius will be chosen.
S45 are the identifier and width in degrees of the angle between the point at
which the nibbling starts (i.e. the end of the arc of nibbling encountered
first when moving anti-clockwise along the arc) and the positive X axis.
If omitted, S will be assumed to have a value of 0.
T90 are the identifier and width in degrees of the angle of nibbling.
If omitted, T will be assumed to have a value of 360.
B-1 are the identifier and value of the angular overhang allowed before the
beginning of the nibbling (angle S). If this value is negative, there must
be a micro-joint at the beginning of the nibbling. The width of this micro-
joint will be given by the W parameter (see below).
If omitted, B will be assumed to have a value of 0.
E10 are the identifier and value of the angular overhang allowed after the
end of the nibbling (angle S+T). If this value is negative, there must be a
micro-joint at the end of the nibbling. The width of this micro-joint will be
given by the W parameter (see below).
If omitted, E will be assumed to have a value of 0.
U100 are the identifier and length of the radius of the circumference to be
nibbled.
V0.5 are the identifier and width of the rough edge considered acceptable.
W0.5 are the identifier and width of a micro-joint.
Z4 are the identifier and number of micro-joints inside the nibbling,
excluding any micro-joints at either end of the nibbling (B and/or E with
a negative value).
D1 are the identifier and code of the type of nibbling required; with D1, the
end of the nibbling will lie at a tangent to the circumference to be nibbled
and, as a result, there will be no rough edges at the ends; with D0, the
end of the nibbling will lie inside the circumference to be nibbled.
If omitted, D will be assumed to have a value of 0.

Figure 29: Example of a RES instruction for nibbling a complete circle

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Figure 30: Example of a RES instruction with D0

Figure 31: Example of a RES instruction with D1

In addition to the parameters described above, the RES instruction will

also accept the J index and a number of specifiers (see Specifiers and
options [} 222]).

3.4.8. IST instruction - Nibbling a triangular figure

The IST instruction is used to perform a triangular nibbling operation by
a triangular punch.

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The IST instruction has the following syntax:

IST: X300 Y250 P1 M1 R1 S30 T40 U70 V0.5 W1 Z2
where:

X300 are the identifier and value of the X co-ordinate of the vertex between the
two oblique sides in the current sheet reference system.
Y250 are the identifier and value of the Y co-ordinate of the vertex between the
two oblique sides in the current sheet reference system.
P1 are the identifier and number of the position of the punch with the form of
an isosceles triangle that determines the cutting figure to be used to make
the figure programmed.
If omitted, the T and U parameters must be present.
M1 are the identifier and code of the type of nibbling required at the vertex and
only apply to punches for which the radius of rounding has been defined (R
parameter in the PUN instruction). The M parameter indicates which point
of the punch you want to coincide with the point P (x,y) that has been
programmed (using the codes illustrated in the figure below):

P IST vertex programmed

0 point that coincides with P if M=0
1 point that coincides with P if M=1
2 point that coincides with P if M=2
3 point that coincides with P if M=3
4 point that coincides with P if M=4
If omitted, M will be assumed to have a value of 0.

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3. Programming the punching machine
3.4. Nibbling instructions

R1 are the rotation identifier and code for the figure to be nibbled; the figure
below illustrates the codes used.
You can avoid writing the R parameter by giving the appropriate value to
the S parameter (see below).
Can be omitted.

S30 are the identifier and width in degrees of the angle between side U of the
figure to be nibbled and the positive X axis. Anti-clockwise rotation is
considered positive.
The S parameter is incompatible with the R parameter and will, therefore,
be ignored if the R parameter has been defined.
If omitted, S will be assumed to have half the value of the angle defined by
the T parameter.
T40 are the identifier and value of the width of the nibbling; cannot be more than
180° or less than the angle at the vertex of the punch programmed.
If omitted, T will be assumed to have the same value as the angle at the
vertex of the punch programmed.
U70 are the identifier and value of side U of the figure to be nibbled.
If omitted, U will be assumed to have the same value as the side of the
punch programmed (G parameter in the PUN instruction).

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 3. Programming the punching machine
3.4. Nibbling instructions

V0.5 are the identifier and value of the overlap between the punchings in the
nibbling operation. Used when nibbling with punches oriented in opposite
directions (see the Z parameter).
If omitted, V will be assumed to have a value of 0 if the punch is not
rounded, or the minimum to avoid having rough edges along the perimeter
of the nibbling if it is.
W1 are the identifier and distinctive number of the nibbling sequences; W1
indicates that nibbling is required from the base to the vertex of the triangle;
W2 that nibbling is required from the vertex to the base.
If omitted, W will be assumed to have a value of 1.
The nibbling sequence is only respected if the IST instruction is in a Zed
block (see Zed programming [} 209]) or if the SQM specifier (see Specifiers
and options [} 222]) is present.
Z1 are the identifier and code of the type of nibbling required. The following
are possible:
Z0 nibbling with the punch oriented in either the same direction as the
figure to be nibbled or the opposite direction: there will be no overhang on
side U, even if this means adding a row of punchings at the base of the
figure to be nibbled;
Z1 nibbling with the punch oriented in either the same direction as the
figure to be nibbled or the opposite direction: there may be some overhang
on side U;
Z2 nibbling with the punch oriented in the same direction as the figure to be
nibbled: there will be no overhang on side U;
Z3 nibbling with the punch oriented in either the same direction as the
figure to be nibbled or the opposite direction: there will be no overhang on
side U, even if this means adding a row of punchings at the base of the
figure to be nibbled; a double row of punchings in the same direction as the
figure to be nibbled will also be added at the vertex to prevent “steps” from
being created on the sides.
If omitted, Z will be assumed to have a value of 0 if an indexing tool is
being used (or 2 if it is not).

Figure 32: Triangular indexing punch in the zero position

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3. Programming the punching machine
3.4. Nibbling instructions

W1 type nibbling sequence W2 type nibbling sequence

Z1 type nibbling Z2 type nibbling

Figure 33: Examples of IST instructions with Z0, Z1, Z2 and Z3 made using the same punch

Figure 34: Examples of IST instructions with M0, M1, M2, M3 and M4

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 3. Programming the punching machine
3.4. Nibbling instructions

In addition to the parameters described above, the IST instruction will

also accept the J index and a number of specifiers (see Specifiers and
options [} 222]).

3.4.9. COR instruction - Triangular notching

If oblique nibbling is performed on the corners of the blank using the
REC instruction, the fact that a triangular piece of material is removed
may prevent some of the punchings from being optimized.
The COR instruction solves this problem because, unlike the REC
instruction which nibbles a rectangle, it only nibbles a triangle. It does
this using one or two rectangular punches.
The instruction has the following syntax:
COR: X0 Y1000 P31 P23 Q1 S0 U300 V200 W2 Z2
where:

X0 are the identifier and value of the X co-ordinate of the corner of the sheet
that is to be nibbled (in the current sheet reference system).
Y1000 are the identifier and value of the Y co-ordinate of the corner of the sheet
that is to be nibbled (in the current sheet reference system).
P31 are the identifier and number of the position of the nibbling punch to be
used for the finishing operation (which, in this case, consists of the
punchings on the hypotenuse of the triangle).
P23 are the identifier and number of the position of the punch used for the
rough punching operation.
If omitted, the nibbling punch will perform the rough punching operation
too.
Q1 are the identifier and number of the vertex of the punching as shown in
the figures below.
If omitted, Q will be assumed to have a value of 1.
S0 are the identifier and width in degrees of the angle between side U of the
figure to be nibbled and the positive X axis. Anti-clockwise rotation is
considered positive.
If omitted, S will be assumed to have a value of 0.
U300 are the identifier and length of the side of the triangle that is parallel to
side X of the sheet.
V200 are the identifier and length of the side of the triangle that is parallel to
side Y of the sheet.
W2 are the identifier and value of the amount by which the hypotenuse of the
nibbling triangle extends beyond the side of the sheet that is parallel to
the X axis. If you write W0, it will not extend beyond the edge of the
sheet.
If you omit W, it will be assumed to have a value of 3.
Z2 are the identifier and value of the amount by which the hypotenuse of the
nibbling triangle extends beyond the side of the sheet that is parallel to
the Y axis. If you write Z0, it will not extend beyond the edge of the sheet.
If you omit Z, it will be assumed to have a value of 3.

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3. Programming the punching machine
3.4. Nibbling instructions

Figure 35: Examples of using the COR instruction

Figure 36: Examples of using the COR instruction with the punch at a 45° angle

In addition to the parameters described above, the COR instruction will

also accept the J index and a number of specifiers (see Specifiers and
options [} 222]).

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 3. Programming the punching machine
3.5. Embossing instructions

3.5. Embossing instructions

3.5.1. Single embossing instructions

The instructions used for punchings can also be used for single
embossings. In particular, the XYP instruction can be used to program
an embossing in one point of the sheet and the STR, GRI and POL
instructions respectively to program single embossings along a straight
line, on a grid or along an arc.
It is important to specify the type of cycle required for each embossing
operation. The following embossing cycles are possible:

DR1: embossing cycle shown in figure A.

a) top die down
b) bottom punch up
c) bottom punch down
d) top die up again
DR2: embossing cycle shown in figure B.
a) top die down
b) bottom punch up
d) top die up again
c) bottom punch down
DR3: embossing cycle for downward embossings (only the top tool acts) shown in
figure C.
DR4: embossing cycle shown in figure D.
b) bottom punch up
a) top die down
c) bottom punch down
d) top die up again

Whether you choose cycles DR1, DR2, DR3 or DR4 will depend on the
form of the embossings you require and, therefore, the sequence of
operations you need.
The choice between cycles DR1 and DR2 can only be made by
experimenting with the tool to see how the blank behaves during the
embossing cycle and choosing the cycle that prevents the sheet from
catching on the tool.
For cycle DR3, the bottom press is not installed because the lower part
of the embossing tool is spring-loaded (i.e. does not have a cylinder).
The operation shown in figure C can, therefore, be performed by any
punching unit, provided that a suitable die is fitted, but to perform it with
an embossing unit, you must add DR3 to the instruction.
Cycle DR4 is used to make shallow upward draws that do not require
the use of the blankholder and need a force of roughly 7 tons (to
change the punching force, see the VAR instruction - Compilation
options [} 233]). Making the bottom punch ascend first means that less
force is required to make the top die descend than if the punch were to
ascend when the die was already down.

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3. Programming the punching machine
3.5. Embossing instructions

When making embossings more than 6.5 mm high, you must ensure
that they do not interfere with the tools during the machining cycle (this
would either misshape them or cause the panel to catch on the head).
Do this using manual programming which gives you direct control over
the movements of the manipulator and rotator (see Zed programming
[} 209]).
If you do not specify the type of embossing cycle you require, it will be
assumed to be DR3.

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 3. Programming the punching machine
3.5. Embossing instructions

A DR1 cycle C DR3 cycle

B DR2 cycle D DR4 cycle

Figure 37: Embossing cycles

3.5.2. KKO instruction - Knock-outs

The KKO instruction is used to program the tool sequence used to
make a knock-out type of embossing.
The instruction has the following syntax:

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3.5. Embossing instructions

KKO: X0 Y1000 tool_list

where:

X0 are the identifier and value of the X co-ordinate of the center of the
knock-out in the current sheet reference system.
Y1000 are the identifier and value of the Y co-ordinate of the center of the
knock-out in the current sheet reference system.
tool_lis is a list of the tools that must be used in the order given to make the
t knock-out. Each tool is programmed by writing the P identifier plus the
number of its position in the head. All the tools except the last (which
can be a planishing tool) must belong to family 14.

A KKO instruction is always performed in close sequence i.e. the

elementary operations in it cannot be divided by rotations,
repositionings or other punchings or embossings. This means that all
the tools listed must be able to reach the position programmed in the
same rotation of the sheet.

Figure 38: Examples of the KKO instruction

Example of the KKO instruction:

PUN: 14 P21 F45.6 G52.3 S87 T133 X26.2 Y-10.4 E1
PUN: 14 P22 F45.6 G52.3 S214 T112 Y38.9 E1
PUN: 2 P31 F107 E1
PUN: 14 P53 F37.7 E1
PUN: 14 P54 F45.6 G52.3 S320 T133 X-26.2 Y-10.4 E1
PUN: 14 P56 F31.4 E1

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 3. Programming the punching machine
3.5. Embossing instructions

KKO: X500 Y500 P56 P53 P54 P21 P22 P31

A P56 embossing D P21 embossing

B P53 embossing E P22 embossing
C P54 embossing F P31 planishing

In addition to the parameters described above, the KKO instruction will

also accept the J index and a number of specifiers (see Specifiers and
options [} 222]).

3.5.3. BBG, ARC, SEG and BND instructions - Continuous

embossing
Continuous embossing means forming the sheet by moving it as
appropriate with an embossing tool in the down position.
The tools used for continuous embossing belong to family 16 and can
be used for ribbing, offsetting or engraving.
The continuous embossing instructions describe the tool path as a
series of segments and arcs.
The BBG instruction defines the beginning of the continuous
embossing, a series of SEG and ARC instructions describes its path
and the BND instruction indicates its end.

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3.5. Embossing instructions

Programming the beginning of a continuous embossing

The BBG instruction has the following syntax:
BBG: X0 Y1000 P36 S1
where:

X0 are the identifier and value of the X co-ordinate of the beginning of the
embossing in the current sheet reference system.
Y1000 are the identifier and value of the Y co-ordinate of the beginning of the
embossing in the current sheet reference system.
P36 are the identifier and number of the position that the tool to be used
occupies in the head.
S1 are the identifier and code of the orientation of the tool at the
beginning of the embossing; the following codes are used: S0 if the
tool has to be oriented in the same direction as the trajectory, S1 if it
does not.
This information is only relevant for offsetting tools.
If omitted, S will be assumed to have a value of 0.

Programming a straight section of continuous embossing

The SEG instruction has the following syntax:
SEG: X0 Y1000 V50 A100 D100 B50
where:

X0 are the identifier and value of the X co-ordinate of the end of the
segment in the current sheet reference system.
Y1000 are the identifier and value of the Y co-ordinate of the end of the
segment in the current sheet reference system.
V50 are the identifier and value of the speed at which the straight section is
machined, expressed in mm/sec.
A100 are the identifier and value of the acceleration required to increase the
speed, expressed in mm/(sec*sec).
D100 are the identifier and value of the braking required to decrease the
speed, expressed in mm/(sec*sec).
B50 are the identifier and value of the dimension of the embossing
perpendicular to the trajectory of the tool: if this value is positive, the
embossing will extend to the right of the trajectory (as seen from the
direction in which the embossing is being made).
This information is used to determine the areas of the sheet near to the
continuous embossing in which the clamping devices will be unable to
descend. It is solely relevant for offsetting tools (since only the
dimension given by the G parameter in the corresponding PUN
instruction is considered for ribbing tools, whilst there is no risk of
flattening engravings).
If omitted, B will be assumed to have a value of 0.

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3.5. Embossing instructions

A PUNCH E S4 head
B DIE F Workpiece
C FORMING PRODUCED G Manipulator
d B parameter

If the continuous embossing tool defined in the following instruction:

PUN: 16 P36 F10 G3 R100 S90 E9
descends at 0, it will produce a forming on the right (as shown above).

Programming a circular section of continuous embossing

The ARC instruction has the following syntax:
ARC: X500 Y400 I550 J450 S1 V50 A100 D100 B50
where:

X500 are the identifier and value of the X co-ordinate of the end of the arc in
the current sheet reference system.
Y400 are the identifier and value of the Y co-ordinate of the end of the arc in
the current sheet reference system.
I550 are the identifier and value of the X co-ordinate of the center of the circle
to which the arc belongs in the current sheet reference system.

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3.5. Embossing instructions

J450 are the identifier and value of the Y co-ordinate of the center of the circle
to which the arc belongs in the current sheet reference system.
S1 are the identifier and code of the direction in which the arc is made: S1
means clockwise, S0 anti-clockwise.
V50 are the identifier and value of the speed at which the circular section is
machined, expressed in mm/sec.
A100 are the identifier and value of the acceleration required to increase the
speed, expressed in mm/(sec*sec).
D100 are the identifier and value of the braking required to decrease the
speed, expressed in mm/(sec*sec).
B50 are the identifier and value of the dimension of the embossing
perpendicular to the trajectory of the tool: if this value is positive, the
embossing will extend to the right of the trajectory (as seen from the
direction in which the embossing is being made).
This information is used to determine the areas of the sheet near to the
continuous embossing in which the clamping devices will be unable to
descend. It is solely relevant for offsetting tools (since only the
dimension given by the G parameter in the corresponding PUN
instruction is considered for ribbing tools, whilst there is no risk of
flattening engravings).
If omitted, B will be assumed to have a value of 0.

Programming the end of a continuous embossing

The BND instruction has the following syntax:
BND
Circular sections of continuous embossing can only be made if an
indexing tool has been programmed and the axis controller offers
interpolation. Otherwise, only straight sections can be made.
SDEX checks that the continuity of the trajectory, the continuity of the
tangent to the trajectory and the minimum radius (the R parameter in
the definition of the tool) in the case of a circular trajectory are
respected.
Continuous embossing is always performed in close sequence i.e. the
path cannot be interrupted by rotations, repositionings or other
punchings or embossings. This means that it must be possible to reach
the entire path in the same rotation of the sheet.
The V, A and D parameters in the SEG and ARC instructions must be
adjusted by experiment. The data given in the example below can be
used as a starting point.

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 3. Programming the punching machine
3.5. Embossing instructions

Programming a continuous embossing that starts at point P:

BBG: X100 Y200 P36
SEG: X100 Y300 V100
ARC: X200 Y400 I200 J300 S1 V100
SEG: X800 Y400 V100
ARC: X900 Y300 I800 J300 S1 V100
SEG: X900 Y200 V100
ARC: X800 Y100 I800 J200 S1 V100
SEG: X200 Y100 V100
ARC: X100 Y200 I200 J200 S1 V100
BND
In addition to the parameters described above, the BBG instruction will
also accept the J index and a number of specifiers (see Specifiers and
options [} 222]) as well as the DR1 instruction.

3.5.4. WRI instruction - Writing a string of characters

The WRI instruction is used to write a programmed string of characters
on the blank using marking or other punches.

Writing with marking punches (family 15)

The instruction has the following syntax:
WRI: X200 Y1000 S0 I1.2 M0 “part_number”
where:

X200 are the identifier and value of the X co-ordinate of the center of the
writing in the current sheet reference system.
Y1000 are the identifier and value of the Y co-ordinate of the center of the
writing in the current sheet reference system.
S0 are the identifier and width in degrees of the angle between the
writing and the positive X axis.
The following values will be accepted: 0, 90, 180 and 270.
If omitted, S will be assumed to have a value of 0.

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3.5. Embossing instructions

I1.2 are the identifier and value of the distance between two
consecutive characters.
If omitted, I will be assumed to have a value of 1.2.
M0 are the identifier and code of the punching machine that is to do
the writing. This is only relevant for S4 tandem systems. The code
is as follows: M0 for the first punching machine, M1 for the
second.
If omitted, M will be assumed to have a value of 0 (i.e. the first
punching machine).
part_number is the string to be written on the blank.

If you do not specify the punches to be used, SDEX will look among all
the family 15 punches for the marking punch that corresponds to each
of the characters to be written.
The writing will be done at the angle S programmed, unless this is not
feasible, in which case its feasibility will be checked first at +180° and
then at +90° and +270°.

Writing with rectangular embossing tools or punches

If you want to use rectangular markers or punches, you must also
specify the position that the type of tool to be used occupies in the
head.
In this case, the instruction will have the following syntax:
WRI: X200 Y1000 P31 S0 I1.2 M0 “part_number”
where:

X200 as above
Y1000 as above
P31 are the identifier and number of the position of the punch or marker
that can be used.
S0 as above
I1.2 are the identifier and value of the distance between two
consecutive characters.
If omitted, I will be assumed to be equal to the long side of the
punch plus five times the short side.
M0 as above
part_numbe as above
r

E6 embossers are used to write on the underneath of the sheet.

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 3. Programming the punching machine
3.6. Defining the parts to be produced

Figure 39: Characters written with E5 tools

Figure 40: Characters written with E6 tools

In addition to the parameters described above, the WRI instruction will

also accept the J index and a number of specifiers (see Specifiers and
options [} 222]).

3.6. Defining the parts to be produced

If the punching machine has the shear, the starting sheet can be sub-
divided into a number of parts.
The instructions described below are used to define the parts to be
obtained from the starting sheet.
SDEX checks that the entire starting sheet is covered. One rectangular
portion may be left. This means that you do not have to define a single
part (when the sheet is not sheared).
None of the parts defined in the program can overlap another part.

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3. Programming the punching machine
3.6. Defining the parts to be produced

3.6.1. PIE instruction - Defining a grid of rectangular parts

The PIE instruction is used to define a grid at right angles to the XY
axes of the current sheet reference system.

Programming a grid of six 250 x 200 mm parts

PIE: X300 Y200 U250 V200 X3 Y2

The PIE instruction has the following syntax:

PIE: “code” X0 Y0 U200 V100 R0 X2 Y3 A50 D30 W60 ZA
10 ZP 50 RA 10 RP 20 M1
where:

code is a string of characters (max. 255) associated with the sheared part:
- if the punching machine is working in line with a bending machine, the
string must also contain the bending program for the Panel Bender.
For example: “code.p4”
“group\code.p4”
- if the part is to be placed in the store, the string is as follows:
“group\code.p4/destack1”
Any other information can be managed in the personalization of the
system.
Can be omitted.
X0 are the identifier and value of the X co-ordinate of vertex P (see the
above figure) in the current sheet reference system.
Y0 are the identifier and value of the Y co-ordinate of vertex P (see the
figure above) in the current sheet reference system.
U200 are the identifier and value of side X of the single part.
V100 are the identifier and value of side Y of the single part.
R0 are the identifier and value of the rotation of the part (in degrees) with
respect to a reference program for the individual part; this information is
used downstream of the punching machine when handling parts that are
identical but have been rotated by multiples of 90°. R can have the
following values: 0, 90, 180 and 270.
If omitted, R will be assumed to have a value of 0.

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3.6. Defining the parts to be produced

X2 are the identifier and value of the number of parts along X.

If omitted, X will be assumed to have a value of 1.
Y3 are the identifier and value of the number of parts along Y.
If omitted, Y will be assumed to have a value of 1.
A50 are the identifier and value of the distance required between the rear
diverter and the theoretical edge of the sheet when the part starts to
pass between the diverters; it will be ignored if it is less than the waiting
distance calculated.
If omitted, A will be assumed to have a value of 0.
D30 are the identifier and value of the distance required between the front
diverter and the theoretical edge of the sheet when the part starts to
pass between the diverters; it will be ignored if it is less than the waiting
distance calculated.
If omitted, D will be assumed to have a value of 0.

A Manipulator E Part to be unloaded

B Front diverter f D position programmed
C Rear diverter g A position programmed
D Shear

W60 are the identifier and value of the correction of the final position of the
diverters: used to center the part with respect to the system downstream.
A positive value moves the part nearer to the manipulator, a negative
value moves it further away from it. If the punching machine does not
have a conveyor (i.e. it belongs to an SP4 system or is the first punching
machine in an S4 tandem system), the W parameter indicates the
correction along Y of the position in which the sheet is unloaded.
If omitted, W will be assumed to have a value of 0.
ZA 10 are the identifier and value of the Y position of the front magnetic transfer
in the reference system of the part to be stacked.
If omitted, ZA will be assumed to have a value of 0 and the position of the
front magnetic transfer will be calculated automatically.
This information is only relevant if the IA stacker is present downstream of
the punching machine.
ZP 50 are the identifier and value of the Y position of the rear magnetic transfer
in the reference system of the part to be stacked.
If omitted, ZP will be assumed to have a value of 0 and the position of the
rear magnetic transfer will be calculated automatically.
This information is only relevant if the IA stacker is present downstream of
the punching machine.

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3. Programming the punching machine
3.6. Defining the parts to be produced

A Manipulator D Side of part used for reference

B Shear E Axis of front transfer
C Part to be stacked F Axis of rear transfer

Figure 41: ZA and ZP determine the positions of the axes of the magnetic transfers with
respect to the side of the part to be stacked that is used for reference (i.e. the manipula-
tor side)

RA 10 are the identifier and value of the correction to the position of the device for
positioning the front rollers.
If omitted, RA will be assumed to have a value of 0.
RP 20 are the identifier and value of the correction to the position of the device for
positioning the rear rollers.
If omitted, RP will be assumed to have a value of 0.
M1 are the identifier and code of the punching machine that is to cut the part (if
necessary) and unload it. This is only relevant for S4 tandem systems. The
code is as follows: M0 for the first punching machine, M1 for the second.
If omitted, M will be assumed to have a value of 1 (i.e. the second punching
machine).

In addition to the parameters described above, the PIE instruction will

also accept the J index and a number of specifiers (see Specifiers and
options [} 222]).

CRT: defining the way in which the Cartesian

manipulator grips the part
The PIE, PPR and ZEX instructions (see ZEX instruction - Information
about a detached part [} 213]) have been integrated with the CRT sub-
instruction described below:
It is used to define the way in which the Cartesian manipulator grips the
part.
It has the following syntax:
CRT: XA nn YA nn SA nn GA "grip code" XB nn YB nn SB
nn GB "grip code " MNP n R n
where:

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XA is the X coordinate of the centre of gripping for the first manipulator.

YA is the Y coordinate of the centre of gripping for the first manipulator.
SA is the angle of gripping for the first manipulator.
GA is the code that identifies the group of suction cups used for gripping on the
first manipulator.
XB is the X coordinate of the centre of gripping for the second manipulator.
YB is the Y coordinate of the centre of gripping for the second manipulator.
SB is the angle of gripping for the second manipulator.
GB is the code that identifies the group of suction cups used for gripping on the
second manipulator.
MNP is the “preferred manipulator” parameter:
- manipulator 1 is preferred;
- manipulator 2 is preferred;
- use of both manipulators is preferred.
R is the rotation of the part for which the grips specified are valid (it is
optional: if it is equal to 0, the grips are valid for all the rotations of the part).

Example: (the sub-instructions are programmed as a continuation of

the main instruction using the & character):
PIE:…
&CRT: XA 100 YA 200 SA 90 GA "1-3-5-12" XB 200 YB300
SB 123.111 GB "2-5-10" MNP 3 R 0

3.6.2. PPR instruction - Defining a non-rectangular part

The PPR instruction is used to define a non-rectangular part.
Non-rectangular parts must be defined by segments parallel to the x
and y axes of the sheet reference system.

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The direction of the segments must be such that the full part of each
segment is on the right.
PPR: X100 Y50 X100 Y300 X300 Y300 X300 Y450 X600 Y450
X600 Y50 X450 Y50
& X450 Y200 X300 Y200 X300 Y50 X100 Y50
& X400 Y300 X400 Y400 X550 Y400 X500 Y300 X400 Y300

The PPR instruction has the following syntax:

PPR: “code” xy_list R0 A50 W60 ZA 10 ZP 50 RA 10 RP
20 M1
where:

code is the code of the sheared part (see the PIE instruction).
xy_list is a list of pairs of X and Y co-ordinates which identify the vertexes of
the part in the current sheet reference system (see the figure above).
Since a part may contain holes inside which other parts can be
arranged, the list of vertexes must be written in the correct order and the
description of each outline will be considered to end when a pair of co-
ordinates is found to be identical to that at the beginning of the outline.
The figure above describes a part with a hole.
R0 are the identifier and value of the rotation of the part (see the PIE
instruction).
A50 are the identifier and value of the position of the rear diverter (see the
PIE instruction).
W60 are the identifier and value of the correction of the final position of the
diverters (see the PIE instruction).
ZA 10 are the identifier and value of the Y position of the front magnetic
transfer (see the PIE instruction).
ZP 50 are the identifier and value of the Y position of the rear magnetic
transfer (see the PIE instruction).
RA 10 are the identifier and value of the correction to the position of the device
for positioning the front rollers.
If omitted, RA will be assumed to have a value of 0.
RP 20 are the identifier and value of the correction to the position of the device
for positioning the rear rollers.
If omitted, RP will be assumed to have a value of 0.
M1 are the identifier and code of the punching machine (see the PIE
instruction).

Sheets that are completely covered by rectangular parts cut with the
sheet at the same angle of rotation can always be processed i.e. it will
always be possible to find a machining sequence that allows each part
to be cut without the blades interfering with the parts that adjoin it.
If, however, the parts are not rectangular, the requirements are slightly
more stringent. In fact, to be able to process such sheets, not only must
there be no sheet coverage or overlap problems, but it must also be
possible to cut and unload each part.

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A part can be cut if it is possible to find an unloading sequence in which

the cuts required to unload the part do not affect any other parts.
To allow you to cut a part, you may need to add suitable nibbling
operations with the dual purpose of covering portions of the starting
sheet and putting more space between the good parts so that you can
cut them. These nibbling operations must be defined as REC's with the
SFR or SFP specifier.

A Manipulator B Shear

This cutting plan is only possible if parts 2 and 4 are nibbling operations,
since they cannot be cut. Part 3 can be cut if the sum of x dimensions of
parts 3 and 4 is bigger than the length of x shear blade.
A part can be unloaded if, once the part has been detached from the
sheet, it is possible to free the area of the conveyor without the sheet
interfering with the part that has been detached. The y or x manipulator
may need to be disengaged to do this.

A Manipulator B Shear

This cutting plan is only possible if parts 2 and 4 are nibbling operations,
since they cannot be cut. Part 3 can only be unloaded if it has the DWN
specifier i.e. can be unloaded through the hatch underneath the shear.
In addition to the parameters described above, the PPR instruction will
also accept the J index and a number of specifiers (see Specifiers and
options [} 222]).

3.6.3. BRS instruction - Nibbling the holding scrap

If the program contains the VAR: T0 option (see VAR instruction -
Compilation options [} 233]), SDEX will assume that holding scrap is
present. You do not have to define the part called “holding scrap”
because its dimensions will be derived from the non-programmed part
of the starting sheet. The holding scrap must run along the top of the y
axis in the sheet reference system (where the highest values of y are),
because it must be divided (i.e. punched) at 0° and unloaded at 180°.

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The y dimension of the holding scrap must usually be between 28 mm

(which is the distance between the x blade and the edge of the sheet
when the manipulator is in the y position nearest to the operating head)
and 50 mm (which is the maximum y dimension that can be unloaded
through the holding-scrap hatch). The x dimension of the holding scrap
must be the same as the x dimension of the trimmed sheet.

A Manipulator C Operating head

B Holding-scrap hatch D Shear

Even if the x dimension of the holding-scrap hatch is approximately

1600 mm, the maximum x dimension of each portion of holding scrap
cannot generally be more than 400 mm because the conveyor that
removes this scrap would not be able to handle it.
SDEX automatically calculates the punchings needed to divide the
holding scrap; the various portions of holding scrap are unloaded while
the cuts next to the holding scrap are being made, while the blank is
being repositioned and when it has been processed.
If you want there to be notches to divide the holding scrap, use the
punching and/or nibbling instructions that we have already described or
the BRS instruction, with which it is very easy to define the punchings
you require.

To sub-divide the sheet as shown above, add the following instruction:

BRS: X300 U100 X600 U50 X900 U50 X1200 U50

The BRS instruction has the following syntax:

BRS: xu_list LSTnnn

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where:

xu_list is a list of pairs of X and U parameters (see the figure above), where X is
the x co-ordinate of the start of the notch in the current sheet reference
system and U is the x dimension of the notch.
LST automatically nibbles the last part of the holding scrap.
LSTnnn nibbles the last “nnn” mm/inches of the holding scrap.

The advantages of using the BRS instruction instead of a series of REC

instructions are that the language is compact and there is no need to
specify the y position of the notch.

3.7. Trimming the sheet

3.7.1. TRI instruction - Trimming one or more sides of the

sheet
The TRI instruction is used to trim one or more sides of the blank or
reduce the dimensions of the starting sheet, because there is no limit to
the maximum value that can be given to the F, G, U and V identifiers.
The instruction has the following form:
TRI: F350 G250 U250 V150 P5
where:

F350 are the identifier and width of strip F to be cut along the side marked 1;
omitted if this side does not require trimming.
G250 are the identifier and width of strip G to be cut along the side marked 3;
omitted if this side does not require trimming.
U250 are the identifier and width of strip U to be cut along the side marked 2;
omitted if this side does not require trimming.
V150 are the identifier and width of strip V to be cut along the side marked 4;
omitted if this side does not require trimming.
P5 are the identifier and number of the position of the rectangular punch used
to nibble the zones that the shear blades cannot reach (or to perform all the
trimming, if the NOC specifier is present). Usually omitted, in which case
the most suitable rectangular punch from among all those declared in the
PUN instruction will be chosen automatically.

When using the TRI instruction, the dimensions you give the X and Y
identifiers in the DIM instruction must be those of the sheet after it has
been trimmed. The axes of the sheet reference system will remain the
same as the sides of the trimmed sheet as shown in the figure below.

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When trimming the sheet with the shear, the width of the strips of
material to be removed must be three times the thickness. These strips
will automatically be divided into small rectangles and unloaded
beneath the shear into the scrap collection bin.

Special specifiers for the TRI instruction

NOC
The TRI instruction will accept the NOC specifier, in which case all the
sides specified in the instruction will be sheared using a punch rather
than the shear. The NOC specifier applies to all the sides specified in
the TRI instruction: if you do not want all of them to be trimmed using a
punch, you will have to write at least two TRI instructions.
NBX and NBY
The TRI instruction accepts the NBX and NBY specifiers; with these
specifiers, trim-cuts are performed without using the shear’s X or Y
blankholders.

3.8. Composite instructions

3.8.1. BLC, EBL and CBL instructions - Managing blocks of

instructions
A certain number of punchings may need to be repeated with the same
configuration in different parts of the sheet.
The lines of program that define this group of punchings (block) must be
contained between a first line with the BLC instruction and a last line
with the EBL instruction.

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Programming the beginning of a block

The BLC instruction has the following syntax:
BLC: 2 X0 Y1000 S0
where:

2 is the code of the block (it must be a whole number above 0 and below
32000).
X0 are the identifier and value of the X co-ordinate of the origin of the block
reference system in terms of the current sheet reference system.
Y1000 are the identifier and value of the Y co-ordinate of the origin of the block
reference system in terms of the current sheet reference system.
S0 are the identifier and code of the type of block declaration: S0 means that
the corresponding punches will be generated, S1 that the block will be
memorized but the corresponding punchings will not be generated.
If omitted, S will be assumed to have a value of 0.

Programming the end of a block

The EBL instruction has the following syntax:
EBL
The punchings in the block can be generated when it is defined and
subsequently called up using the CBL instruction.

Programming the repetition of a block

The CBL instruction has the following syntax:
CBL: 2 X0 Y1000
where:

2 is the code of the block (which must, of course, already have been
defined by the BLC and EBL instructions).
X0 are the identifier and value of the X co-ordinate (in the current sheet
reference system) of the point to which the block is moved.
Y1000 are the identifier and value of the Y co-ordinate (in the current sheet
reference system) of the point to which the block is moved.

There is no point in defining a block with S1 (i.e. memorizing the block

without generating the punchings) if you do not write a CBL instruction
to recall it.
Consider the following example:
BLC: 1 X300 Y200
XYP: X0 Y0 P12
XYP: X100 Y0 P16
EBL
The co-ordinates of the punchings in the block must be given in terms of
the block reference system.

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All the instructions available can be used in the block.

One block can contain other blocks, provided that there are no more
than six levels of nesting in all.
Example of nesting blocks:

BLC: 1 X100 Y200 ;nesting level 1

BLC: 2 X100 Y200 ;nesting level 2
EBL ;return to level 1
BLC: 3 X100 Y200 ;nesting level 2
BLC: 4 X100 Y200 ;nesting level 3
EBL ;return to level 2
EBL ;return to level 1
EBL ;return to level 0 (leave the block)

The blocks can be defined in any order i.e. they do not need to be
numbered in ascending order when the program is written. The EBL
instruction automatically restores the reference system to the position
given by the last REF instruction (see the chapter on the REF
instruction) written before the BLC block was defined or, if there is no
REF instruction, to the position with co-ordinates of X=0, Y=0 i.e. the
sheet reference system.

3.8.2. NET and ENT instructions - Repeating a block of

instructions on an orthogonal grid
When a block of punchings is repeated a number of times on the same
sheet and the block reference system lies on the nodes of a regular
orthogonal grid, it is not practical to use the CBL instruction to call up
the block because you would have to repeat it as many times as there
are blocks.

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In such cases, you can use the NET ... ENT instruction instead of the
BLC, EBL, CBL sequence.

Programming the beginning of the block

The NET instruction has the following syntax:
NET: X100 Y130 U200 V260 W4 Z2
where:

X100 are the identifier and value of the X co-ordinate of the origin of the block
reference system in terms of the current sheet reference system.
Y130 are the identifier and value of the Y co-ordinate of the origin of the block
reference system in terms of the current sheet reference system.
U200 are the identifier and value of the pitch from one block to the next along
the X axis.
V260 are the identifier and value of the pitch from one block to the next along
the Y axis.
W4 are the identifier and number of repetitions along the X axis.
Z2 are the identifier and number of repetitions along the Y axis.

Programming the end of the block

The ENT instruction has the following syntax:
ENT
In the following example:
NET : X100 Y130 U200 V260 W4 Z2
XYP: X0 Y0 P3
XYP: X-50 Y50 P4
XYP: X50 Y-50
ENT
the block of punchings contained between the NET and ENT
instructions is given in terms of the reference system which originates at
the point with co-ordinates of (100,130) in the current sheet reference
system.
This block is first repeated 4 times along X and then another 4 times
along X (with different Y co-ordinates) for a total of 2 repetitions.

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Other NET...ENT instructions can be written between the NET and ENT
instructions, up to a maximum of 3 levels of nesting.
Example of nesting NET blocks:

NET: X0 Y0 U400 V400 W2 Z2 ;nesting level 1

NET: X0 Y0 U200 V200 W2 Z2 ;nesting level 2
ENT ;return to level 1
NET: X200 Y0 U200 V200 W2 Z2 ;nesting level 2
NET: X0 Y100 U100 V100 W2 Z2 ;nesting level 3
ENT ;return to level 2
ENT ;return to level 1
ENT ;return to level 0 (leave the block)

Special specifiers for the NET instruction

The NET instruction will accept the PAC specifier which automatically
adds a J index (see Specifiers and options [} 222]) to all the instructions
in the NET..ENT block.
In view of the meaning of the J index, this specifier is only relevant if a
part is defined in the NET...ENT block (see the paragraphs on the PIE
or PPR instructions).

3.8.3. SIM and ESM instructions - Repeating a block of

instructions symmetrically
You will often need to repeat blocks of punchings symmetrically with
respect to X and/or Y or to produce panels that have reverse symmetry
with respect to X or Y.

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The SIM and ESM instructions are used to repeat a block of punchings
symmetrically.

PUN: 2 P20 F50 G20

SIM: X1000
XYP: X70 Y50 P20
XYP: X120 Y100 P20
XYP: X70 Y150 P20
ESM

Programming the beginning of the block that is to be

repeated symmetrically
The SIM instruction has the following syntax:
SIM: X100 Y130 U200 V260 S1
where:

X100 are the identifier and value of the X co-ordinate of the symmetry
operation in the current sheet reference system; if only the X parameter
is present, the block will be repeated symmetrically with respect to a
straight line drawn parallel to the Y axis through X=100 (symmetry
around an axis), if the Y parameter is present too, the block will be
repeated symmetrically with respect to a point with co-ordinates of X,Y
(symmetry around a point).
Y130 are the identifier and value of the Y co-ordinate of the symmetry
operation in the current sheet reference system; if only the Y parameter
is present, the block will be repeated symmetrically with respect to a
straight line drawn parallel to the X axis through Y=130 (symmetry
around an axis), if the X parameter is present too, the block will be
repeated symmetrically with respect to a point with co-ordinates of X,Y
(symmetry around a point).
U200 are the identifier and value of the translation along X of the punchings
that are to be repeated symmetrically.
If omitted, U will be assumed to have a value of 0.

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PUN: 2 P20 F50 G20

SIM: X1000 U-1000
XYP: X70 Y50 P20
XYP: X120 Y100 P20
XYP: X70 Y150 P20
ESM

V260 are the identifier and value of the translation along Y of the punchings
that are to be repeated symmetrically.
If omitted, V will be assumed to have a value of 0.
S1 are the identifier and code of the type of execution required: S0
indicates that both the specified and the symmetrical punchings must be
made; S1 that only the symmetrical, but not the specified, punchings
must be made and S2 that only the specified, but not the symmetrical,
punchings must be made (in which case the SIM instruction is
superfluous: S2 is only of use with parametric programming).
If omitted, S will be assumed to have a value of 0.

Programming the end of the block that is to be repeated

symmetrically
The ESM instruction has the following syntax:
ESM
Consider the following example:

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If the punches are installed in positions 1 and 2, the two punchings in

the bottom left-hand corner will be programmed as follows:
XYP: X50 Y50 P1
XYP: X100 Y80 P2

If you write:
SIM:X350
XYP: X50 Y50 P1
XYP: X100 Y80 P2
ESM
SDEX will automatically calculate the co-ordinates not only of the first
two punchings but also of the two punchings in the bottom right-hand
corner that are symmetrical to the first two punchings with respect to the
axis X=350.

If you write:
SIM:Y250
XYP: X50 Y50 P1
XYP: X100 Y80 P2
ESM
SDEX will automatically calculate the co-ordinates not only of the first
two punchings but also of the two punchings in the top left-hand corner
that are symmetrical to the first two punchings with respect to the axis
Y=250.

Lastly, if you write:

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SIM:Y250 SIM:Y500/2
SIM:X350 SIM:X700/2
XYP: X50 Y50 P1 XYP: X50 Y50 P1
XYP: X100 Y80 P2 XYP: X100 Y80 P2
ESM ESM
ESM ESM
(a) (b)

SDEX will automatically calculate the co-ordinates of all the punchings

shown in the figure.
Examples (a) and (b) have the same effect. Example (b) underlines the
fact that the punchings are repeated symmetrically with respect to the
center-lines of the sheet.
If, instead, the drawing only showed the punchings in the bottom left-
and top right-hand corners, you would write:
SIM:X350 Y250
XYP: X50 Y50 P1
XYP: X100 Y80 P2
ESM

In other words, you would repeat the punchings symmetrically with

respect to the point with co-ordinates of X=350, Y=250.
Each SIM instruction must be followed by an ESM instruction.
Other SIM...ESM instructions can be written between the SIM and ESM
instructions, up to a maximum of 6 levels of nesting.
Example of nesting SIM blocks:

SIM: X1000 ;nesting level 1

SIM: Y500 ;nesting level 2
ESM ;return to level 1
SIM: X500 ;nesting level 2
SIM: X200 ;nesting level 3
ESM ;return to level 2
ESM ;return to level 1
ESM return to level 0 (leave the block)

Whether each punching can be repeated symmetrically will depend on

the figures of the punches used in it. If these cannot be repeated
symmetrically, SDEX will give an error.
A punching will be repeated symmetrically as long as its figure can be
reflected around an axis. A concave-convex punch with parameters of T
# 0 or H # I cannot be repeated symmetrically. A single punching with
such a punch would therefore produce an error (but a RIS or RES
nibbling operation with it could be repeated symmetrically).

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When repeating symmetrically punchings made using special punches

with an unknown cutting figure, it is important to define the punch
correctly, bearing in mind that the X axis of the punch reference system
will be used as the axis of symmetry.
All the instructions in the S4 programming language (with the exception
of INK, PIE and PPR) can be written between the SIM and ESM
instructions.
Here is an example of a panel with reverse (i.e. mirror-image)
symmetry:

COD: “SPECULARE”
DIM: X2000 Y1000 S1
PUN: 2 P20 F50 G20
BLC: 1 S1
XYP: X70 Y50 P20
XYP: X120 Y100 P20
XYP: X70 Y150 P20
EBL
; part at the bottom
CBL: 1 X0 Y0
; part at the top
SIM: X2000 U-2000 S1
CBL: 1 X0 Y500
ESM
PIE: X0 Y0 U2000 V500 Y2
END

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3.8.4. Specifying the order in which two or more instructions

are performed
When SDEX generates the punching program for the machine, it
normally rearranges the instructions written by the operator in order to
optimize the path of the manipulator. If two or more punching
instructions need to be performed one after the other in a particular
order, the SEQ instruction must be used to indicate the beginning of the
sequence and the ESQ instruction to indicate its end.

Programming the beginning of the block that is to be

performed in a given order
The SEQ instruction has the following syntax:
SEQ: S0
where:

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S0 are the identifier and code of the type of sequence required.

S0 indicates that all the instructions in the SEQ-ESQ block must be
performed in the order given but that other punchings, repositionings
and/or rotations may be made between the operations that these
instructions produce.
S1 indicates that all the instructions in the block must be performed in
the order given without being interrupted by other punchings,
repositionings and/or rotations.
S2 has the same effect as S0 if the O22 compilation option is present
(see the paragraph VAR instruction - Compilation options [} 233]);
otherwise it will be ignored (and the block of instructions will be
performed in any order).
S3 indicates that the instructions between one SEQ and instruction and
the next (which must have S4) belong to the same step in the sequence
i.e. can be made in any order as long as they are performed before the
next step; a SEQ: S3 instruction can be followed by an ESQ instruction
but there is no point in this.
S4 indicates the beginning of a new step in the sequence i.e. a SEQ: S4
instruction can be preceded by a SEQ: S3 or a SEQ: S4 instruction.
S5 defines a narrow sequence, similar to S1, which allows the strokes to
be performed simultaneously (multiple punching) if the manipulator does
not move between one stroke and the next.
Example:
SEQ: S5
XYP: X100 Y100 P1
XYP: X100 Y155 P2
XYP: X100 Y210 P3
ESQ
S6 defines a sequence of machinings to be performed before a part is
cut.
All the operations in an S6 type sequence are performed in the order
programmed and immediately before the part they are on is cut (this is
an alternative to, and expansion of, O56 PCT for embossings made
before a cut).
S7 defines a sequence of machinings to be performed before the sheet
is rotated.
It can be used as a single sequence, or as a sequence of steps to be
performed before the sheet is rotated.
It is typically used to delay, as much as possible, machinings that could
weaken the sheet, or to produce dangerous formings by making them
just before the sheet is rotated or terminated. It differs from the S0 S1
S3 S4 S5 S6 sequences in that it avoids adding the extra rotations that
would normally be generated to respect the sequence.
If omitted, S will be assumed to have a value of 0 and the instruction
can simply be written as SEQ (without the “:”).

Programming the end of the block that is to be performed in

a given order
The ESQ instruction has the following syntax:
ESQ

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Several SEQ ... ESQ instructions can be written in an S4 program. All

the punching instructions in the S4 programming language can be
written between the SEQ and ESQ instructions.
When the SEQ: S0 block of instructions is made, the various
instructions in it will be performed in the order in which they are written,
but if one instruction gives rise to a number of elementary operations,
these will be performed in any order. To force these operations to be
performed in a particular order, write the SQM specifier (see Specifiers
and options [} 222]) in the instruction concerned.
In the following example, an embossing by the punch in position 5 is
made after a hole by the punch in position 1 at each of the following
points: (50,50), (950,50), (500,450).

A Embossing B Hole

The program will contain the following instructions:

SIM:X500
SEQ
XYP: X50 Y50 P1
XYP: X50 Y50 P5 DR1
ESQ
ESM
SEQ
XYP: X500 Y450 P1
XYP: X500 Y450 P5 DR1
ESQ

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As far as possible, it helps if the co-ordinates of the instructions written

between the SEQ and ESQ instructions are fairly near to one another
so that the cycle time is not increased by unnecessary movements of
the manipulator.
In this example, the sequence (P1, P5) will be used for each of the
three points programmed. The three sequences (P1, P5) will be
performed in whichever order optimizes the path of the manipulator. If
you want the sequences to be performed in a particular order, write:
SEQ
SIM:X500
XYP: X50 Y50 P1
XYP: X50 Y50 P5 DR1
ESM
XYP: X500 Y450 P1
XYP: X500 Y450 P5 DR1
ESQ

Remember that the O12 and O13 compilation options (see VAR
instruction - Compilation options [} 233]) can be used to automatically
establish the sequence in the case of embossings and punchings that
would otherwise interfere with one another.
Here is an example of a step-by-step sequence for the panel described
above with tall embossings. The punchings are made first (in any order)
and then the embossings in the following order: that at (50,50) followed
by that at (500,450) and then that at (950,50).
The program will be written as follows:
SEQ: S3
XYP: X50 Y50 P1
XYP: X950 Y50 P1
XYP: X500 Y450 P1
SEQ: S4
XYP: X50 Y50 P5 DR1
SEQ: S4
XYP: X500 Y450 P5 DR1
SEQ: S4
XYP: X950 Y50 P5 DR1
ESQ

3.8.5. REF instruction - Defining a new reference system

Sometimes all or some of the dimensions on the drawing of the sheet to
be punched are given with reference to orthogonal axes that do not
coincide with those of the conventional sheet reference system.
The REF instruction is used to apply a new reference system.
The REF instruction has the following syntax:
REF: X100 Y100 S90

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where:

X100 are the identifier and value of the X co-ordinate of the origin of the new
system with reference to the sheet reference system.
If omitted, the X co-ordinate of the origin of the new reference system will
be the same as that of the old one.
Y100 are the identifier and value of the Y co-ordinate of the origin of the new
system with reference to the sheet reference system.
If omitted, the Y co-ordinate of the origin of the new reference system will
be the same as that of the old one.
S90 are the identifier and value of the angle of rotation of the new system with
reference to the sheet reference system. It must be a multiple of 90° and
is measured anti-clockwise.
If omitted, S will be assumed to have a value of 0.

The new reference system defined by the REF instruction will be valid
for all the instructions that follow it in the program until the next REF
instruction or, if there is not one, until the end of the program.
In particular, the instruction:
REF: X0 Y0
restores the (absolute) sheet reference system.
Example:

Point P can be defined as (600,500) in the sheet reference system

(REF: X0 Y0), or as (200,400) in the reference system of the sheet after
it has been rotated and translated (REF: X1000 Y300 S90).

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3.9. Parametric programming

3.9.1. S4 functions
Function Description Example
SIN Sine (argument in degrees) SIN(90) = 1
COS Cosine (argument in degrees) COS(90) = 0
TAN Tangent (argument in degrees) TAN(45) = 1
ATAN Arc tangent, result in degrees between – ATAN(1) = 45
90 and +90
FTOA “Float To ASCII” See paragraph: Joining
together composite
strings [} 191].
FTOI “Float To Integer” FTOI (10.2) = 10
FTOI (10.9) = 10
MOD “Modulus or Remainder” 10 MOD 4 = 2
11 MOD 4 = 3

3.9.2. Principles of master programming

The initial program contains some parameters with assigned values, in
the PAR or LET instructions. Compiling the initial program, the master
program is included and the different values of the parameters are
entered correctly. The master program contains: calculations, conditions
programmed with the IF THEN ELSE instruction, punching and cutting
instructions. Several sub-programs can be used in the master program
and are included using the INC instruction.
If the parametric program is used in parametric nesting, please bear in
mind that the VAR and REF instructions are ignored by nesting (REF: is
ignored only if it is found within SIM or NET instructions).
Contrary to what is indicated in the programming manual for the S4
punching machine, the "dim X, dim Y, dim S, dim P" variables cannot
be used with AutoNest.

3.9.3. LET instruction - Defining parameters

As an alternative to the LET instruction, it is preferable to use the PAR
instruction.
One or more of the dimensions on the drawing of the sheet to be
punched may be given in parametric rather than numeric form, i.e. in
letters instead of numbers.
Such drawings will generally contain a table that gives the values of the
parameters for each type of sheet to be produced.

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Parametric measurements can be given in lower or upper case letters.

In the S4 programming language, parameters are always given in lower
case.
The LET instruction is used to define the values of the parameters in the
program.
The LET instruction has the following syntax:
LET: par_list
where:

par_list is a list of “parameter names” followed by the values associated with

them. The name of each parameter consists of a lower case letter
from the English alphabet (i.e. up to 26 variables can be defined).

3.9.4. PAR instruction

This can be used as an alternative to the LET instruction in parametric
programming in order to overcome its principal limitation of only being
able to use one lower case letter and, therefore, a maximum of 26
different parameters.
The PAR instruction has the following syntax:
PAR: parameter_List
where:

parameter_List is a list of “parameters”. Each parameter is composed of an

identifier followed by the “ = ” assignment symbol and the value
associated with it. The identifier is a string of any length
created using the lower case letters of the English alphabet (a-
z); an unlimited number of parameters can be defined.
It is also possible to define string-type parameters where the
value of the string is specified between double inverted
commas. These parameters can be used in the codes of the
relative instructions.

Example showing how numerical parameters are used:

PAR: firstpar = 1000 secondpar = 2000 thirdpar = 60
…….
…….
XYP: Xfirstpar Y(secondpar/2) P36 Athirdpar

It is also possibile to declare “string” type parameters:

Example showing how a material code is assigned to the

“material” parameter according to the value assigned to the
“thick” parameter used for thickness:
PAR: thick = …
…

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IF thick(1.5) THEN
PAR: material = “IRON_1.5”
ELSEIF thick(1.2) THEN
PAR: material = “IRON_1.2”
ENDIF
…
DIM: X1000 Y700 Sthick material

Example showing how string parameters join together:

PAR: maincode = “Xzy123abc” subcode = “56FGJ”
.......
PIE: maincode+subcode ....

Parametric measurements
Variants
on a b c d e f
drawing
34500
34500-1 900 600 150 200 50 50
34500-2 900 600 750 200 100 50
34500-3 1200 800 200 300 75 60
34500-4 1200 800 1000 300 50 75
34500-5 1500 1000 250 400 50 50
34500-6 1500 1000 1250 400 200 100

These panels must be programmed in two phases:

1. the sheet in the base drawing is programmed (the dimensions in
the base drawing are given in parametric form);
2. the individual variants are programmed (to give numeric values to
the parameters).

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For point 1), follow the normal programming procedure for sheets where
the dimensions are given in numeric form, treating the parameters
(letters) as though they were numeric values. In this way, you will
generate a reference program.

Example of a reference program (program 34500.S4):

DIM: Xa Yb
PUN: 1 P1 F9/2
PUN: 2 P2 F20
XYP: X(c-50) Y(d+e) P1
XYP: X(c+50) Y(d-f) P1
XYP: Xc Yd P2

Algebraic expressions can also be used with parameters. For example,

the following instructions are correct:
SIM: Xa/2
XYP: X(b-30)*2 Y(b+c)/2 P5

Reference programs cannot be elaborated because the parameters

(letters) are not defined using numeric values.
For point 2), the LET or PAR instruction is written in the executive
program to attribute numeric values to the parameters used in the
reference program.

Examples of executive programs (programs 34500-1.S4,

34500-2.S4, 34500-3.S4, 34500-4.S4, 34500-5.S4 and
34500-6.S4)
LET style:
COD: “34500-3.S4”
LET: a1200 b800 c200 d300 e75 f-10
INC: “34500.S4”
END
PAR style:
COD: “34500-3.S4”
PAR: a=1200 b=800 c=200 d=300 e=75 f=-10
INC: “34500.S4”
END
PAR style:
COD: “34500-4.S4”
PAR: a=1200 b=800 c=1000 d=300 e=-50 f=75
INC: “34500.S4”
END
PAR style:
COD: “34500-5.S4”
PAR: a=1500 b=1000 c=1250 d=400 e=-10 f=-10
INC: “34500.S4”

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END

Each executive program consists of 4 lines:

• the first line identifies the code of the variant;
• the second line attributes numeric values to the variant concerned;
• the third line calls up the reference program;
• the fourth line is the usual end of program instruction.
More than one LET or PAR instruction can be written as long as the
same parameter is not defined twice.

3.9.5. Joining together composite strings

It is now possible to:
• create strings between inverted commas in all the instructions that
can use them;
• write the parametric values.
A plus sign “ + ” is used to link the strings together; the parametric
values are printed using the function
FTOA(value,number_decimals)
where:

value is a fixed value or a parameter that has already been

defined with the PAR instruction.
number_decimals is the number of decimals you want to print.

Examples
Defining the group/part and sending information to a P4 Panel
Bender in line
PAR: ab = 123 cb = 321 cd =333
PIE:"gruppo\program.P4/"+"option"+FTOA(ab,
0)+"ofsx"+FTOA(cb,0)+"ofsy"+FTOA(cd,0) X0 Y0 …..
is equivalent to:
PIE:"gruppo\programma.P4/option123ofsx321ofsy333" X0
Y0 …..

Managing material codes for the connection with the stores

PAR: mat=25.00
DIM: X3000 Y1500 S1 "inox" + FTOA(mat,2)
is equivalent to:
DIM: X3000 Y1500 S1 "inox25.00"

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Or:
DIM: X 1000 Y 700 S 1.5 “IRON_” + FTOA(1.5)
is equivalent to:
DIM: X 1000 Y 700 S 1.5 “IRON_1.500000”
with a precision of six decimal numbers (default).

You can also specify the number of decimals:

DIM: X1000 Y700 S1.5 “IRON_” + FTOA(1.5, 1)
is equivalent to:
DIM: X1000 Y700 S1.5 “IRON_1.5”

Writing a string on the blank

PAR: ma = 100 mb = 212
WRI:X0 Y0 "A"+FTOA(ma,0)+ " B"+FTOA(mb,0)
is equivalent to:
WRI:X0 Y0 "A100 B212"

3.9.6. Functions for rounding off and truncating

MOD means ”module” so A MOD B, means A module B. The module is
a mathematical function (such as division) that gives as a result the
remainder of the first number divided by the second one. So an ”Even
number” MOD 2 gives 0, and an “Odd number” MOD 2 gives 1.
Example:

PAR: length = 108 height = 2

IF (length MOD height) (0) THEN ; Even

XYP: X100 Y100 P1
ELSEIF (length MOD height) (1) THEN ; Odd
XYP: X200 Y100 P1
ENDIF

In this case, 108 MOD 2 is equal to 0, so the punching will be made at

X100 and Y100.

The FTOI function can truncate and round off a “real number” into a
whole number.

Example of a truncated number Example of a rounded number

(FTOI(108 / 10)) (FTOI((108 / 10)+0.5))
Returns a value of 10 Returns a value of 11

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Reserved parameters
There are some parameters that do not need to be declared with the
PAR instruction as the compiler (Sdex) already knows them from
previous settings of the S4 program (in the DIM: and REF: instructions).
If you do not use the REF: instruction, the default values will be: X0 Y0
S0.
These parameters are as follows:

Name Description
dimx Sheet size on x
dimy Sheet size on y
dims Sheet thickness
dimp Sheet specific weight
refx Sheet reference point on x
refy Sheet reference point on y
refs Sheet reference point angle

3.9.7. SIM and ESM instructions - Repeating a block of

instructions symmetrically
Sometimes it is necessary to use specular instructions with respect to
the x and/or y axis in order to abbreviate the written code. The SIM and
ESM instructions allow you to do this. An important function is the
creation of one part on the right or on the left simply by parameterizing
the use of the SIM instruction, for instance SIM: X(xdim/2) S1.
Each SIM instruction must be closed by an ESM instruction.
Several SIM...ESM instructions can be written between the SIM and the
ESM, up to a maximum of six levels.

SIM: X1000 ; level 1

SIM: Y500 ; level 2
ESM ; return to level 1
SIM: X500 ; level 2
SIM: X200 ; level 3
ESM ; return to level 2
ESM ; return to level 1
ESM ; return to non-symmetrized instructions

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3.9.8. IF THEN ELSEIF ELSE ENDIF instructions - Conditional

parametric programming

Comparative operators
The comparative operators have been added to further simplify the
parametric programming.
The comparative operators that can be used are as follows:

Operator Description Example

== Equal to IF( para == parb) THEN
> Greater than IF( para > parb) THEN
>= Greater than or equal to IF( para >= parb) THEN
< Less than IF( para < parb) THEN
<= Smaller than or equal to IF( para <= parb) THEN
<> Not equal to IF( para <> parb) THEN
STR_EQ String equal to string IF( para STR_EQ parb) THEN

AND, OR and NOT logical operators

The logical operators that can be used in the IF THEN instruction are as
follows:

Operator Example
AND IF( (para > parb ) AND ( parb >parc) ) THEN
OR IF( (para > parb ) OR ( parb >parc) ) THEN
NOT IF( (para > parb ) NOT ( parb >parc) ) THEN

In an S4 program, 30 variables are available for parametric

programming: the 26 lower-case letters a, b, ... z seen in the paragraph
on the LET instruction, plus another four, known as "dimx", "dimy",
"dims" and "dimp", that adopt the values given to the X, Y, S and P
identifiers by the DIM instruction. These four variables have been added
because parametric programs often have conditions that depend on the
dimensions of the sheet.
For example, the co-ordinates of the holes for the locks in metal
windows or doors depend on the height of the object (this shows us
whether it is a door or a window).
This problem can be solved by using the dimx parameter and the IF,
THEN, ELSEIF ELSE and ENDIF instructions to define alternatives.

Programming the first alternative

The IF instruction has the following syntax:

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IF Exp1 (Expc1, Expc2) THEN

where:

Exp1 is the expression whose value determines the first term in the
comparison.
Expc1 is the expression whose value determines the minimum value of
the second term in the comparison.
Expc2 is the expression whose value determines the maximum value of
the second term in the comparison; if the first term in the
comparison is greater than (or equal to) the minimum value of the
second term and less than (or equal to) the maximum value of the
second term (i.e. it falls between the two extremes of the second
term) the condition will have been satisfied and the alternative
(composed of all the subsequent instructions up to the next ELSE,
ELSEIF or ENDIF instruction) will be performed; otherwise, the
alternative will be ignored.

Or:
IF Exp1 (Expc) THEN
which is a shorter way of writing IF Exp1 (Expc,Expc) THEN. In other
words, the minimum and maximum values of the second term in the
comparison coincide i.e. if Exp1 has the same value as Expc, the
condition will have been satisfied.

Programming a subsequent alternative

The ELSEIF instruction has the following syntax:
ELSEIF Exp1 (Expc1, Expc2) THEN
or:
ELSEIF Exp1 (Expc) THEN
where:
Exp1, Expc1, Expc2 and Expc have the same meanings as for the IF
instruction.

Programming the final alternative

The ELSE instruction has the following syntax:
ELSE

Programming the end of the alternatives

The ENDIF instruction has the following syntax:
ENDIF

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Since the first alternative and the end of the alternatives must always be
present, the IF and ENDIF instructions must always be part of a series
of alternatives. The subsequent alternatives (if present) must be written
after the first alternative and before the final alternative (ELSE) if this is
present, or before the end of the ENDIF alternatives if it is not. There
can be only one final alternative (if any) and it must precede the end of
the ENDIF alternatives.
In any case, only one (if any) of the alternatives programmed will be
performed (i.e. the first to be satisfied).

Example 1
IF a (1000,500) THEN
XYP: X0 Y0 P1
ELSE
XYP: X0 Y0 P2
ENDIF
In this case, it is the last alternative that will always be performed
because the condition in the first alternative will never be satisfied,
given that a can never be above 1000 and below 500.

Example 2
IF a (500,1000) THEN
XYP: X0 Y0 P1
ELSEIF a (600,700) THEN
XYP: X0 Y0 P2
ELSE
XYP: X0 Y0 P2
ENDIF
In this case, the second alternative will never be performed, because
whenever the condition in the second alternative is satisfied, the
condition in the first alternative will also be satisfied. It is therefore this
alternative that will be performed.

Example 3
IF a (500) THEN
XYP: X0 Y0 P1
ELSEIF a (600)
XYP: X0 Y0 P2
ENDIF
In this case, if the value of a is neither 500 nor 600, neither alternative
will be performed.
This will not happen if the final alternative (ELSE) is present, because it
is this that will be performed if none of the preceding conditions are
satisfied.

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Example 4

Parametric measurements
Variants a b c d e f
on
drawing
34500
34500-1 900 600 150 200 50 50
34500-2 900 600 750 200 100 50
34500-3 1200 800 200 300 75 ---
34500-4 1200 800 1000 300 --- 75
34500-5 1500 1000 250 400 --- ---
34500-6 1500 1000 1250 400 200 100

The two circular holes may be absent if the value of parameter e or fis
not specified. In such cases, these parameters will be given a negative
value.
The reference program (see Parametric programming [} 187]) is as
follows:
DIM: Xa Yb
PUN: 1 P1 F9/2
PUN: 2 P2 F20
IF e (0,1500) THEN
XYP: X(c-50) Y(d+e) P1
ENDIF
IF f (0,1500) THEN
XYP: X(c+50) Y(d-f) P1
ENDIF
XYP: Xc Yd P2

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In this example, the first punching programmed with P1 is conditioned

by the value of parameter e. If this falls between 0 and 1500, the
punching will be performed, otherwise it will not. This also applies to the
second punching programmed with P1 (but this is conditioned by the
value of parameter frather than by e).
The executive programs concerned with the missing punchings will be:
COD: “34500-3.S4”
LET: a1200 b800 c200 d300 e75 f-10
INC: “34500.S4”
END

COD: “34500-4.S4”
LET: a1200 b800 c1000 d300 e-50 f75
INC: “34500.S4”
END

COD: “34500-5.S4”
LET: a1500 b1000 c1250 d400 e-10 f-10
INC: “34500.S4”
END

Example 5
IF dimx (500,1000) THEN
IF dimy (0,500) THEN
XYP: X(dimx/2) Y(dimy/2) P8
ELSE
XYP: X(dimx/2) Y(dimy-100) P8
XYP: X(dimx/2) Y100 P8
ENDIF
ENDIF
In this case, a series of alternatives is programmed in an alternative
branch (up to 50 different levels of alternative can be programmed).

3.9.9. INC instruction - Including a file

A number of punching programs can often have a lot of information in
common. It may therefore be useful to write this information in another
file so that you do not have to keep on repeating it and to make it easier
to modify if necessary.
The INC instruction is used to include a file.
The INC instruction has the following syntax:
INC: “nome_file”
where:

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file_name is the name of the file to be included.

A typical example is the declaration of the punches present in a certain

configuration of the head. All the programs processed with that
configuration will have the same PUN instruction and it will therefore be
useful to write a file containing this information once and for all.

File HEAD1.PUN
PUN: 1 P1 F10
PUN: 2 P3 F20 P4 F10 G20
PUN:........................
At this point,you only need to write the following instruction in all the
programs that are to be processed with the punches defined in
HEAD1.PUN:
INC: “TESTA1.PUN”
instead of writing all the PUN instructions.
File inclusion is also useful with parametric programming.

3.9.10. Error management: stopping Sdex compilation in the

event of an error

ERR instruction – stopping Sdex compilation

with an error message
When parameters are programmed, they are often initialized with a
value of 0.
The ERR: instruction can be used to check for elaboration errors due to
incorrect parametric values that would cause the product to be
processed with holes missing or similar.
The syntax of the instruction is as follows:
ERR: “error message”
where:

error message is the error text shown in the error window

It is also possible to use an incorporation instruction if several master

programs use the same logic and the same parameters.

EXAMPLE:
IF ((ab>=10) OR (ab==5)) THEN
ERR: ”The ab parameter is out of range”
ENDIF

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3.9.11. Diagnostics: how to stop Sdex even if logic and syntax

are correct
When writing a program with a number of IF THEN ELSE levels, it can
be difficult to understand why an instruction has not been performed. It
may be useful to enter the ERR: instruction in various parts of the text in
order to identify the exact point at which the interpretation of the
program by the Sdex compiler was interrupted.

3.9.12. Parametric MetalNest

BEX: EEX instruction – Include external

parameters
If a master program is being used with MetalNest, the maximum length
of the name of the parameters is 64 characters. The BEX: instruction
means the beginning of the external parameters, whereas EEX means
the end of the external parameters. This is an indication that these
parameters come from outside the master program and that the rest of
the parameters written outside BEX: and EEX cannot be seen by
MetalNest (this means that they will not accept any new values from
outside the master program).
The syntax is as follows:
COD: “MASTER.S4”
BEX:
PAR: a = 500 b = 400 y = 50 z = 40
EEX
PAR: code = “iron”

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DIM: Xa Yb S1 code
PUN: 1 P1 F5
IF a(100, 200) THEN
XYP: X(a-z) Y(b-y) P1
ENDIF
END

This program is interpreted as follows:

COD: “MASTER.S4”
DIM: X500 Y400 S1 “iron”
PUN: 1 P1 F5
XYP: X400 Y300 P1 ; 10mm diameter for cable insertion
END

Comments from the source program to

MetalNest
Writing a comment after a punching instruction in the source program
will make it easier to search for errors in the new S4 program that has
just been created.
For instance:
XYP: X460 Y350 P1 ; 10mm diameter for cable insertion
The comment "10mm diameter for cable insertion" will be displayed in
the .*_mtn*.S4 file created by MetalNest.

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A This information can be displayed by simply passing the mouse pointer over
the drawing of the part. It comes from the information written in the COD: line
of the S4 source program after the semi-colon.

B In the example, you can see the parameters written between BEX: and EEX in
the source program (.S4). The symbol of a pen means that the value is
modified by hand.
C This information comes from the master program, after the semi-colon used to
give information in the BEX: and EEX instructions.

3.9.13. OPS, MetalNest, parametric

Parametric nesting with OPS

If you use parametric programming with OPS and MetalNest, the
beginning of the S4 program needs the syntax illustrated below.
OPS sends a parameter called createdbyops=1 which means that the
values of the parameters come from OPS. In this case, the values
written between the lines of BEX EEX instruction will be skipped by the
IF condition. The parameters coming from OPS will be entered later by
the S4 master program and their values will be used (the last value
assigned to a parameter cancels all the preceding values). The PAR
line that is found before <OPS_DEFINED_PARAMETERS> can be
used to initialize the parameters that are not always defined by OPS.
The main reason is that you should not send all the parameters with a
zero value that are not used for this particular order. If the parameter
comes from OPS, it has greater priority and the values will be taken
during the Sdex elaboration.
Example:
PAR:createdbyops=0 ;<DEFINE_IF_CREATED_BY_OPS>
;***** Do not remove the above line, OPS needs it
COD: "TEST.S4"
IF createdbyops (0) THEN ;
;***** Do not remove the above line, OPS needs it

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;
BEX: ;values of the parameters used by Sdex
;when compiling without nesting and OPS
PAR: st=0 sta=1 or=1
EEX
ELSE
;
;OPS default values
;Here you can initialize parameters
;that do not come from OPS
PAR: st=0 sta=0 or=0
;
;Values defined by MRP/OPS
;
;<OPS_DEFINED_PARAMETERS>***** Do not remove
;this line, OPS needs it;
;above there are the parameters entered by OPS
ENDIF

3.10. Special instructions

3.10.1. INK instruction - Managing printers

The INK instruction is used with the PRINT option to write an
identification code on the punched, and possibly sheared, sheet.
Both label and ink-jet printers can be used. In the first case, the blank
being processed is positioned and the printer then attaches the label; in
the second case, the sheet is moved while the code is written.

The INK instruction has the following syntax:

INK:"J34A4" X100 Y200 S90 H5 M-1 I100 K500 L1

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where:

"J34A4" is the alphanumeric code to be written on the part.

For formatting or inserting special control characters within the code to
be printed, if the model installed requests them, please consult the
manual of the model of the printer or labelling machine being used.
X100 are the identifier and value of the X co-ordinate of the center of the
printing in the current sheet reference system.
Y200 are the identifier and value of the Y co-ordinate of the center of the
printing in the current sheet reference system.
S90 are the identifier and value of the angle between the label and the X
axis. It can have a value of 0° o 90° (clockwise rotation is considered
positive).
If omitted, S will be assumed to have a value of 0.
H5 are the identifier and value of the height, in mm, of the character. Its
use depends on the printer used.
If omitted, the default value assumed will depend on the printer used.
M-1 optional writing (if the manipulator does not reach the X, Y position, a
message warns you that the writing will not be performed so as to
avoid an error).
The inkjet printer always writes while moving the sheet along the X axis. If the
programmed centre of the printing is on the edge of the part and the part is rotated
(90°/270°), the printing may extend beyond the edge of the part. Use the I and K
coordinates to program another point within the part:
I100 X coordinate, centre of the printing for parts produced vertically for an
inkjet printer.
K500 Y coordinate, centre of the printing for parts produced vertically for an
inkjet printer.
L1 type of label printing layout.

3.10.2. RFO instruction - Managing the RF option

The RF option is used to reposition the blank after rotating it and before
starting to shear it. This is done to recover the error that is due to the
release of residual stress when the manipulator pincers open.
It consists of two push-rods with conical heads. These are inserted in a
special pair of holes made near to side V of the sheet (or in the holding
scrap, if present). SDEX positions and then automatically selects the
pairs of holes (1200 mm apart) so that the RF push-rods do not interfere
with the manipulator.
The intervention of the sheet repositioning device is programmed with
the RFO instruction which has the following syntax:
RFO: P2 Z1
where:

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P2 are the identifier and position number of a circular punch with the same
diameter as the push-rods (these differ for each S4). Push-rods with
diameters of between 6 and 13.2 mm are supplied.
Z1 are the identifier and code of the type of cycle to be performed, described
as follows:
Z1 the RF option intervenes after each sheet re-grip in the last rotation
block, then after the last rotation and after each subsequent repositioning.
Z2 the RF option only intervenes after the last rotation.
If it is omitted, or if the cycle code is # 2 and # 1, Z will be assumed to have
a value of 1.

3.10.3. MTI instruction - Modifying the punch descent and

ascent times
The MTI instruction is used to modify the punch ascent and descent
times (the standard times are defined in the machine constants).
It is used when wear and tear have blunted or shortened the punches.
It is also useful for punches that require a punching force which is near
to the limit.
The MTI instruction has the following syntax:
MTI: P4 P9 H150 J120
where:

P4 are the identifier and position number of the first punch in the group of
adjoining punchings being considered.
P9 are the identifier and position number of the last punch in the group of
adjoining punchings being considered.
If omitted, the first punch will be considered.
H150 are the identifier and value of the new descent time for the group of
punches (expressed in milliseconds).
If omitted, the descent time for the group of punches will remain the
same.
J120 are the identifier and value of the new reascent time for the group of
punches (expressed in milliseconds).
If omitted, the reascent time for the group of punches will remain the
same.

With the following instruction:

MTI: P4 P9 H150 J120
the punches in positions 4, 5, 6, 7, 8 and 9 will start their reascent 150
milliseconds after the descent command and will be considered to have
reached the “up” position 120 milliseconds after the reascent command,
so that the manipulator can make the next movement.
For embossing tools, the ascent time for the bottom punch is
considered to be the same as the descent time for the top die while the
descent time for the bottom punch is considered to be the same as the
reascent time for the top die.

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The MTI instruction will be repeated in a program as many times as

there are non-adjacent groups of punches to be modified.

3.10.4. MPP instruction - Modifying the position in which the

pincers hold the blank
The MPP instruction is used to:
• prevent the manipulator pincers from holding the blank in certain
positions;
• force a movement forwards along Y in order to be able to hold the
blank at a certain rotation.
It has the following syntax:
MPP: R180 xu_lst G10
where:

R180 are the identifier and value in degrees of the angle of rotation of the sheet
at which manual intervention is required. It can have the following values:
0, 90, 270, 180 and 360 degrees (possible second hold at 0 degrees).
xu_lst is a list of the zones that the pincers are not allowed to hold. Each is
indicated by the following pair of parameters:
X1000 U20
where X1000 are the identifier and value of the X co-ordinate of the
beginning of the prohibited zone in the sheet reference system with the
sheet rotated at R and U20 are the identifier and value of the width of the
prohibited zone.
The axes of the pincers are considered.
Can be omitted.

A Reference at 90 degrees C Reference at 180 degrees

B Reference at 0 degrees D Reference at 270 degrees

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G10 are the identifier and value of the movement forwards along Y in order for
the pincers to be able to hold the blank.
Since this value must be given with reference to the original side of the
sheet, the movement forwards must take account of any trimming
present.

EXAMPLE 1

A Zone that the pincers are not

allowed to hold

To prevent the pincers from holding the sheet between X500 and X550
after it has rotated by 180°, write the following instruction:
MPP: R180 X500 U50

EXAMPLE 2

A Manipulator B Workpiece

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The blank shown in the figure cannot be held at Y=0 because most of
this side has been removed: it must be held at Y=20. To move the y
axis manipulator forwards, write the following instruction:
MPP: R180 G20

3.10.5. DWP instruction - Destroying shearing scrap with a

punch
The DWP instruction is used to destroy non-trimming shearing scrap
with a punch.
It has the following syntax:
DWP: D30 p_lst
where:

D30 are the identifier and value of the maximum dimension for scrap to be
destroyed with a punch. A piece of shearing scrap will be destroyed with
a punch if one of its two dimensions is less than D.
p_lst is a list of the punches that can be used to destroy the shearing scrap.

The following instruction:

DWP: D30 P20 P22
asks for shearing scrap with an X and/or Y dimension of less than 30
mm to be destroyed by punches P20 or P22.
Only scrap that one of the punches specified in the list can reach
completely will be destroyed.
Generally speaking, punches larger than D are used and SDEX
automatically calculates the sequence between punchings and cuts so
that the punchings added do not damage the parts adjoining the scrap
concerned.

3.10.6. VFY instruction - Broken punches check

The VFY instruction is used to periodically check that a punch is not
broken. This is done with the assistance of the optical sheet centering
photo-cell.
It has the following syntax:
VFY: P5 D10
where:

P5 are the identifier and value of the punch to be checked.

D10 are the identifier and value of the frequency of the check for each blank
processed. If omitted, only one check is made for each blank.

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Punches with a minimum diameter of 1.5 mm can be checked, provided

that the relative position of the hole on the blank can be reached by the
manipulator without any additional regrips. This is because the photo-
cell lies away from the punching head.

3.11. Zed programming

The order in which machine movements are performed is normally
determined by the SDEX algorithms. If, however, the existing controls
are not sufficient, you can use Zed instructions to specify the order in
which these movements are made.

First example
SDEX will check that no embossings are flattened but not whether any
“high” embossings (i.e. those that cannot pass underneath the head)
interfere with the head.
You must therefore define the path of the manipulator so that any high
embossings do not catch on the head.

Second example
SDEX will not allow any parts to be unloaded with the sheet rotated at
90 or 270°. If you need to unload any parts at 90 or 270°, you can use
Zed programming to do so.

Third example
Since all parts must be detached using the shear, SDEX will give a
scrap loss error if any sheets are detached using punches. As a result,
you must use Zed programming if you need to detach a part by
punching it.

Blocks of Zed instructions

It is possible to program certain sequences manually without having to
program the entire blank to be processed. Zed instructions can be
added to the program in a number of blocks: the only limit is that you
must establish the sequence between those parts of the program that
are to be managed automatically and those that are to be performed
with a series of Zed instructions.
Each block of Zed instructions must be written between the following
two instructions: ZBG (beginning of the block of Zed instructions) and
ZND (end of the block of Zed instructions). To all intents and purposes,
the block of Zed instructions is a sequence that, unlike SEQ...ESQ
sequences, is found at a particular point in the program.
All the instructions in the S4 programming language can be used in a
block of Zed instructions. In view of the definition of a block of Zed
instructions, there is no point in writing sequence instructions.

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Zed sequence
If the program contains blocks of Zed instructions, a Zed sequence will
be generated. It will be composed of steps of operations to be optimized
together with steps of single Zed operations. Thereafter, the Zed
operations will be managed in exactly the same way as the non-Zed
operations.

Limits on the actions that are performed automatically by

SDEX
The presence of the Zed sequence that concerns all operations affects
certain actions that are performed automatically by SDEX.
• Shearing scrap consolidation: when Zed instructions are present,
the shearing scrap is not consolidated;
• Automatic holding scrap division: the holding scrap will still be
divided automatically and the relative operations will be added to
the first step of the Zed sequence generated;
• Trimming: trimming is managed in exactly the same way and the
relative operations are added to the first step of the Zed sequence;
this forces all the Zed operations to be performed after the trimming
and is done to avoid having any doubts about the holding offset
which depends on the number of rotations made previously;
• Opti-Notch: Opti-Notch is not performed when Zed instructions are
present;
• Overlap check: when ZEX (Zed part exit) instructions are present,
the coverage check is performed but the overlap check is not
(because the parts programmed are allowed to overlap).

Automatic generation of a Zed program relating to a .S4

program
If you write the VAR: O40 compilation option (seeCompilation options
[} 233]) in the name.S4 program, the name_Z.S4 program will be
generated automatically. It will contain a single Zed block with the
sequence of machine movements that has been generated
automatically for the name.S4 program.
When only small modifications need to be made to the program that has
been generated automatically, it is better to intervene manually on the
name_Z.S4 program than to add the Zed blocks to the name.S4
program.

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3.11.1. ZGL instruction - Program composed solely of Zed

instructions
If SDEX finds the VAR: O40 compilation option (see VAR instruction -
Compilation options [} 233]) when it compiles the name.S4 program, it
will automatically write the ZGL instruction in the name_Z.S4 program.
The ZGL instruction will contain the information for trimming the
name.S4 program, given that the name_Z.S4 program is entirely in Zed
and cannot contain the TRI instruction.
The ZGL instruction has the following syntax:
ZGL: F0 G10 U20 V20
where:

F0 are the identifier and value of the trimming on side F of the starting sheet;
G10 are the identifier and value of the trimming on side G of the starting sheet;
U20 are the identifier and value of the trimming on side U of the starting sheet;
V20 are the identifier and value of the trimming on side V of the starting sheet.

3.11.2. ZBG and ZND instruction - Defining a Zed block

At the beginning of a block of Zed instructions, the ZBG instruction must
be used to declare the position of the blank being processed with
reference to the manipulator. The ZND instruction is used to announce
the end of a block of Zed instructions.

Start of a block of Zed instructions

The ZBG instruction has the following syntax:
ZBG: R0 M1200
where:

R0 are the identifier and code of the rotation of the blank at the beginning of
the block of Zed instructions; the following codes are used: R0 blank at
0°, R1 blank at 90°, R2 blank at 180° and R3 blank at 270°.
M1200 are the identifier and value of the X co-ordinate of the center of the
manipulator in the sheet reference system with the sheet as currently
rotated (see the figure below).

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A Reference at 90 degrees C Reference at 180 degrees

B Reference at 0 degrees D Reference at 270 degrees

End of a block of Zed instructions

The ZND instruction has the following syntax:
ZND

3.11.3. ZTG instruction - Elementary shearing

In a block of Zed instructions, you can program a part with the PIE or
PPR instructions (it must be possible to make these elementary cuts
with the sheet in its current position with reference to the manipulator).
Alternatively, you can program the individual elementary cuts with the
ZTG instruction and, once they have been made, use the ZEX
instruction to declare the part that is detached from the sheet.
The ZTG instruction has the following syntax:
ZTG: X500 Y650 K1
where:

X500 are the identifier and value of the X co-ordinate of the vertex of the shear
(i.e. the point at which the X and Y blades meet) in the current sheet
reference system.
Y650 are the identifier and value of the Y co-ordinate of the vertex of the shear in
the current sheet reference system.
K1 are the identifier and code of the elementary cutting operation. The
following codes are used:
K1: partial cut along X;
K2: partial cut along Y;
K3: total cut with both blades;
K4: total cut with the X blade;
K4: total cut with the Y blade;
If omitted, K will be assumed to have a value of 3.

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Since the point of programming coincides with the vertex of the shear,
you must consider that, when you make a partial cut, the portion of
material that is sheared completely does not reach the vertex of the
shear (see the figure below).

A Blade B Vertex of the shear

Since the blade is at a 2° angle and there will usually be 0.2 mm

clearance between the blank and the blade at the vertex of the shear, if
the material is S mm thick, distance D between the vertex of the shear
and the end of the complete cut will be:
D = (0.2+S)/ tan(2°), i.e. D=(0.2+S) * 28.636
In addition to the parameters described above, the ZTG instruction will
also accept the SLO specifier (which makes the manipulator move
slowly). Moreover, if the cut is the result of expanding the TRI
instruction (for trimming the starting sheet), SDEX will automatically
insert the TRS specifier in the name_Z.S4 file.

3.11.4. ZEX instruction - Information about a detached part

In a block of Zed instructions you are allowed to detach a part by
punching and/or cutting it. The ZEX is used to enter all the information
about the part that is detached without, however, generating the
operations for detaching it.
SDEX checks that, when the ZEX instruction appears, there is indeed a
detached part inside the rectangle it defines.

Programming the part that is detached

ZEX: X300 Y200 U750 V400

The ZEX instruction has the following syntax:

ZEX: “code” X0 Y0 U200 V100 R0 B1 A50 W60 ZA 10 ZP 50
RA 10 RP 20

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where:

code is a string of characters (max. 255) associated with the detached part; if
the punching machine is working in line with the bending machine, the
string must include the bending program for the Panel Bender.
Any other information can be managed in the personalization of the
system.
Can be omitted.
X0 are the identifier and value of the X co-ordinate of vertex P (see the figure
above) in the current sheet reference system.
Y0 are the identifier and value of the Y co-ordinate of vertex P (see the figure
above) in the current sheet reference system.
U200 are the identifier and value of side X of the rectangle that contains the
detached part.
V100 are the identifier and value of side Y of the rectangle that contains the
detached part.
R0 are the identifier and value of the rotation of the part (in degrees) with
respect to a reference program for the individual part; this information is
used downstream of the punching machine when handling parts that are
identical but have been rotated by multiples of 90°. R can have the
following values: 0, 90, 180 and 270.
If omitted, R will be assumed to have a value of 0.
B1 are the identifier and code of the type of clamping. The following codes
are used:
B0 the part is not being held by the pincers and can therefore be
unloaded.
B1 the part is being held by the pincers and the blank has not been
completely processed; it must be repositioned (ZRP) before the part can
be unloaded.
B-1 the part is the last portion of the blank being processed; the
manipulator must be moved (ZMV) before the final loading operation. If
holding scrap is present, it is the last portions of holding scrap still in the
pincers of the manipulator that will be unloaded.
If omitted, B will be assumed to have a value of 0.
Examples:
To cut and unload a part that is being held by the pincers of the
manipulator:
ZTG:....
ZEX:...B1
ZRP:...
To make a cut with the manipulator disengaged:
ZTG:..
ZEX:...
ZMV:..D1
To unload the last part:
ZMV:....
ZEX:....B-1

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A50 are the identifier and value of the distance required between the rear
diverter and the theoretical edge of the sheet when the part starts to pass
between the diverters; this will be ignored if it is less than the waiting
distance calculated (see the paragraph on the PIE instruction).
If omitted, A will be assumed to have a value of 0.
W60 are the identifier and value of the correction of the final position of the
diverters; this can be used to center the part with respect to the system
downstream. If the punching machine does not have a conveyor (i.e. it
belongs to an SP4 system or is the first punching machine in an S4
tandem system), the W parameter indicates the correction along Y of the
position in which the sheet is unloaded.
If omitted, W will be assumed to have a value of 0.
ZA 10 are the identifier and value of the Y position of the front magnetic transfer
in the reference system of the part to be stacked (see the paragraph on
the PIE instruction).
If omitted, ZA will be assumed to have a value of 0 and the position of the
front magnetic transfer will be calculated automatically.
This information is only relevant if the IA stacker is present downstream of
the punching machine.
ZP 50 are the identifier and value of the Y position of the rear magnetic transfer
in the reference system of the part to be stacked (see the paragraph on
the PIE instruction).
If omitted, ZP will be assumed to have a value of 0 and the position of the
rear magnetic transfer will be calculated automatically.
This information is only relevant if the IA stacker is present downstream of
the punching machine.
RA 10 are the identifier and value of the correction to the position of the device
for positioning the front rollers.
If omitted, RA will be assumed to have a value of 0.
RP 20 are the identifier and value of the correction to the position of the device
for positioning the rear rollers.
If omitted, RP will be assumed to have a value of 0.

3.11.5. ZMV instruction - Moving the manipulator

The ZMV instruction is used to program a movement by the manipulator
in a block of Zed instructions.
The ZMV instruction has the following syntax:
ZMV: X-500 Y-650 D1 R0
where:

X-500 if R=0, these are the identifier and value of the X co-ordinate (in the head
reference system) of the origin of the blank as currently rotated;
otherwise, they are the identifier and value of the X co-ordinate of point M
of the manipulator at the end of the movement (see the figures below).
Y-650 if R=0, these are the identifier and value of the Y co-ordinate (in the head
reference system) of the origin of the blank as currently rotated;
otherwise, they are the identifier and value of the Y co-ordinate of point M
of the manipulator at the end of the movement (see the figures below).

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A Origin of the blank at 90° C Origin of the blank at 180°

B Origin of the blank at 0° D Origin of the blank at 270°

A Conveyor D Manipulator reference system

B Head E Head reference system
C Rotator F Manipulator

The origin of the head reference system is the center of the head.
The origin of the manipulator reference system is the median point (M)
of the manipulator when the X axis is at the end of its stroke in the
direction of the stacking section and the Y axis is furthest from the head.

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Dn are the identifier and code for a possible disengagement operation. The
codes are as follows:
D0: indicates that it is a normal movement of the manipulator;
D1: indicates the disengagement that the manipulator is required to make
with respect to the ZEX unloading operation that must precede the ZMV
instruction; in this situation, the X axis will move before the Y axis;
D2: indicates the disengagement that the manipulator is required to make
with respect to the ZEX unloading operation that must precede the ZMV
instruction; in this situation, the Y axis will move before the X axis;
D3: indicates the disengagement that the manipulator is required to make
with respect to the ZEX unloading operation that must precede the ZMV
instruction; in this situation, the X and Y axes will move simultaneously.
If omitted, D will be assumed to have a value of 0.
R0 are the identifier and code of the reference system in terms of which the X
and Y co-ordinates are given. The following codes are used:
R0 head reference system;
R1 manipulator reference system;
If omitted, R will be assumed to have a value of 0.

In addition to the parameters described above, the ZMV instruction will

also accept the SLO specifier (which makes the manipulator move
slowly).

3.11.6. ZRT instruction - Rotating the sheet

The ZRT instruction is used to program a rotation of the sheet in a block
of Zed instructions.
The ZRT instruction has the following syntax:
ZRT: X500 Y650 S90 M1000 P10
where:

X500 are the identifier and value of the X co-ordinate of the axis of the rotator
in the sheet (i.e. absolute) reference system.
Y650 are the identifier and value of the Y co-ordinate of the axis of the rotator
in the sheet (i.e. absolute) reference system.
S90 are the identifier and value in degrees of the rotation required; a positive
value indicates an anti-clockwise rotation.
The following values are allowed: 90, -90, 180, -180, 270 and -270.
M1000 are the identifier and value of the X co-ordinate of point M of the
manipulator after the rotation, given in terms of the reference system of
the sheet after the final rotation (see the figure below).

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A Reference at 90 degrees C Reference at 180 degrees

B Reference at 0 degrees D Reference at 270 degrees

P10 are the identifier and value of the movement forwards along Y in order
to hold the sheet after the rotation.
Since this value must be given with reference to the original side of the
sheet, the movement forwards must take account of any trimming
present.
If omitted, the holding position will be calculated automatically according
to the dimensions of the trimmed sheet.

In addition to the parameters described, the ZRT instruction also

accepts the SLO specifier (the movement of the manipulator is made at
low speed).

3.11.7. ZRP instruction - Repositioning

The ZRP instruction is used to program a sheet repositioning operation
in a block of Zed instructions.
The ZRP instruction has the following syntax:
ZRP: X-500 Y-650 B100 M1000
where:

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X-500 are the identifier and value of the X co-ordinate of the axis of the
clamping device in the sheet (i.e. absolute) reference system; if there is
more than one clamping device, that with the highest priority in the
following list (given in decreasing order) will be considered: rotator
clamp, blankholder, blind punch.
Y-650 are the identifier and value of the Y co-ordinate of the axis of the
clamping device in the sheet (i.e. absolute) reference system; if there is
more than one clamping device, that with the highest priority in the
following list (given in decreasing order) will be considered: rotator
clamp, blankholder, blind punch.
B100 are the identifier and code of the clamping device; the codes are the
same as those used with VAR:Ppp:
B100: rotator clamp and blankholder;
B27: blankholder;
B100+x: rotator clamp and blind punch in position x;
Bx: blind punch in position x.
If omitted, the rotator clamp alone will be used to hold the sheet.
M1000 are the identifier and value of the new X co-ordinate of point M of the
manipulator, given in terms of the reference system of the sheet as
currently rotated (see the figure below).

A Reference at 90 degrees C Reference at 180 degrees

B Reference at 0 degrees D Reference at 270 degrees

In addition to the parameters described, the ZRP instruction also

accepts the SLO specifier (the movement of the manipulator is made at
low speed).

3.11.8. Examples of Zed programming

Example 1
Let us suppose that we want to obtain a cross-shaped sheet from a
rectangular blank as shown in the figure below.

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The fastest way of processing this blank is to make four strokes with the
shear, one for each rotation of the sheet. Since SDEX does not
automatically perform cutting and unloading operations at 90 and
270, we will have to use Zed programming.
The program will be as follows:

COD: “example 1”
DIM: X1000 Y1000 S1
ZBG: R0 M820 ; to start at 0 degrees
ZTG: X300 Y700 K3 ; to cut part 1
ZEX: X0 Y700 U300 V300 ; to unload part 1
ZRT: X500 Y500 S90 M820 ; to rotate by 90° (sheet at 90°)
ZTG: X700 Y700 K3 ; to cut part 2
ZEX: X700 Y700 U300 V300 ; to unload part 2
ZRT: X500 Y500 S90 M820 ; to rotate by 90° (sheet at 180°)
ZTG: X700 Y300 K3 ; to cut part 3
ZEX: X700 Y0 U300 V300 ; to unload part 3
ZRT: X500 Y500 S90 M820 ; to rotate by 90° (sheet at 270°)
ZTG: X700 Y300 K3 ; to cut part 4
ZEX: X0 Y0 U300 V300 ; to unload part 4
ZRT: X500 Y500 S-90 M820 ; to rotate by 90° (sheet at 180°)
ZND

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PIE: X0 Y0 U1000 V1000 ; to unload part 5

END

Example 2
Let us suppose that we want to obtain two parts, each with a high
embossing, from a rectangular blank (see the figure below). A “high”
embossing means that the material is shaped to such an extent that it
can no longer pass underneath the head.

Since it does not envisage making punchings or embossings while a

part is being cut, SDEX would automatically determine a sequence in
which part 1 was embossed and then cut. The embossing would,
however, interfere with the head while the sheet was being cut.
This can be avoided by starting to cut part 1, embossing it and then
finishing cutting it. Zed programming must be used to do this. The
program will be as follows:

COD: “example 2”
DIM: X2000 Y1000 S1
PUN: 1 P36 F30 E4
ZBG: R0 M1823 ; to start at 0 degrees
ZTG: X397 Y500 K1 ; to start cutting part 1
ZTG: X749.7 Y500 K1 ; to continue cutting part 1
ZTG: X1102.4 Y500 K1 ; to continue cutting part 1
ZTG: X1455.2 Y500 K1 ; to continue cutting part 1
ZTG: X1650.8 Y500 K1 ; to continue cutting part 1
XYP: X1900 Y600 P36 ; to emboss part 1
ZTG: X2003 Y500 K3 ; to finish cutting part 1
ZEX: X0 Y500 U2000 V500 ; to unload part 1

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ZND
XYP: X1900 Y100 P36 ; to emboss part 2
PIE: X0 Y0 U2000 V500 ; to unload part 2
END

3.12. Specifiers and options

Instruction specifiers must be written (in any order) after all the
parameters in the instruction.

3.12.1. J index - PAC specifier

The J index is used to associate punchings or embossings with parts.
It must always be written before any instruction specifiers and after all
the instruction parameters.
Let us consider the following example:

A Single part B Multiple part

C Shear

Let us suppose that we want to make two parts with a punching on the
edge.
In the multiple punching instruction, we must declare which punchings
belong to the top part and which to the bottom one. If we do not, SDEX
will assume that all the punchings that interfere with a part belong to it.
As a result, the top part will not be punched as it should. We could
program a strip of scrap between the two parts, but this might waste an
unacceptable amount of material.
That is why we have made it possible to associate a punching with a
part.

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The program for the above example is as follows:

COD: “PAC”
DIM: X1500 Y700 S1
PUN: 1 P20 F50
XYP: X1000 Y350 P20 J1
XYP: X1000 Y700 P20 J2
PIE: X0 Y0 U1500 V350 J1
PIE: X0 Y350 U1500 V350 J2
END

J1 has been added to the instructions for the central punching and
bottom part; J2 to those for the top punching and top part.
J1 and J2 are interpreted as part indexes: punchings with a J index will
only affect parts with the same J index.
In the above example, the operations required will be performed in the
following order:
• making the top punching;
• cutting the top part;
• making the central punching;
• unloading the part.
Generally speaking:
A part with a J index that is either 0 or unspecified can only be made
after all the punchings that interfere with it have been made.
A part with a J index other than 0 can only be made after all the
punchings that interfere with it and have either the same J index or no J
index at all have been made. Moreover, it must be made before all the
punchings that interfere with it and have a J index that is neither 0 nor
the same as its own J index are made.
A punching is considered to interfere with a part if they overlap by more
than the value of machine constant no.
The J index can be written in:
• PIE and PPR part definition instructions;
• XYP, RHO, RAD, STR, GRI, POL, REC, REK, CWP, RIC, NIK,
RIS, RES, IST, COR, KKO, BBG and WRI punching or embossing
instructions;
• the REF instruction for moving the reference system, in which case
all the subsequent instructions will have the J index specified in the
REF instruction (unless they themselves contain a J index).
The PAC specifier can be written in the NET instruction to automatically
add a progressive J index to all the instructions in the NET...ENT block.

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Programming the multiple part:

NET: X0 Y0 U700 V350 W2 Z2 PAC
XYP: X300 Y350 P2
PIE: X0 Y0 U700 V350
ENT

3.12.2. Punching instruction specifiers

MHI, MLO, MLE, MRI and MSQ - Specifying which side of the
sheet is held during punching
If you want a punching to be made with the sheet rotated at a given
angle, you must specify which side of the sheet is to be held:

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MHI: the punching will be made with the sheet at 0°;

MLO: the punching will be made with the sheet at 180°;
MLE: the punching will be made with the sheet at 270°;
MRI: the punching will be made with the sheet at 90°;
MSQ: the punching will be made with the sheet at 90° or 270°.
The sheet is always rotated anti-clockwise.

A Punch in the head

The above example indicates which side of the sheet is held during
each punching but, to program the panel, you only have to declare the
special punch by writing T360 and program the angle of the punching.
You only need to specify the side held if a punching can be made with
the sheet at several different angles.
If you specify which side of the sheet is to be held but do not rotate the
figure of the punch correctly, SDEX will signal an error because it will
not find any punches that are suitable for the punching.

HIG and LOW, LEF and RIG - Rotating a punching

A figure can be rotated by programming the angle (A) of the punch or, if
this angle is a multiple of 90°, writing the following specifiers:
HIG: keeps the figure of the punch at 0°;
LOW: rotates the figure of the punch by 180°;
LEF: rotates the figure of the punch by 90°;
RIG: rotates the figure of the punch by 270°.
Remember that the sheet is rotated anti-clockwise.
If we return to the example given above, we will have:

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A Punch in the head

Therefore, you only need to declare the special punch by writing T360
and add the appropriate figure rotation specifier.

DR1, DR2, DR3 and DR4 - Specifying the embossing cycle

These specifiers are described in the paragraph on single embossing
instructions.

NSB - Preventing punch substitution

SDEX always considers the cutting figure of the punch specified.
Consequently, if there are a number of punches with the same cutting
figure, the punching operation may be carried out by a punch that is in a
different position from that programmed. The NSB specifier disables
punch substitution i.e. forces the punching operation to be performed by
the punch programmed.

NOP - Disabling punching

In certain cases, you may need to add suitable movements of the sheet
to prevent it from getting caught. You can do this with Zed programming
or by programming fictitious instructions as appropriate. The NOP
specifier positions the sheet for the punching to be made but does not
cause the punch to descend.
It is usually advisable to program an NOP punching inside a sequence
because otherwise the fictitious punching might not be made at the right
moment.

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SLO - Making the manipulator move slowly

You may sometimes need certain movements to be made with the
manipulator travelling slowly. The SLO specifier is used for this i.e. the
manipulator moves slowly when a punching with the SLO specifier is
made.

NLS - Disabling the punch figure check

SDEX checks whether the figure that is made on the sheet as a result of
each punching programmed interferes with any other punchings. This
takes time and is sometimes unnecessary.
Punchings with the NLS specifier are not considered when SDEX
checks the scrap loss or the way in which the manipulator pincers and
repositioning devices hold the sheet. Nor are they considered when the
cutting lengths are determined automatically or the holding scrap
divided.
If the NLS specifier is present in the RIC, REC, IST and COR
instructions, it is ignored if the punchings generated by these particular
instructions could cause scrap to be lost.
In any case, the NLS specifier is ignored in the final simulation, when all
the complete checks are made.

SQM - Specifying the order in which an instruction is

performed
In certain cases, it may be useful to specify the order in which an
instruction is performed. This is done by adding the SQM specifier to it.
The STR and POL punching instructions will begin at the starting point
and gradually reach the finishing point; the GRI punching instruction will
be performed in columns, beginning at the point programmed; the REC
and IST nibbling operations will be performed in the direction
programmed; for the RIC and COR nibbling operations, the rough
punching will be performed first and then the finishing.

TRS – Instruction that is the result of expanding the trimming

When SDEX automatically generates the name_Z.S4 program (see Zed
programming [} 209]), it will write the TRS specifier in the instructions
that are the result of expanding the TRI instruction (for trimming the
starting sheet).

BTG – Embossing interfering with cut

SDEX normally generates an error if an embossing is cut by a blade of
the shear. The BTG specifier tells SDEX that the embossing will not be
damaged by the shear, with the result that no error messages will be
issued in this connection.

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FST – Punching priority for punching with the whole punch

Punchings with the FST option are performed before the other
punchings in the same macro-figure. In addition, they are performed as
early as possible, i.e. with the first grip and rotation that allow them to
be performed. The FST instruction is respected if the punching point
can be reached and there is no risk of losing the scrap.
The punching is performed before the scrap it touches is cut, be this
trimming scrap (VAR: O4) or sheet completion scrap (even when
VAR:O3 is present).
Useful with radius and other punch shapes that, if they hit the sheet only
partially, may have difficulty unloading the punching scrap (depending
on the material used).

Specifiers that are mutually exclusive

The following groups of specifiers are mutually exclusive. If more than
one specifier from the same group is used, SDEX will generate an error.
Group 1: MHI, MLO, MLE, MRI, MSQ
Group 2: LOW, LEF, RIG
Group 3: DR1, DR2, DR3, DR4

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3.12.3. Part definition instruction specifiers

SCR - Piece of scrap

When sub-dividing a blank into parts with various dimensions (using the
PIE and PPR instructions), you will often need to add “rectangles of
scrap” in order to cover the sheet completely. Adding this specifier to
the PIE instruction allows you to manage the part correctly on the part
collection system downstream of the punching machine e.g. by stacking
it on a scrap collection pallet.

DES - Scrap to be destroyed

If you do not want an entire rectangle of scrap to be unloaded (because
it cannot be re-used or because you do not have a device for collecting
large pieces of scrap), you can add the DES specifier so that the scrap
is eliminated through the hatch below the blades of the shear. If it needs
to be divided, this is done automatically by making alternate cuts with
both blades so as to create a series of rectangles of the correct size for
removal via the scrap unloading system.

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DWN - Unloading below the shear

This specifier is used to convey small sheared parts along a slide below
the blades of the shear and onto a belt transfer or into a scrap collection
bin, a good part collection bin or a number of collection bins with the
SC8 connection, underneath the S4 worktable.

DWF - Forced unloading below the shear

This specifier is similar to the DWN specifier but is used to unload larger
parts (you must check that they can be removed correctly).

UPP - Unloading onto the SC8 via the conveyor

This specifier is used to transfer the sheared parts into the bins of the
SC8 connection. If the dimensions of the sheared part are compatible
with the dimensions of the bins of the SC8 connection and you add the
UPP specifier to the instruction, the part will be unloaded into one of the
8 bins of this connection. If you do not add either the UPP or the DWN
specifier, the part will be stacked on the connections downstream of the
S4 + SC8 system.

IM1, IM2 and IM3 - Unloading in special positions

The part will be conveyed into the unloading position indicated by one of
the following three identifiers: IM1, IM2 or IM3. The association between
the identifier and the unloading connection is made when the system is
personalized.

TRU - Enabling the air-blast

This specifier activates a blast of air while the part is being unloaded.
This is used with small parts to improve their adherence to the brushes.

NOR - Disabling part diversion

This specifier prevents the sheet diverter from moving the part in the Y
direction while it is being unloaded by the conveyor.

EMB - Slowing down the sheet diversion cycle

If there is only one diverter, it will intervene after the part reaches the
end of the conveyor rather than while it is being moved.
If there are two diverters, instead of stopping at the end of the conveyor
to wait for the system downstream to be ready, the part will wait before
it starts to be transferred.

CWR - Rotating the part clockwise

This specifier is used to rotate the sheet clockwise by 90° on the ROF
connection downstream of the S4.

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CCR - Rotating the part counter-clockwise

This specifier is used to rotate the sheet counter-clockwise by 90° on
the ROF connection downstream of the S4.

RIB - Turning the part over

This specifier is used to turn the sheet over on the RI** connection
found after the S4.

NOB - Enabling the tunnel cycle

This specifier is used to stack the part using the tunnel cycle if the IA
connection is present. This cycle is automatically used to stack small
non-magnetic parts.

VRA - Enabling the use of the rollers

This specifier is used to stack the part with the help of the rollers if the
IA connection is present. The rollers will be employed automatically if
the sheet is declared non-magnetic using the VAR: A option.

SLO - Making the manipulator move slowly

In certain cases, you may need the manipulator to move slowly for
cutting. Use the SLO specifier to do this.

MHI, MLO - Unloading the part at 0° or 180°

Generally speaking, all parts are unloaded with the sheet at the same
rotation. If you want some parts to be unloaded with the sheet at 0° and
others with it at 180°, you must write the MHI specifier for those that are
to be unloaded at 0° and the MLO specifier for all the others.

PCT - Cutting the part immediately after it has been punched

Punchings are usually alternated with cuts in order to minimize the cycle
time. In special cases, such as when there are a large number of
punchings on the part, it is a good idea to prevent it from being
misshapen by asking for all the punchings to be made immediately
before it is cut.
See the O5, O9 and O15 compilation options.
The figure below gives an example of PCT processing.

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A Panel programmed D Punching and unloading the third part

B Punching and unloading the first part E Punching and unloading the fourth part
C Punching and unloading the second part

You should anyway remember that the PCT sequence does not affect
punchings made with the sheet at a different rotation from that at which
the cuts are made. If the O5 or O15 options are not present, the PCT
sequence will be generated inside a holding block.
The PCT specifier is not recommended for use with DWN parts: in this
case, it is advisable to make all the punchings first and then all the cuts,
so as to avoid continually opening and closing the hatch.

CNU - Cutting in comb-style

There is normally a single part during the cutting phase. This means
that, if you have to make strips of parts, each of which needs to be
repositioned before all the elementary cuts required can be made, it will
take a long time to process the blank.
To reduce this time, you can add the CNU specifier to the parts that can
start to be cut at the same time as other CNU parts.
See compilation option O37.
The figure below gives an example of CNU processing where, instead
of starting one cut at a time, four cuts are started, the sheet is
repositioned and all four cuts are then completed.
Without the CNU specifier, each part would need to be repositioned
once to complete the cut and then again before beginning the next cut.

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Panel programmed

First part of processing

DER - Delaying the diversion of the outgoing part

The diverters normally start to divert the part leaving the conveyor when
its barycenter reaches them. Sometimes, however, the edge of the part
is machined in such a way that the part cannot be diverted correctly with
the conveyor moving.
The DER specifier allows the front of the part to reach the end of the
conveyor before the part is diverted with the conveyor at a standstill.

HSO - Operating the shear hatch

The shear hatch will also open for parts that require only a partial cut.

NBX - Disabling the X blankholder during cutting

The cuts for the production of the part are performed without using the
shear’s X blankholder.

NBY - Disabling the Y blankholder during cutting

The cuts for the production of the part are performed without using the
shear’s Y blankholder.

Specifiers that are mutually exclusive

The following groups of specifiers are mutually exclusive. If more than
one specifier from the same group is used, SDEX will generate an error.
Group 1: DWF, DWN, IM1, IM2, IM3, UPP
Group 2: CCR, CWR
Group 3: NOB, VRA
Group 4: MLO, MHI

3.12.4. VAR instruction - Compilation options

The VAR instruction uses specific identifiers and values to influence the
behaviour of the machine. The instruction can contain a list of identifiers
and values in any order.

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Example:
VAR: P100 N T0 A FLM
The many identifiers and values of these instructions have been
conceived to guarantee compatibility between product evolution and
existing program libraries. They are usually used to solve malfunctions
or to find optimizations that cannot be obtained in any other way. The
table below lists the options available for the different machine
workcycles. A full description of each individual option is given in
alphabetical order.

VAR: Description Phase

A non-magnetic sheet cycle feeding
C1 mechanical centering cycle feeding
FLM sheet with protective film cycle feeding
F1…F3 pusher force selection cycle feeding
NDF NO double sheet check cycle feeding
O47 feeding of sheet rotated by +90° SDEX feeding
O48 feeding of sheet rotated by -90° SDEX feeding
O49 feeding of sheet rotated by 180° SDEX feeding

E40 search limited to macrofigure execution sequence SDEX manipulator

E42 NO aggregation of macrofigure punchings SDEX manipulator
E43 NO aggregation of macroinstruction punchings SDEX manipulator
O43 effect of alternative punches in manipulator path SDEX manipulator
V1…V10 selection of manipulator dynamics cycle manipulator

O2 NO priority for punchings towards downstream sheet grips SDEX repositioning

O8 correct hold on portion of holding scrap SDEX repositioning
O11 NO check on correct pincer grip SDEX repositioning
O20 manipulator pincer in front of x blade SDEX repositioning
O46 priority of VAR:Pnnn with respect to repositioning SDEX repositioning
constraints
P1…P122 selection of sheet locking devices for repositioning SDEX repositioning
R1…R5 selection of low pressure for closing pincers and/or clamp cycle repositioning

L1…L10 selection of rotation speed cycle rotation

O6 NO priority for punchings towards downstream sheet SDEX rotation
rotation phases
O45 rotation of sheet in most geometrically central position SDEX rotation
O62 unloading of last sheet rotated SDEX rotation

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VAR: Description Phase

B maximum force cycle punching
H high pressure in punching cycle punching
N Opti-Notch SDEX punching
MRC0.4 percentage of punch side engaged in REC nibbling SDEX punching
O14 complete machining without rotations SDEX punching
O15 generation of complete machining sequence SDEX punching
O17 correct attachment check SDEX punching
O22 conversion of S2 sequences into S0 sequences SDEX punching
O24 translation of all feasible operations at 180° SDEX punching
O44 NO automatic punch exchange – automatic NSB SDEX punching
O54 NO DBHT punch database and PUN cross-check SDEX punching
O55 REC on edge of sheet SDEX punching
O61 simultaneous operation of S2 manipulators SDEX punching
O63 elimination of overlapping punchings SDEX punching
Q0…Q1500 Y position comparison for assigning punchings at 0° or 180° SDEX punching
W presence of masking tool SDEX punching

O12 automatic generation of punch-embossing sequences SDEX embossing

O13 automatic generation of embossing–punch sequences SDEX embossing
O56 embossings before PCT part detachment SDEX embossing
O57 automatic rounding of edges in continuous embossings SDEX embossing
O59 centered manipulator grip with continuous embossing SDEX embossing
O72 embossings-pincers interference check SDEX embossing

D straightening of preliminary cut cycle shearing

E10 NO shearing scrap consolidation SDEX shearing
E11 shearing scrap consolidation on X SDEX shearing
E12 shearing scrap consolidation on Y SDEX shearing
E20 NO recovery of lost scrap SDEX shearing
G1…G4 blade clearance selection cycle shearing
M5…M100 modification to length of preliminary cut at 0° SDEX shearing
O1 preservation of entire holding scrap SDEX shearing
O3 priority of DES scrap destruction with respect to REC SDEX shearing
nibbling
O4 priority of TRI trimming with respect to REC nibbling SDEX shearing
O5 priority of PCT constraints with respect to regripping SDEX shearing
operations
O9 extended PCT SDEX shearing

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VAR: Description Phase

O10 NO PAC SDEX shearing
O18 sheet pressing device always up with high embossings cycle shearing
O21 extension of scrap loss check SDEX shearing
O27 NO PCT – execution of all cuts after all punchings SDEX shearing
O32 first S4-tandem – punchings after rotation SDEX shearing
O35 use of X blade blankholder disabled cycle shearing
O36 use of Y blade blankholder disabled cycle shearing
O37 slow Y retraction during CNU comb-style cutting cycle shearing
O41 holding-scrap collection hatch always open cycle shearing
O52 detachment of parts by punch SDEX shearing
O58 punching – DES scrap cutting sequence SDEX shearing
O64 scrap machining allowance close to holding scrap SDEX shearing
O65 NO x limits when regripping with cut in progress (CNT) SDEX shearing
O66 upward movement of conveyor with flexing sheet cycle shearing
O69 inversion of X partial cuts sequence SDEX shearing
O70 grip on holding scrap with a quarter of a pincer SDEX shearing
O73 NO O70 SDEX shearing
O83 replacement of precut at 0 degrees SDEX shearing
T0…T80 mode of holding scrap sub-division SDEX shearing

E41 NO search for punchings that can be made while a part is SDEX unloading
being unloaded
S1…S3 scrap bin selection cycle unloading
Z wait for part request from machine downstream cycle unloading

E1 reduced processing SDEX

O19 generation of .mcy file report SDEX
O23 generation of .time file report SDEX
O25 NO NLS – complete processing SDEX
O40 generation of info for ZED programming SDEX
O68 scrap weight calculation SDEX
O71 generation of data for S4 with PDP-11 SDEX
O67 reserved for tests SDEX

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A enables non-magnetic sheets to be fed and transferred.

B enables the maximum punching force for each punch. To save time the
force used for the reascent of the punch is always inserted by removing
the pushing force during the descent of the punch. For example, the
punches installed in the 7-ton positions normally lose 800 kg, whereas
those installed in the 26-ton positions normally lose 2450 kg.
VAR:B excludes the reascent force during the descent of the punch and
automatically increases reascent times of the punches according to the
value of machine constant 1008 (PNT08).
For example, if you write VAR:B and punch P22 has a reascent time of 70
milliseconds and machine constant 1008 a value of 0.4, the punch
reascent time will be 70 * (1 + 0.4) = 98 milliseconds.
C1 selects the sheet centering cycle against mechanical stop rather than
using an optical sensor; it is used when greater centering accuracy is
required.
D activates the sheet straightening cycle during shearing.
If several shear strokes are needed to separate a part, the partial cuts
along y will be made first, then those along x and lastly the total cut with
both blades.
Partial cuts produce a slight downwards bend in the flange downstream of
the blade in action.
When a partial cut along x is required after a partial cut along y, the sheet
must move towards the head and the partially cut flange may catch on the
lower y blade or the head. The straightening cycle is activated to prevent
this from happening. It is performed after the last partial cut along y and
consists of:
- clamping the sheet with the y blankholder;
- making the sheet extractor ascend in order to straighten the last flange
of the sheet cut.
The machine automatically prepares to perform this cycle when
processing material more than 2 mm thick as this is when the problem
usually occurs. With the VAR:D option, the cycle is also activated when
necessary for sheets less than 2 mm thick.
E1 enables partial processing. This is useful when you want to check quickly
that the program is correct without calculating the sequence of the
machine movements and the cycle time.
E10 disables the shearing scrap consolidation procedure.
The shearing scrap is consolidated in an attempt to reduce the total
number of cuts needed to eliminate all the shearing scrap present. If there
is any scrap below the minimum permitted dimension (three times the
thickness), the consolidation will go into error: at this point, you can either
correct the program or disable the consolidation by writing VAR:E10. This
option is automatic if PPR, REC...SFR or REC...SFP parts are present
and you have specified the rotation at which some of them are to be
unloaded.
E11 asks for priority to be given to the X direction when the shearing scrap is
consolidated.
E12 asks for priority to be given to the Y direction when the shearing scrap is
consolidated.

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E20 disables the recovery of any scrap lost in zones covered by shearing
scrap. If scrap is lost inside good parts, SDEX will go into error because
the sheet has not been programmed properly.
If, however, scrap is lost inside shearing scrap, this simply means that
some of the punchings on the perimeter of good parts have generated
scrap outside these good parts. SDEX will attempt to eliminate this scrap
by adding punchings.
This check can be removed by writing VAR:E20. You will then have to
add manually the punchings needed to eliminate the scrap that has been
generated inside the shearing scrap.
E40 speeds up the search for the sequence in which a macrofigure is
performed (the algorithm will stop at the first correct sequence it finds
instead of making all the attempts possible).
E41 disables the search for punchings that can be made while a part is being
unloaded.
E42 disables the aggregation of punchings in a macrofigure (a group of
several macroinstructions) with a view to optimizing the path of the
manipulator. This is useful with large macrofigures. The elaboration time
increases since there are more figures to analyze.
E43 disables the aggregation of punchings in a macroinstruction with a view to
optimizing the path of the manipulator. This is useful with large
macroinstructions. The elaboration time increases since there are more
figures to analyze.
F1 selects the minimum force for the pushers to center the blank.
F1 selects the minimum force;
F2 selects the medium force;
F3 selects the maximum force.
If you do not write this compilation option, the force of the pushers will be
chosen according to the value of machine constant no. 21.
FLM is the identifier for sheets with protective film.
G1 selects the minimum blade clearance.
G1 selects the minimum clearance;
G2 selects the medium clearance;
G3 selects the maximum clearance.
If you do not write this compilation option, the blade clearance will be
chosen according to the values of machine constants nos. 547 and 548.
H enables high-pressure operation. The S4 punching machine has two
distinct hydraulic circuits for moving the punches, one at low pressure and
one at high pressure. The machine usually works at low pressure. If you
write VAR:H, high pressure will be used to increase the punching and
shearing force. For example, the low pressure punching force for 7-ton
punches becomes 4.7 tons, that for 26-ton punches becomes 17.4 tons,
that for 12-ton punches becomes 8.4 tons, that for BU options goes from
8 tons to 5.4 tons and that for EI options goes from 5.4-tons to 3.1 tons.
L7 selects the dynamic characteristics required to rotate the sheet on a scale
of 1 to 10. Low values select slower characteristics and are used, for
example, to prevent sheets covered by protective film from slipping when
underneath the rotator.
M50 changes the depth of the preliminary cut made by the shear before the
sheet is rotated when using the PIE and PPR instructions without the 28
mm holding scrap. The value that has been attributed, for example 50, is
the variation to the length of the original preliminary cut.

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MRC0.4 defines the minimum percentage of engagement by the side of the punch
during a REC nibbling operation. For example, MRC0.4 means no less
than 40%.

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N enables the Opti-Notch function (only available under licence). Opti-Notch

reduces the number of punchings by aggregating adjoining REC
macroinstructions: the geometrical shape obtained uses a mixture of
larger punches and therefore requires fewer punchings. Opti-Notch only
elaborates REC instructions that satisfy the following requirements:
- they must be parallel to the axes of the sheet reference system
- they must not be included in a sequence
- they must not have the NSB specifier
- there must not be an obligatory way of holding the sheet (MHI, MLO,
MLE, MRI specifiers)
- they must not be linked to a part (see PAC specifier and J index)
- they must not have the SQM specifier
- they must not have the NLS specifier
- they must not have the SFR or SFP specifiers
- if the punch is specified, its E parameter must not be less than -100 (i.e.
the user gave the tool its code and it can only be replaced by tools with
the same E parameter).

Notches programmed (without VAR:N)

Notches optimized with Opti-Notch (with VAR:N)

NDF disables the double sheet check.

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 3. Programming the punching machine
3.12. Specifiers and options

O1 is used to prevent the trimming scrap on side U from being nibbled. The
punch is used to cover the portion of trimming that cannot be done by the
shear. It can serve to avoid these punchings.

V Side V U Side U
F Side F A Processing without VAR: 01
G Side G B Processing with VAR: 01

O2 disables the attribution of punchings in favour of manipulator grips further

downstream in the work cycle. The punchings are concentrated
downstream to make the workpiece more rigid. However, if the workpiece
is already rigid because of the geometry of the machinings, you can write
VAR:O2 to remove the constraint and reduce the number of sheet
regrips. See also VAR:06.
O3 forces the inner trim-cuts to be made by the shear before the figures that
interfere with them are punched. This may entail additional regrips and is
generally used with large nibbling operations that generate flexible strips.

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3. Programming the punching machine
3.12. Specifiers and options

Figure 42: Machining sequence without VAR: O3

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 3. Programming the punching machine
3.12. Specifiers and options

Figure 43: Machining sequence with VAR: O3

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3. Programming the punching machine
3.12. Specifiers and options

O4 forces the trim-cuts to be made on the starting sheet by the shear before
the figures that interfere with them are punched. This may entail
additional regrips and is generally used with large nibbling operations that
generate flexible strips.
O5 forces the punchings belonging to each PCT part to be made as late as
possible. In the absence of this option, the punchings are made according
to the position of the manipulator and with the smallest number of sheet
regrips. The PCT specifier is used when there are a lot of holes in a small
space because sheet detachment using the shear releases the
mechanical stress accumulated during punching. Adding the VAR:O5
option increases the number of punchings associated with each PCT part
at the cost of increasing the number of regrips.

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 3. Programming the punching machine
3.12. Specifiers and options

Figure 44: PCT parts programmed without VAR:05: sequence for punching and unloading the six parts program-
med. Punching is interrupted during the fourth part because of the need to regrip the sheet.

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3. Programming the punching machine
3.12. Specifiers and options

Figure 45: PCT parts programmed with VAR:05: sequence for punching and unloading the six parts programmed.
The sheet is only regripped after a part has been unloaded.

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 3. Programming the punching machine
3.12. Specifiers and options

O6 disables the attribution of the punchings in favour of the part that is

machined after the sheet has been rotated. The punchings are postponed
after the rotation to guarantee the rigidity of the sheet being machined.
Remember that SDEX first divides the punchings performed before and
after the rotation and then searches for any sheet grips and regrips within
the sets thus identified. O6 acts on the rotation attribution criteria whereas
O2 acts on the sheet regrips.
O8 enables the check that makes sure that the portions of the holding scrap
are held correctly. This check must not be confused with the pincer hold
check; VAR: O8 makes sure that any portions of holding scrap held touch
the pincer for a greater length than that defined in the machine constant
1492.
O9 automatically attributes the PCT specifier to the good parts adjoining
other parts declared PCT, except for shearing scrap. Using the O5 and
O9 options together allows you to respect the PCT constraints for all the
good parts on the sheet.

Figure 46: Panel programmed

A Punching and unloading the C End of punching and

first part unloading the second part
B Punching and unloading the
shearing scrap

Figure 47: Execution with VAR: O5

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3. Programming the punching machine
3.12. Specifiers and options

A Punching and unloading the C Punching and unloading the

first part second part
B Unloading the shearing scrap

Figure 48: Execution with VAR: O5 O9

O10 declares non-PAC (see Specifiers and options [} 222]) any punchings that
interfere with a part by less than the value of machine constant 1017.
O11 disables the manipulator pincers minimum grip check (half a pincer). This
option can be used to produce parts that have punchings on their edges
that prevent them from being held correctly.
O12 enables the automatic attribution of a work sequence between punchings
and embossings that interfere with each other. With this option, a
punching that interferes with an embossing will be made before it (unless
the sequence has been programmed otherwise).
O13 enables the automatic attribution of a work sequence between
embossings and punchings that interfere with each other. With this
option, a punching that interferes with an embossing will be made after it
(unless the sequence has been programmed otherwise).
O14 demands that all the punchings be performed before the sheet is rotated.
Remember that, if the blank can be processed entirely at 0°, SDEX will do
so automatically. This option is used to control which punchings cannot
be made at 0°.
O15 enables the machining sequences to be generated automatically during
the scrap loss dynamic check. This results in sequences where the
punchings are made inside a part and the part is then cut, as though all
the parts had the PCT specifier. It may entail additional regrips.
O17 enables the check that no parts are attached with microjoints smaller than
0.5 mm. SDEX checks that no scrap is lost but not that all the portions of
scrap in the sheet being processed are attached correctly.
O18 enables the request for the sheet presser to remain in the “up” position
between making the first high embossing and unloading the part with the
last high embossing (only for the CC type shear).
O19 generates the.mcy file report which contains all the information that SDEX
calculates for the machine cycles.
O20 enables the request for a pincer to be always in front of the X blade when
cutting parts with a Y co-ordinate (in the current sheet reference system)
of less than the value of machine constant n. 1092 (if the constant has a
value of 0, it will be assumed to be 200).

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 3. Programming the punching machine
3.12. Specifiers and options

O21 enables the request for the scrap loss check to also consider as “lost” any
shearing scrap that is attached to portions of holding scrap that were
detached from the sheet when it was punched and sheared). This scrap
is not normally eliminated automatically during the scrap loss check
because it will most probably be held by the manipulator during the final
execution sequence.
O22 enables the request for S2 type sequences to be considered as S0
sequences (see SEQ-ESQ instructions).
O23 generates the .time file report containing the partial times calculated by
SDEX for the current program.
O24 postpones all possible punchings until after the rotation. SDEX orders the
macrofigures to be performed after the rotation without breaking them up
or, as an alternative, before the rotation, again without breaking them up.
In the second case, O24 breaks the macrofigure up, performing the
possible punchings after the rotation.
O25 performs the entire elaboration, ignoring all the NLS specifiers present in
the program.
O27 performs all the cuts after all the punchings, ignoring the PCT requests
present in the program.
O32 enables the execution of punchings after the rotation performed by the
first punching machine in an S4-tandem system.
O35 disables the use of the blankholder of the X blade of the shear. Is used to
avoid flattening embossings near the cutting edge.
O36 disables the use of the blankholder of the Y blade of the shear. Is used to
avoid flattening embossings near the cutting edge.
O37 commands the Y manipulator to move slowly when retracting while
cutting parts with the CNU specifier (“comb” cutting).
O40 automatically generates the “name_Z.S4” program and the "name_Z.zgr"
file requested by Z_viewer to simulate and edit the Zed program. The
name_Z.S4 program will be generated if the name.S4 program contains
the VAR: O40 compilation option and SDEX does not find any errors. It
will be composed of the sequence of Zed operations needed to run the
name.S4 program.
O41 enables the request for the holding-scrap collection hatch to be kept open
when cutting parts adjoining the holding scrap too. Normally, this hatch is
only opened when one or more portions of holding scrap are about to be
detached.
O43 enables the use of alternative punches when optimizing the movements
of the manipulator. Normally, if a punching operation can be made by
several punches, the alternative punch will be considered during all the
machining phases except when optimizing the movements of the
manipulator.
O43 increases the machining time but it can reduce the cycle time.
O44 disables the automatic search for alternative punches: it is as though all
the instructions had the NSB specifier.
O45 forces the sheet to be rotated in the most geometrically central position.
This may increase the number of regrips.

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3.12. Specifiers and options

O46 forces all the sheet clamping organs programmed with VAR:Pnnn to be
used for regripping.
Respecting the sheet repositioning constraints such as:
a) Y limit for unloading the holding scrap through the dedicated hatch,
b) X and Y limit for maintaining the cutting edge along X,
c) X limit for regripping after a final cut along Y,
may sometimes cause some of these organs to be excluded.
Example: If you have written the VAR: P100 compilation option (so that
the rotator clamp and blankholder are used to clamp the sheet) and the
sheet is repositioned while an X cut is being made but the cutting edge
can only be maintained if the rotator clamp is not used to clamp the sheet,
the sheet will be repositioned using just the blankholder. If you write
VAR:P100 O46, the regripping operation will move the sheet so that both
the blankholder and the rotator clamp are used.
O47 forces the sheet to be fed with a rotation of +90° with respect to the
program written. This is useful when it is easier to program the sheet
rotated with respect to the orientation usually required for feeding. With
VAR:O47, any holding scrap is allocated to side F of the sheet instead of
side V as usual.
O48 forces the sheet to be fed with a rotation of -90° with respect to the
program written. This is useful when it is easier to program the sheet
rotated with respect to the orientation usually required for feeding. With
VAR:O48, any holding scrap is allocated to side U of the sheet instead of
side V as usual.
O49 forces the sheet to be fed with a rotation of +180° with respect to the
program written. With VAR:O49, any holding scrap is allocated to side G
of the sheet instead of side V as usual.
O52 enables a part to be detached by means of punchings. SDEX checks that
all the parts are cut and released by means of the shear blades,
otherwise it gives an error. O52 prevents this check from being made.
O54 disables the data check between PUN instructions and DBHT punch
database and the acquisition of the geometry of the special punches.
O55 increases by 6 mm along Y (value defined by CTM) those nibbling
operations that extend beyond the edge of the starting sheet. This means
that all the parts will be detached correctly, even if the sheets do not
respect the dimensional tolerances.
O56 makes sure that the embossings are made immediately before the part is
detached. With O56, the embossings are moved towards the end with
respect to the optimized path within the part.
O57 automatically rounds the sharp edges of continuous embossing profiles.
O58 alternates punchings that extend beyond the edge of the sheet with DES
scrap cuts. This prevents punchings that nibble a small amount of
material and wear the punch out prematurely from being made.
O59 enables the sheet to be gripped by positioning the middle pincer in front
of the profile to be made with continuous embossing. This is used to
guarantee a better grip during machining that releases a large amount of
stress on the sheet.
O61 enables the two manipulators of an S2 to work simultaneously if the
machine and the geometry of the panel permit it.
O62 rotates the last part produced by 180 degrees before unloading it, if no
holding scrap is present on the starting sheet. This is useful if the
machine downstream requires the part to have been rotated. The
modification of the Y grip is programmed as MPP: R360 Gnn.

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 3. Programming the punching machine
3.12. Specifiers and options

O63 eliminates the punchings (except the first) which overlap one another by
less than 0.2 mm.
O64 allows a 0.15 mm overhang on the scrap cuts adjacent to the holding
scrap, so as to eliminate any threads.
O65 allows the manipulator to move along X in order to reach the rotator
clamp, during regrips with an X cut in progress.
O66 forces the conveyor to rise before starting to unload, for XY cuts that have
the sheet down from the Y blade which flexes.
O67 reserved for tests.
O68 calculates the weight of the unused scrap in the sheet, considering
punchings and sheared scrap.
Weight of sheet fed - weight of scrap = net weight of part.
O69 An X shearing consists of a sequence of partial cuts and a total cut. The
partial cuts are made with a constant step except for the last one that is
made with a shorter step.
O69 inverts this sequence so as to make the short partial cut first and
then the remaining cuts with a constant step. It may increase the number
of regrips.
O70 forces all the holding scrap released when cutting the parts to be gripped
with at least one quarter of a pincer. As a result, the holding scrap is only
unloaded during the regripping operations or at the end of the sheet. O70
may increase the number of regrips.
(If you set machine constant 1049=1, all the programs will be elaborated
as O70).
O71 generates the .obj binary file compatible with the cycle for S4 punching
machines with PDP-11 controller and H head type.
This option is only available under licence.
O72 enables the check that the manipulator pincers do not crush the
embossings. Is useful when there are embossings on the edge of the
sheet. May increase the number of regrips.
O73 performs processing like VAR:O70 (or CTM1049) but, if it is not possible
to respect the grip on all the scrap, ignores this constraint.
O77 generates an error if preliminary cuts are required to produce good parts
and reduces the size of any recoverable scrap requiring preliminary cuts.
O78 enables slightly oversized parts (above 1524 mm) to be unloaded by
taking the rear deflector to the end of its stroke and thus avoiding the
“incorrect deflector positioning” error.
O80 forces a pincer to be present in front of the X blade when cutting with this
blade and generates a regripping error if this is not possible (like O20
which does not, however, generate an error but only a warning).

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3. Programming the punching machine
3.12. Specifiers and options

O83 allows trimming scrap that coincides with a precut at 0 degrees to be

punched, thus eliminating these precuts by punching them instead. To be
able to use this variable, there must be trimming scrap on side U of the
part;
if there isn’t, trimming scrap must be added using the TRI: U nn
instruction, where the value nn of the dimension of the trimming scrap will
depend on the dimensions of the punches installed in the head.

Example of eliminating a precut at 0 degrees by punching the scrap

instead.
O85 allows the Y manipulator to retract while the blank is being repositioned
between partial X cuts: this improves the unloading of the holding scrap
but impairs the accuracy of the cutting edge.
O86 aligns the cuts for breaking up the scrap with the partial cuts on the parts
located near the holding scrap. This prevents strips from being formed by
the partial cuts protruding into the portions of scrap.
O87 LWM option – device for measuring sheet fed – No sheet measurement.
O90 LWM option – device for measuring sheet fed – Y measurement with
centering guide.
O91 LWM option – device for measuring sheet fed – Y measurement with
LWM.
O92 LWM option – device for measuring sheet fed – X/Y measurement with
centering guide.
O93 LWM option – device for measuring sheet fed – X/Y measurement with
LWM.
O94 gives priority to unloading the shearing scrap that adjoins the holding
scrap.
O95 checks the minimum nibbling between punchings with different punches
on a macrofigure (the minimum nibbling is set using CTM 1528; if = 0, the
minimum will be 0.5.
O96 disables the anti-oscillation grip check whenever a part is cut.
This is useful for reducing the elaboration times for panels with a large
number of small parts, as it avoids performing the check each time the
shape of the sheet changes.
P22 enables the blank to be held during regripping cycles by punch P22 fitted
with a blind die instead of by the rotator clamp. Any other punch in the
head can be used, provided that it is fitted with a blind die (for example, if
you write "VAR:P5", punch P5 will be used).

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 3. Programming the punching machine
3.12. Specifiers and options

P27 enables the blank to be held during regripping cycles by the shear
blankholder instead of by the rotator clamp.
P100 enables the blank to be held during regripping cycles by the rotator clamp
and the shear blankholder acting at the same time. This is done to obtain
greater accuracy for large sheets.
P122 enables the blank to be held during regripping cycles by the rotator clamp
and punch P22 (122-100=22), fitted with a blind die, acting at the same
time. Any other punch in the head can be used, provided that it is fitted
with a blind die (for example, if you write "VAR:P105", punch P5 will be
used at the same time as the rotator clamp). This is done to obtain
greater accuracy for large sheets.
Q150 defines Y comparison value used to establish whether a punching must
be performed before or after the sheet has been rotated. SDEX normally
tries to make the punchings as late as possible (scrap loss check
permitting) because it is generally preferable to rotate the sheet when it is
as complete as possible. With VAR:Q150 all the punchings having y co-
ordinate in the program reference greater than 150 mm are made before
the sheet is rotated whenever it is possible to do so.
R selects low pressure to be used to close the manipulator pincers. This
prevents soft material from being scratched. Low pressure can be
selected for closing the rotator clamp too by adding the following values:
R1 closure of manipulator pincers;
R2 closure of rotator clamp;
R3 closure of manipulator pincers and rotator clamp;
R4 closure of rotator clamp only when regripping;
R5 closure of manipulator pincers and rotator clamp only when
regripping.
S1 selects bin 1 for the punching scrap. S2 and S3 select bins 2 and 3
respectively.
SU1 SU1 selects punching scrap extractor number 1;
SU2 selects punching scrap extractor number 2;
SU3 selects punching scrap extractor number 3.
SPH uses worktable with steel balls for rotation on S4 with additional worktable
with steel balls.
T22 declares the presence of holding scrap and the punch used to divide it. If
the position of the punch is not indicated (VAR: T), the holding scrap will
not be divided automatically and you who will have to choose which
punch to use. With VAR: T0, no punch, SDEX will automatically choose
which punch to use from among all those present.
V7 selects the dynamic characteristics of the manipulator (on a scale from 1
to 10). Low values select slower characteristics and are, for example,
used when processing sheets that are not completely flat.
Z forces all the parts to be transferred to the P4 Panel Bender. If the P4 is
engaged in a work cycle, the S4 waits for it to finish before transferring
the part; without this specifier, the parts can still be sent to the P4 (using
the appropriate selector on the S4 console) but, if the P4 is busy, the
sheet will be stacked and the S4 will not interrupt its production.
W defines the presence of masking tools.

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3.12. Specifiers and options

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 4. Monitor
3.12. Specifiers and options

4. Monitor

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2 MONITOR

Version 2.1

'
 This page has been left blank on purpose.

-2-
Table of contents
Introduction 5
What is Monitor? ............................................................................................................ 5

Definition of the functional areas 7

Main window .................................................................................................................. 7

Main menu commands 8

File menu......................................................................................................................... 8
Open …............................................................................................................. 9
Save as … ......................................................................................................... 9
Print …............................................................................................................ 10
Print setup ....................................................................................................... 11
Exit.................................................................................................................. 11
Edit menu ...................................................................................................................... 11
Find ................................................................................................................. 11
Add object....................................................................................................... 12
Add actor objects ............................................................................................ 12
Remove object ................................................................................................ 12
Remove all ...................................................................................................... 13
Flush................................................................................................................ 13
View menu .................................................................................................................... 13
Full mode (F8) ................................................................................................ 14
Watch mode (F9) ............................................................................................ 14
Picture ............................................................................................................. 14
User notes ....................................................................................................... 14
Object address................................................................................................. 15
Watch dialog ................................................................................................... 15
Log file............................................................................................................ 16
Select columns … ........................................................................................... 16
Toolbar............................................................................................................ 17
Status bar......................................................................................................... 17
Options menu ................................................................................................................ 17
Always on top ................................................................................................. 17
Auto-flush ....................................................................................................... 17
Auto watch dialog ........................................................................................... 18
Do not close command window...................................................................... 19
One command window for each axis.............................................................. 19
Help menu ..................................................................................................................... 19
Help topics ...................................................................................................... 19
Real-time CPU errors...................................................................................... 19
MACHM errors............................................................................................... 20
Plant safety documentation ............................................................................. 20
About Monitor ... ............................................................................................ 20

Shortcut button bar 21

Table of contents -3-

 Area for selecting a group of signals 22
Description .................................................................................................................... 22

Area for viewing the list of signals 24

Description .................................................................................................................... 24

Area for reading and commanding signals 26

Description by group..................................................................................................... 26
3 Drives ......................................................................................................... 26
3 Input and output states................................................................................ 27
3 Internal states.............................................................................................. 27
3 Numerical information ............................................................................... 28
3 Regulators, actors and generic actors ......................................................... 29
3 Can Nodes .................................................................................................. 31
3 Axes............................................................................................................ 32

Environment 34
Support files .................................................................................................................. 34
Application files.............................................................................................. 34
Machine files................................................................................................... 34

Trouble-shooting 35
Common problems ........................................................................................................ 35
Some families of signals or actors are not visible even when selected........... 35
Using panel-type windows.............................................................................. 35
Messages ....................................................................................................................... 35
Unable to open file.......................................................................................... 35
Operation not allowed at current user level .................................................... 36
Parameter outside range .................................................................................. 36
Error signals .................................................................................................................. 36

-4- Table of contents

MONITOR - EN 2.1 '

Introduction

What is Monitor?
Salvagnini machines are a complex set of kinematics with electrical and
hydraulic drives. These drives are composed of actuators, control systems,
regulators and sensors of various kinds; these devices interact using electrical
signals. An electrical signal allows us to identify the state of a device and to
command its operation. From a logical point of view, an electrical signal is
identified by an alphanumeric string that identifies the physical unit it belongs
to and the type of device it is associated with.
Example:
67 A 1 SQ 19 S
indicating:
67 The primary unit it belongs to: stacking station;
A Multiplicity indicator: when a sub-system occurs more than once
within the same system, the first occurrence is indicated by A, the
second by B, the third by C, and so on;
1 Whole number which identifies the primary units that are identical
or similar to one another within the same sub-system;
SQ Class of signal: position state signal;
19 Progressive whole number of the component in the system;
S Further identifier (if needed).
In graphic terms, the signal code can be represented as follows:
Impilatore 1 Stackers Impilatore 2

S4

67A1... 67B1...

67A2... 67B2...

67A3... 67B3...
tavole tables

The Monitor application is used to view and command the states and actions
of the active parts of the machine (axes, regulators, solenoid valves and
sensors) directly.
Its interface allows the user to manage the signals for complex systems,
configured with more than one power cabinet, in the same window.

Introduction -5-
MONITOR - EN 2.1 '
The new version of the application retains all the functions of the old one,
such as axis command management (interpolated axis movement, speed
tracking and so on), the possibility of saving work configurations and the
ability to record all the operations performed by the user, together with a
number of other helpful functions.
It is now also possible to monitor the states of the Drives, to monitor and
command the states of the Generic actors and to work with different
display modes.
The new interface also allows different types of information to be displayed in
the same window, which makes it much more compact and easy to manage.

-6- Introduction
MONITOR - EN 2.1 '

Definition of the functional

areas

Main window
To activate the Monitor application, select and click on the program in the
Salvagnini Console Tools menu.

When you start to use Monitor, the following window appears:

1. Menu bar: Main menu

commands for the
application.
2. Shortcut button bar:
contains buttons that
duplicate the most
frequently used menu
items.
3. Area for selecting a group
of signals.
4. Area for viewing the list
of signals that belong to
the group selected.
5. Area for reading and
commanding signals.
6. Status bar.
Fig. 1

Definition of the functional areas -7-

MONITOR - EN 2.1 '

Main menu commands

File menu
When you select File in the main menu, the following pull-down menu
appears:

If you want to perform a Command/Action, you must log on as an Expert

User by selecting Expert logon in the File menu.
In particular, you will only be allowed to read information about the axes.
You will only be able to command the movement of an axis if you log on as
an Expert User and give the password reserved exclusively for use by
Salvagnini staff. Axis movement commands can endanger both staff and the
machine.

If you attempt to perform a Command/Action as a Normal User, the following

message will appear:

Fig. 2

-8- Main menu commands

MONITOR - EN 2.1 '
Open …
If you select Open in the File menu, the following window will appear,
allowing you to retrieve a configuration you saved earlier.

Select the configuration you want from the list and click on Open. The
"photograph" of the objects you selected earlier will reappear on the screen.

Save as …
The File menu allows you to save work configurations.
The concept of "work configuration" arises from the fact that you may need to
control certain machine functions again and again, repeatedly selecting the
same group of objects to be read and commanded. It can, therefore, be useful
to "photograph" this group of objects and give it a name. It will then be saved
on file and, the next time you want to use it, you can simply retrieve the
configuration with that name without having to reselect the objects one by
one.
If you select Save as in the File menu, the following window will appear. It
allows you to select a number of objects and save them in the Read and
command area as a work configuration.

Write the name you want to give the configuration in the File name box and
click on Save.
The configuration has now been saved and, from now on, you will always be
able to retrieve it, even if you close Salvagnini Monitor and then reopen it.

Main menu commands -9-

MONITOR - EN 2.1 '
Print …
If you select Print in the File menu, the following window will appear:

All the information currently present in the area where you have positioned
the cursor will be printed in a table.
For example, if you give the Print command when you have selected a signal
in the 71HArea for viewing the list of signals as shown below ...

... the following table will be printed:

The same is true if you want to print the information in the 72HArea for
reading and commanding signals, just position the cursor on any of the lines
in area 5.

- 10 - Main menu commands

MONITOR - EN 2.1 '
Print setup
If you select Print setup in the File menu, the print setup window will
appear:

Exit
Select Exit in the File menu to close the application.

Edit menu
When you select Edit in the main menu, the following pull-down menu
appears:

Find
If you select Find in the Edit menu, the following window will appear:

Main menu commands - 11 -

MONITOR - EN 2.1 '
This command helps you to search for a signal among those present in the
71HArea for viewing the list of signals in Fig. 1.
To search in either the Code or the Description column, set the Criteria in
this window accordingly.

Add object
The Add object command in the Edit menu is only active if there are signals
present in the 71HArea for viewing the list of signals (area 4). It is used to add
the signal selected to the Area for reading and commanding signals (area 5).

Add actor objects

The Add actor objects command in the Edit menu is only active if an
object belonging to the Actors group has been selected in the Area for
reading and commanding signals.
An Actor object is a signal that uses other objects (axes, solenoid valves, etc.)
to perform a given action.
When this command is given, all the objects that are involved in performing
the action concerned are listed beneath the Actor object selected.

Remove object
The Remove object command in the Edit menu is only active when a
signal is selected in the Area for reading and commanding signals (area 5).
It is used to eliminate the line relating to the signal selected.

- 12 - Main menu commands

MONITOR - EN 2.1 '
Remove all
The Remove all command in the Edit menu is only active when a line is
selected in the Area for reading and commanding signals (area 5).
It allows the entire signal configuration you created in area 5 to be removed in
a single operation.
Before the configuration selected is removed, the following window appears
to ask you for confirmation:

Click on YES to remove the configuration; click on NO to exit without

removing it.

Flush
The Flush command in the Edit menu is only active if the Auto-flush
option in the Options menu is disabled.
When you modify the value of a signal, an asterisk appears in the appropriate
“Value” field. To make the modification effective, you must either press F5 or
click on Flush in the Edit file.
This command is useful when you need to modify a number of signals at the
same time: first act in the “Command/Action” fields of the signals concerned,
then press F5 to update all the values at the same time.

View menu
When you select View in the main menu, the following pull-down menu
appears:

Main menu commands - 13 -

MONITOR - EN 2.1 '
Full mode (F8)
The Full mode command in the View menu activates the full-screen viewing
mode.
The Monitor window appears with all the areas indicated in Fig. 1.
This mode can also be activated using the F8 key.

Watch mode (F9)

The Watch mode command in the View menu reduces the Monitor window
to just the Area for reading and commanding signals (5).

Fig. 3

This viewing mode is very useful when the operator has to work with other
applications while keeping an eye on the values of a number of signals.
This mode can also be activated using the F9 key.
Another way of going from one mode to the other is to press the first of the
four buttons in the top right-hand corner of the Monitor window (as shown by
the arrow in Fig. 3).

Picture
The Picture command in the View menu shows a photo of the part of the
machine that contains the physical sensor associated with the signal under
examination (if such a photo is available).

User notes
The User notes command in the View menu activates a window in which
you can read and write any information about the object. This notepad can
also be accessed from the Salvagnini Console time-out window (see the
relative manual).

- 14 - Main menu commands

MONITOR - EN 2.1 '

Object address
The Object address command in the View menu activates the following
window, which shows the memory address of the Object on the electronic
card used to run the real-time processes.

Watch dialog
An axis is a system composed of a movable organ and the units that govern it.
An axis type signal is characterized by a number of parameters.
The Watch dialog command in the View menu is only active if the Auto
Watch dialog option in the Options menu is disabled.
If you select a signal relating to an axis in the Area for reading and
commanding signals (5) in Fig. 1 and enable the Watch dialog command,
the following window will appear and you will be able to monitor the signal
selected.

Main menu commands - 15 -

MONITOR - EN 2.1 '
Log file
The Log file command in the View menu opens the SMON.log file in a
new, read-only window. The activities of the Monitor application are recorded
in this file.

To search for a word or phrase in this file, click on the Find button:

Select columns …
The Select columns command in the View menu activates the following
window where you can select which columns you want to appear in the
Objects list.
The “Object code” and “Description” columns will always appear.

- 16 - Main menu commands

MONITOR - EN 2.1 '
Toolbar
The Toolbar command in the View menu activates or deactivates the toolbar
(2) shown in Fig. 1.

The tick (9) next to the command means that the toolbar can be seen on the
screen.

Status bar

This is located at the bottom of the Monitor interface. It provides information

about the status of the system.
For help, press F1 . : the F1 function button opens the Salvagnini Monitor
manual on the screen.

: this shows whether communication with the RTCPU

real-time process control card has been interrupted (plug out) or is active as
normal (plug in).

The tick (9) next to the command means that the status bar can be seen on
the screen.

Options menu
When you select Options in the main menu, the following pull-down menu
appears:

Always on top
If the Always on top command in the Options menu is active, the Monitor
window will always be on top of the windows for all the other applications.

Auto-flush
If the Auto-flush command in the Options menu is active, when you
modify the “Command/Action” field for a signal, the real-time card will apply
the value to the Object selected.
The result of this action will be shown in the “Value” field.

Main menu commands - 17 -

MONITOR - EN 2.1 '

If the Auto-flush command is not active, and you modify the state in the
“Command/Action” column, the “Value” column for the Object selected will
not change but an asterisk (*) will appear next to the existing value.

To confirm the modification you made in the “Command/Action” field, press

F5 (see the description of the Flush command).

Auto watch dialog

If the Auto watch dialog command in the Options menu is active, when
you double-click on the signal relating to an axis in the list of signals present
in area 4 of Fig. 1, the “Watch dialog” window will appear automatically.
A description of the information contained in this window can be found in the
3 Axes chapter on page 32.

If the command is not active, proceed as indicated in the Watch dialog

paragraph on page 15.

- 18 - Main menu commands

MONITOR - EN 2.1 '
Do not close command window
The Do not close command window command in the Options menu is
used to keep the Exec action window open even after executing the
command.
This command can also be enabled/disabled directly from the Exec action
window by clicking on the buttons indicated by the arrows in the figures
below.

One command window for each axis

The One command window for each axis command in the Options
menu is used to handle a number of Axis windows.
It is useful when you need to command several Axes at the same time.

Help menu
When you select Help in the main menu, the following pull-down menu
appears:

Help topics
This function allows you to view this manual.

Real-time CPU errors

This function allows you to view the manual where the errors generated by
the electronic real-time process control card are described.

Main menu commands - 19 -

MONITOR - EN 2.1 '
MACHM errors
This function allows you to view the manual where the errors generated by
the MACHM electronic axis control card are described.

Plant safety documentation

This function allows you to view the safety manual.

About Monitor ...

The About Monitor item in the Help menu activates the window that gives
information about the application.

- 20 - Main menu commands

MONITOR - EN 2.1 '

Shortcut button bar

Fig. 4

1. This button has the same function as Exit in the File menu
2. This button has the same function as Open in the File menu
3. This button has the same function as Save as in the File menu
4. This button has the same function as Find in the Edit menu
5. This button has the same function as Add object in the Edit menu
6. This button has the same function as Remove object in the Edit
menu
7. This button has the same function as Remove all in the Edit menu
8. This button has the same function as Watch dialog in the View
menu
9. This button has the same function as User notes in the View menu
10. This button has the same function as Picture in the View menu
11. This button has the same function as Print in the File menu
12. This button has the same function as About Monitor in the Help
menu

Shortcut button bar - 21 -

MONITOR - EN 2.1 '

Area for selecting a group of

signals

Description
This tree structure represents a set of objects that can be sub-divided as follows:
At the top level, there are the
Groups of signals:
ƒ Drives: contains information about the state of the drives (i.e. whether
or not they are enabled);
ƒ Input states: contains information about the state of the discrete sensors
that are connected as inputs to the controller;
ƒ Output states: contains information about the state of the discrete
actors that are connected as outputs from the controller;
ƒ Internal states: contains information about the logical states that the
system has to respect;
ƒ Numerical information: contains information about the analog sensors
that are connected as inputs to the controller;
ƒ Regulators: contains information about the state of the proportional
valves that are connected as inputs to the controller;
ƒ Can Nodes: contains information about the Can Nodes that are present
in the system;
ƒ Axes: contains information about the numerically controlled axes that
are present in the system and connected to the controller;
ƒ Generic actors: these are complex actors (such as the angle
measurement device on the ROBOformER system);
ƒ Actors: contains information about the regulators and axes that are
present in the system and connected to the controller.
At a lower level, each group may contain a number of sub-systems that go to
compose the machine.
For example, some of the groups of signals for the ROBOformER system are
sub-divided into:
ƒ H80_PPU: contains all the signals for the H80 robot;
ƒ LVD: contains all the signals for the press.
Family of signals: each sub-system, in turn, contains different types or families
of signals: SA selectors, SB pushbuttons, SP pressure sensors, ST temperature
sensors, SL level sensors, SF filter sensors, SQ position sensors, SAB-SAR-
SAT-SAZ etc. axis states, etc.

- 22 - Area for selecting a group of signals

MONITOR - EN 2.1 '
If the configuration of the Salvagnini system contains not only the electrical
cabinet of the main machine but also a second cabinet that governs a loading-
unloading station, the tree structure will have the following appearance:

In the area for selecting the group of signals, there will be two tree structures
with the same groups of signals: the first with the signals for the main system
and the second with those for the loading-unloading station.

Area for selecting a group of signals - 23 -

MONITOR - EN 2.1 '

Area for viewing the list of

signals

Description
If, in the selection area, you select the box 3 relating to a main group of
signals, all the boxes relating to its sub-groups will automatically be selected.
This means that all the signals relating to the group selected will appear in the
viewing area, without distinguishing between sub-systems and families of
signals.
To narrow down the field of signals to certain sub-systems and families of
signals, tick only the box 3 near the sub-group you want to view.

- 24 - Area for viewing the list of signals

MONITOR - EN 2.1 '
The following information about the signal will appear in the viewing area:
Obj. code: this is the code of the signal;
System: this is the code of the Salvagnini system;
Sub-system: these are the sub-systems that go to compose the Salvagnini
system under examination;
Family: this is the type of signal:
AD Signal for commanding flow regulators
AH Signal for commanding hydrodynamic axes
AI Signal for commanding interpolated axes
AP Signal for commanding pressure regulators
AR Signal for commanding the robot
AS Signal for commanding hydrodynamic axes with
servovalves
AT Signal for commanding position counters
AX Signal for commanding electrical axes
HA Signal for commanding sirens
HL Signal for commanding bulbs
IN Numerical information
KA Signal for commanding relays
KM Signal for commanding contactors
SA State signal for selectors
SAB State signal for axes (enable)
SAR State signal for axes (stop)
SAZ State signal for axes (reset)
SB State signal for pushbuttons and control-sticks
SC State signal
SE State signal for axes (position)
SEI State signal for axes (error)
SF State signal for blockages
SIT State signal for axes (persistence)
SL State signal for level
SP State signal for pressure
SQ State signal for position
SRI State signal for axes (relaxation)
SRQ State signal for axes (position setting)
SSD State signal for axes (safety disable)
ST State signal for temperature
SVE State signal for axes (reaching required speed)
YA Signal for commanding electromagnets
YB Signal for commanding brakes
YC Signal for commanding gears
YV Signal for commanding solenoid valves
YV**A Signal for commanding solenoid valves (solenoid A)
YV**B Signal for commanding solenoid valves (solenoid B);
Description: this is the function of the signal.

Area for viewing the list of signals - 25 -

MONITOR - EN 2.1 '

Area for reading and

commanding signals

Description by group
To read or command (if permitted) the state of a signal, it must be added to
the 72HArea for reading and commanding signals we are about to
describe. To do this, double click on the signal in the 71HArea for viewing
the list of signals or give the Add object command.
The configuration that appears in the 72HArea for reading and
commanding signals will vary depending on which group the signal selected
belongs to.

3 Drives

The signals that belong to the Drives group cannot be commanded. You can
only read whether their value is ON or OFF (i.e. whether or not they are
enabled).

- 26 - Area for reading and commanding signals

MONITOR - EN 2.1 '
3 Input and output states

Input states

Output states

All the “Input state” and “Output state” signals can be commanded.
The ON/OFF value of the signal (shown in the “Value” column) can be
modified by clicking on one of the two buttons in the “Command/Action”
column (see the chapter on Auto-flush).

3 Internal states

All the signals that belong to the Internal States group can have one of the
following values: ON, OFF or VALUE SET.

Area for reading and commanding signals - 27 -

MONITOR - EN 2.1 '
To set a value other than ON/OFF, click on the button with the three dots. The
following window will appear:

3 Numerical information

The signals that belong to the Numerical Information group cannot be

commanded, but only read.
The red line in the box in the Value field gives a graphic representation of the
percentage of the real value with respect to the maximum value that can be
reached. In the above example, the value of 0.00 is represented by the red line
that extends from the far left to the very centre of the cell.

- 28 - Area for reading and commanding signals

MONITOR - EN 2.1 '
3 Regulators, actors and generic actors

The signals that belong to these groups are signals that can perform
commands.
Click on the pull-down menu in the “Command/Action” column to select
the command you want to perform on the signal chosen.
Which commands are present in the pull-down menu will depend on the
signal you have selected.
When you click on the command in the pull-down menu, the following
window appears:

Area for reading and commanding signals - 29 -

MONITOR - EN 2.1 '
The “Exec action” window contains the following information:
Actor: corresponds to the description/function of the signal;
Action: describes the action you want to perform;
the pull-down menu of the “Exec action” window contains
the same actions as the pull-down menu of the
Command/Action column in the 72HArea for reading
and commanding signals;
Commands: shows the syntax of the action;
Parameters: lists the parameters that need to be set in order to perform
the action selected.

If the action does not include any modifications to parameters, the “Exec
action” window will have the following appearance:

When a command is performed while the system is running, the “Values”

shown in the 72HArea for reading and commanding signals for the
Generic Actors group (such as the angle measuring tool) will change
according to the measurements made by the system.

- 30 - Area for reading and commanding signals

MONITOR - EN 2.1 '
3 Can Nodes

If you select the group Can Nodes in area 3, you will see in area 4 a list of
all the Can Nodes that are present in the system.
In area 4, you will see the following information about the Can Node that has
been selected:

Obj Code:
CAN_1_1A1+P100_5 indicates the code relating to the CAN
node;
System:
S4_1048 identifies the system;
Description:
Node ID 5 identifies the CAN node;
box 1A1+P100 identifies the terminal box within the
electrical cabinet;
CAN network 1 indicates the number of the CAN network.

If you select a CAN node in area 4, you will see in area 5 a list of all the
signals run by the CAN node that has been selected.
The signals that a CAN node can run are: input/output signals, numerical
information and regulators.

Area for reading and commanding signals - 31 -

MONITOR - EN 2.1 '
3 Axes
There are three categories of axis: normal axes, robot axes and interpolated
axes.
Each category of axis has its own reading window.
Which of the following windows appears will depend on the type of axis
selected:

Normal axis Robot axis Interpolated axis

All the information in the Axis window can also be read in the 72HArea for
reading and commanding signals by expanding the structure beneath the
signal selected.

- 32 - Area for reading and commanding signals

MONITOR - EN 2.1 '
Normal axis
The title-bar of this window gives the code and name of the axis selected. The
window is divided into four areas:
1. Axis states area: this area shows the states associated with the axis;
2. Commands area: this area shows the last command received by the
axis, together with the relative Parameters and Values. The type
and number of parameters will depend on the axis and on the action
commanded;
3. Parameter/alternative value: this area shows the value of the
parameter selected in the pull-down menu;
4. Real position: this area gives the current position of the axis,
expressed in the appropriate unit of measurement.

Robot axis
The title-bar of this window gives the code and name of the axis selected. The
window is divided into four areas:
1. Axis states area: this area shows the states associated with the
axis;
2. Commands area: this area shows the last command received by the
axis, together with the relative Parameters and Values. The type
and number of parameters will depend on the axis and on the action
commanded;
3. Parameter/alternative value: this area shows the value of the
parameter selected in the pull-down menu;
4. Real position: use the scroll up/down arrows to view the values of
the positions/joints in this area. Lengthen the window to view all these
values without using the arrows.

Interpolated axis
In Salvagnini Monitor, you can select an interpolated axis and ask to read the
commands that have been given to it.
A window like the one shown above will appear, but only two areas will be
significant: the Axis states area (1) and the Commands area (2).

Area for reading and commanding signals - 33 -

MONITOR - EN 2.1 '

Environment

Support files
The part of the file system that is concerned with the Monitor application can
be divided into Application files and Machine files.

Application files
These are the files that the application needs for it to be able to operate.
In the $SYSCON/syscon/bin/smon directory:
smon.exe: file for running the application;
smon_*.dll: resource files in the various languages used.

Machine files
Support for Salvagnini Console:
These are the files contained in the $SYSCON/syscon/<nome_macchina>
directory.
The scsfiles/monitor/WS directory contains the files for saving and restoring
workspace but is not indispensable.
scsfiles/bird_add: the "GA_add" file has been added. It contains a list of the
Generic Actors.
scsfiles/monitor/action: an ".ini" file has been added for each Generic Actor,
describing its characteristics.
scsfiles/monitor/action: the "SubSets" file has been added. It contains the
association between the code and the number of the sub-systems; it is not
indispensable.
Only the Action and Actors files for the current language will be used (the
Axes file is no longer used).
scsfiles/monitor/command: only files for the current language will be used.
scsfiles/monitor/state: only files for the current language will be used.
The scsfiles/scs_config/sysCon.ini file has been up-dated with a number of
new items and some modifications to existing ones.
The scsfiles/scs_db/monTrace directory has been added for the Monitor log
files; it is not indispensable.

- 34 - Environment
MONITOR - EN 2.1 '

Trouble-shooting

Common problems

Some families of signals or actors are not

visible even when selected
This is typically a machine configuration problem. The most probable cases
are: the signals are missing because the machine does not have them; the
signals or actors file has not been translated into the language being used;
there is an error in the "sysCon.ini" file.

Using panel-type windows

Most of the windows in this application are panel-type windows that can be
shortened or lengthened as required. To obtain the view you require, position
the pointer on one of the sides and press MB1 while dragging the mouse
upwards or downwards.
Panel-type windows may give you a few problems the first time you use them.
If you close a panel almost completely (so that only the title remains), you
will not be able to see any of the information in it (you may also do this on
purpose, so as to leave more space for the other panels). To re-open a panel,
simply re-lengthen the window by dragging the rectangles on the separators.

Messages

Unable to open file

This error message may appear in different situations and for different types
of file. It usually gives the absolute path of the file it has been unable to find.

Trouble-shooting - 35 -
MONITOR - EN 2.1 '
Operation not allowed at current user level
With Salvagnini Console it is possible to access Monitor from user levels
below that of Expert User. Not all functions of Monitor are, however,
accessible to all users:
user levels below that of Expert User have "read only" access;
Expert Users have "read and command (all)" access.
If you attempt to issue a command but did not access Monitor as an Expert
User, the message in Fig. 2 will appear and the command will not - of course -
be implemented.

Parameter outside range

This message will appear if you give an action parameter a value that is
outside the permitted range. The message gives the code of the parameter that
is invalid; in this version, you can only see the permitted range of values via
the configuration file for the actor concerned (this will generally be an axis or
a regulator).

Error signals
Error signals are messages that appear on the error standard (usually the shell
or the console). These messages sometimes appear in irrecoverable situations
and are mainly used for debugging. Please contact the Automation and
Control Systems Office.

- 36 - Trouble-shooting
4. Monitor
3.12. Specifiers and options

- 292 - S4XE.30 - S4_1553 - V20160202EN

 5. Maintenance Manager
3.12. Specifiers and options

5. Maintenance Manager

S4XE.30 - S4_1553 - V20160202EN - 293 -

3 Maintenance Manager

Version 1.1

'
 This page has been left blank intentionally.

-2-
Table of contents
Introduction 5
What is MAINTENANCE MANAGER ......................................................................... 5
Who uses MAINTENANCE MANAGER...................................................................... 6

Definition of functional areas 7

Main window .................................................................................................................. 7
1. Main menu........................................................................................................ 8
2. Toolbar ............................................................................................................. 8
3. Task bar ............................................................................................................ 9
4. Current view selection buttons ......................................................................... 9
5. Triggered events viewing filters ....................................................................... 9
7. State of connection with Real-Time control ................................................... 11

Main menu commands 12

File menu....................................................................................................................... 12
Logon.................................................................................................................. 12
Change password................................................................................................ 12
Refresh Data ....................................................................................................... 12
Print… ................................................................................................................ 12
Print setup… ....................................................................................................... 12
Exit ..................................................................................................................... 12
Shutdown............................................................................................................ 12
Edit menu ...................................................................................................................... 13
Add ..................................................................................................................... 13
Modify ................................................................................................................ 13
Delete.................................................................................................................. 13
View menu .................................................................................................................... 13
Current view ....................................................................................................... 13
Triggered Events................................................................................................. 14
Salvagnini Events ............................................................................................... 14
User Events......................................................................................................... 14
States................................................................................................................... 14
Axis Interval ....................................................................................................... 14
Action ................................................................................................................. 14
WorkSpaces........................................................................................................ 14
Toolbar ............................................................................................................... 15
Status bar ............................................................................................................ 15
Tools menu.................................................................................................................... 15
Options ............................................................................................................... 15
? menu ........................................................................................................................... 16
Help guide .......................................................................................................... 16
About Maintenance Manager… ......................................................................... 16

How to use the application 17

Programme structure ..................................................................................................... 17
MAINTENANCE View................................................................................................ 17

Table of contents -3-

 Triggered Events Table ...................................................................................... 18
Salvagnini Events Table ..................................................................................... 20
User-defined Events Table ................................................................................. 21
SYSTEM View… ......................................................................................................... 23
States Table......................................................................................................... 24
Axis Interval Table ............................................................................................. 26
Action Table ....................................................................................................... 28
WorkSpace Table ............................................................................................... 30
Tables and Graphs .............................................................................................. 32

Environment and configuration 34

Application files ............................................................................................................ 34
System files ................................................................................................................... 34
DATABASE....................................................................................................... 34
CONFIGURATION ........................................................................................... 34

Glossary 35

-4- Table of contents

MAINTENANCE MANAGER - EN 1.1 '

Introduction

What is MAINTENANCE MANAGER

Version 2.0 of the MAINTENANCE MANAGER is an application created
for managing the scheduled maintenance of Salvagnini systems.
The programme can manage maintenance events, suitably defined by
Salvagnini engineers, and events associated with wear of particular system
components.
The objective of this application is thus to assure the utmost efficiency of the
Salvagnini system.
The events managed can be split into two categories:
1. Salvagnini-defined events:
! inspection events for system inspection
! routine maintenance events
! non-routine maintenance events performed by Salvagnini’s
own specialized personnel only
2. User-defined events:
! inspection events for system inspection
! routine maintenance events
Said events may be encountered in one of the following cases:
1. we pass a given moment (spot time) in the time since the system was
first started.
2. a given frequency value (days, weeks, months etc.) in the time since
the system was first started is exceeded.
3. we pass a spot time relating to the machine time associated with the
system remaining in a given status (production, laser on, error etc.).
4. a given machine time frequency value, expressed in hours, associated
with the system remaining in a given status (production, laser on, error
etc.) is exceeded.
5. the change of state (ON/OFF) counter for a particular system
component exceeds a given alarm threshold.
6. the counter for the distance run over time by an electric or hydraulic
axis exceeds a given alarm threshold.
7. notification from a machine cycle.

Introduction -5-
MAINTENANCE MANAGER - EN 1.1 '
Whenever set alarm limits or time limits are exceeded, the programme
generates and stores an alarm and sends a relevant warning up on screen so
that the operator, advised of the problem, can act accordingly.
In addition, storing alarms means a log file is created with a record of events
that have occurred on the machine and what maintenance was performed.
The MAINTENANCE MANAGER application is launched from
SysConShell using the Instruments menu.
This document is split into two parts: the first is a “user guide” for the
application and integration of the SysConShell user guide; the second is a
document containing environment and configuration specifications of the file
system required to make MAINTENANCE MANAGER work.

Who uses MAINTENANCE MANAGER

The MAINTENANCE MANAGER application is meant for use by anybody
working directly on the system or managing its maintenance so that alarm
warnings can be received and dealt with.

-6- Introduction
MAINTENANCE MANAGER - EN 1.1 '

Definition of functional areas

Main window
When the application is run, the following window appears:

1. Menu bar: the application’s main menu items.

2. Command button bar or toolbar: contains buttons performing the same
functions as some of the most commonly used menu options.
3. Task bar
4. Current view selection buttons
5. Alarm viewing filters
6. Display area
7. State of connection with Real-Time control

Definition of functional areas -7-

MAINTENANCE MANAGER - EN 1.1 '
1. Main menu
At the top of the window is the main menu, which allows you to perform all
the functions offered by the MAINTENANCE MANAGER programme.
To launch a function, simply open the pull-down menu the function appears in
and select it with the mouse.
Some menu items do not perform an operation directly, but let you enable or
disable an option: in this case, there is a selection button next to the menu
item indicating whether that option is enabled or not.

2. Toolbar
To make using the system more immediate, some operations that can be called
up via the menus are also featured on a command bar located directly below
the main menu.

Same as Exit option from File menu

Same as Add option from Edit menu

Same as Modify option from Edit menu

Same as Delete option from Edit menu

Same as Current View / Graph option from View menu

Same as Current View / List option from View menu

Same as Refresh Data option from File menu

Same as Print option from File menu

Same as About Maintenance Manager… option from Help

menu

-8- Definition of functional areas

MAINTENANCE MANAGER - EN 1.1 '
3. Task bar
To make using the application easier and help the user switch quickly
between the various interfaces, a scroll menu has been introduced on the right
of the display area. With this scroll menu, you can switch from
MAINTENANCE view to SYSTEM view, and you are shown the current
view option selected.

4. Current view selection buttons

Let you call up the tables relating to the currently active view.

5. Triggered events viewing filters

Let you filter events based on their status or the date they occurred.
Starting with the full view of triggered events:

we can switch to viewing just those events that have not been checked:

Definition of functional areas -9-

MAINTENANCE MANAGER - EN 1.1 '
or to viewing just pending events:

or to viewing just events that have occurred in the last week:

or to viewing just events that have occurred in the last week and, of these,
only events that are still pending:

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MAINTENANCE MANAGER - EN 1.1 '
6. Display area
Area in which the various alarm events or system components being
monitored are displayed.
It is made up of a series of columns, each with a heading depending on what
kind of table is active.

7. State of connection with Real-Time control

Symbol indicating the state of MAINTENANCE MANAGER connection
with Real-Time Software.

If symbol appears, the MAINTENANCE MANAGER

programme is not connected with Real-Time control. Counter values
calculated by the RTCPU are not forwarded to MAINTENANCE
MANAGER meaning the application’s counters are not updated. This is an
anomalous situation meaning there is some error or other.

If symbol appears, the MAINTENANCE MANAGER

programme is connected with Real-Time control and the counters’ value is
updated correctly. This is the programme’s normal operating condition.

Definition of functional areas - 11 -

MAINTENANCE MANAGER - EN 1.1 '

Main menu commands

File menu

Logon
Used to log on to the application as an “expert user”.
In this mode, Salvagnini’s specialized technical personnel can change the
status of any non-routine maintenance events.

Change password
Lets you change the password associated with the “expert user”.

Refresh Data
Updates all counters of monitored objects.
This command causes a refresh request to be sent to the Real-Time control,
which replies by sending the counter values of all components currently being
monitored.

Print…
Prints the contents of the display area.

Print setup…
Calls up the dialogue box for setting print options.

Exit
Closes the programme’s main window. The maintenance events scheduling
part remains active, however, as long as SysConShell is still active.

Shutdown
Closes the application; maintenance events scheduling is aborted. This
command is only available to “expert users”.

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MAINTENANCE MANAGER - EN 1.1 '
Edit menu

Add
Calls up the dialogue box for entering new events.
If the display area is active, it allows you to add a new element.

Modify
Calls up the dialogue box for editing the currently selected element.
If the display area is active, it allows you to edit the selected element.

Delete
Deletes the currently selected element.
If the display area is active, it allows you to remove the selected element.

View menu

Current view
Lets you filter the viewing type:

Selected event
Only displays the event currently selected in the Triggered Events
table.

Unchecked events
Selects events from the Triggered Events table, displaying only
those that have not been dealt with yet.

Pending events
Selects events from the Triggered Events table, displaying only
those that are pending.

Last day
Selects events from the Triggered Events table, displaying only
those that have occurred during the last day.

Last week
Selects events from the Triggered Events table, displaying only
those that have occurred during the last week.

Last month
Selects events from the Triggered Events table, displaying only
those that have occurred during the last month.

List
Switches from the “graph” view to the “list” view.

Main menu commands - 13 -

MAINTENANCE MANAGER - EN 1.1 '
Graph
Switches from the “list” view to the “graph” view (only active for
System View tables).

Triggered Events
Displays the table of Triggered Events.

Salvagnini Events
Displays the table of Salvagnini Events.

User Events
Displays the table of User Events.

States
Displays the table of States being monitored.
States are variables indicating the state (ON/OFF) of some of the system’s
components (microswitches, buttons, relays, solenoid valves etc.).

Axis Interval
Displays the table of Axis Intervals for axes being monitored.
By axes we mean axes of electric motors, mechanical axes, encoders, i.e.
objects that can run distances or that are used to measure distances run. An
axis interval, therefore, is a length run or that can be run by the axis.

Action
Displays the table of Actions being monitored.
An action is a “complex” operation carried out by the system, which comes
down to the enabling/disabling of states (microswitches, solenoid valves,
relays etc.) in a suitable sequence.
Monitoring an action hence means monitoring the enabling/disabling
sequences of the individual components.

WorkSpaces
Displays the list of existing Workspaces.
The workspace is a set of some of the system’s various components being
monitored. It can be considered as a filter to view only those system
components you are actually interested in.

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MAINTENANCE MANAGER - EN 1.1 '
Toolbar
Shows or hides the Toolbar.

Status bar
Shows or hides the Status bar.

Tools menu

Options
Calls up the dialogue box for selecting options.

By selecting the Show Application tab, you can choose how the programme
will advise the user of any inspection/maintenance work to be performed on
the system.
The various available options are as follows:
1. On Event: the programme’s main window is activated whenever an
inspection/maintenance event occurs.
2. On Time: the programme’s main window is activated at a precise time
of day specified by the user.
3. On Shift Change: the programme’s main window is activated at each
work shift change previously specified by the user.
In addition, you can select the “Show application on start-up” option so that
the application will be shown whenever SysConShell is launched.
The dialogue box also features another tab via which you can specify how
triggered events can be notified via email or SMS. This feature has not been
implemented yet.

Main menu commands - 15 -

MAINTENANCE MANAGER - EN 1.1 '
? menu

Help guide
Use to view this manual.

About Maintenance Manager…

Shows the panel with information on the programme version.

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MAINTENANCE MANAGER - EN 1.1 '

How to use the application

Programme structure
The MAINTENANCE MANAGER programme is made up of two main
views, each of which is, in turn, split into a series of tables containing a
variety of information.
! Maintenance View
Contains information of use to the operator on the machine regarding
inspection/maintenance events and their management.
! System View
Contains information on system components being monitored and is
meant for expert users or Salvagnini testers.

MAINTENANCE View
This is the only interface the user should use as it already contains all tools
required for correct maintenance of the Salvagnini system.
This view gives you the option of viewing three types of tables:

Table of Triggered Events

Table of Salvagnini Events

Table of User-defined events

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MAINTENANCE MANAGER - EN 1.1 '
Triggered Events Table
This is the most important table as it displays a log of all
inspection/maintenance events encountered.

First of all, we can determine the current status of an event, which can be:

Not yet dealt with (Triggered and Not Checked)

Pending (Triggered and Checked)
Action taken successfully (OK)
Action taken unsuccessfully (FAIL)

For each event, the table also indicates:

a) Event description.
b) Type of action required (inspection / maintenance / non-routine
maintenance).
c) Number of times the alarm has been given before being dealt with.
d) Current event status.
e) Date and time the event occurred.
f) Date and time the event was dealt with by the operator.
g) Name of the operator performing inspection / maintenance.

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MAINTENANCE MANAGER - EN 1.1 '
FILTERS
The table’s contents can be filtered based on the date the event occurred using
the Current View option from the View menu and selecting either:
! Last day
! Last week
! Last month
or using the following buttons in the top right corner above the table:

An additional filter can be applied based on the status of the event using the
Current View option from the View menu and selecting either:
! Selected Event
! Pending Events
! Unchecked Events
or using the following buttons in the top right corner above the table:

RECOGNIZING AN ALARM
Selecting an event and choosing the Modify option from the Edit menu, or
double clicking the mouse on the actual event, calls up the following dialogue
box via which event status can be edited:

This box gives the event description, type of action required (inspection,
maintenance or Salvagnini maintenance) and result of action taken by the
operator.
In addition, if the event is part of those defined by Salvagnini, the user can
press the Handbook button to view information available in the system’s
maintenance manual.

How to use the application - 19 -

MAINTENANCE MANAGER - EN 1.1 '

Salvagnini Events Table

This table contains the description of alarms entered by Salvagnini and is not
user editable.

The table features the following information:

a) Event description.
b) Type of action required (inspection / maintenance).
c) Event type:
! time-based
! based on machine operating time
! count-based

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MAINTENANCE MANAGER - EN 1.1 '
! notified by machine cycles
d) Alarm threshold or expiry date (for time-based events).
e) Production stop requested after a given number of event warnings.

VIEWING THE MANUAL

Selecting an event and choosing the Modify option from the Edit menu, or
double clicking the mouse on the selected event, calls up the window via
which you can view the maintenance manual relating to the current selection.

User-defined Events Table

This table contains all events that the user can define on his/her own to meet
his/her own needs.

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MAINTENANCE MANAGER - EN 1.1 '
The table features the following information:
a) Event description
b) Type of action required (inspection/maintenance)
c) Alarm threshold or expiry date (for time-based events)
d) Any notes
Any event can be entered, edited or deleted in this table via the Edit menu
item or the buttons on the Toolbar.

ENTERING A NEW USER EVENT

Selecting the Add option from the Edit menu or clicking on button:

calls up the following dialogue box for entering a new user event:

In addition to the description of the user event and any notes, the user must
select the type of action to be taken when the event (inspection or
maintenance) occurs, and specify one of the following event types:
! Time Spot Event
This event is only triggered once and the date it will occur must be
chosen.
! Frequency-based Event
This is a repetitive event and the frequency (daily, weekly, monthly
etc.) and time it occurs must be chosen.
! Count-based Event
This is an event that occurs whenever the counter for the specified
D&F object exceeds the alarm threshold entered.

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MAINTENANCE MANAGER - EN 1.1 '
EDITING A USER EVENT
Selecting the Modify option from the Edit menu or clicking on button:

calls up the following dialogue box for editing the currently selected user
event:

All information on the user event selected can be edited in this dialogue box
following the same procedure described for entering a new user event.
Press the Modify key to implement the changes made, otherwise press the
Cancel key to disregard changes.

DELETING A USER EVENT

Once you have selected one or more alarm events, you can use the Delete
option from the Edit menu or click on button:

and the programme will delete the event(s) selected after first prompting you
to confirm.

SYSTEM View…
This view is for use by expert users only who are suitably familiar with the
system. It enables you to select and read counter values of most of the
components on the machine and to group them together using the
Workspaces table.

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MAINTENANCE MANAGER - EN 1.1 '
This view gives you the option of viewing four types of tables:

States table

Axis Interval table

Action table

WorkSpace table

States Table
This table contains all state-type (ON/OFF) objects being monitored by the
MAINTENANCE MANAGER programme.

The table indicates:

a) Code of the object being monitored
b) Object description
c) Object type (input, output, axis state)
d) Counter type (ON/OFF)
e) Counter value
f) Alarm threshold
Any component can be entered, edited or deleted in this table – with the
exception of those linked to Salvagnini maintenance events – using the Edit
menu item or the buttons on the Toolbar.

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MAINTENANCE MANAGER - EN 1.1 '
ENTERING A NEW STATE
Selecting the Add option from the Edit menu or clicking on button:

calls up the following dialogue box for entering a new component:

In this window, you can select the subsystem, type and family to which the
component to be monitored belongs.
You will need to indicate the alarm threshold and counter type (ON or OFF)
to be taken into consideration.
In addition, clicking the mouse on the heading of the table’s various columns
causes the elements in the table to be sorted.
Press the Add key to make the entry or the Cancel key to close the window
without making any changes.

EDITING A STATE
Selecting the Modify option from the Edit menu or clicking on button:

calls up the following dialogue box for editing the currently selected
component:

Here we find the code of the object selected and its description in full.

How to use the application - 25 -

MAINTENANCE MANAGER - EN 1.1 '
For each state, we can edit both the alarm threshold and value of the counter
associated with it.
Press the Modify key to edit or the Cancel key to close the window without
making any changes.

DELETING A STATE
Once you have selected a state, you can use the Delete option from the Edit
menu or click on button:

and the programme will delete the state selected after first prompting you to
confirm.

Axis Interval Table

This table contains the intervals for each of the various axes monitored.
Basically, every time an axis is commanded to a point within the chosen
interval, the value of the associated counter increases by one unit.

The table indicates:

a) Code of the object being monitored
b) Object description
c) Lower limit of interval (Minimum Level)
d) Upper limit of interval (Maximum Level)
e) Counter value
f) Alarm threshold
Any component can be entered, edited or deleted in this table – with the
exception of those linked to Salvagnini maintenance events – using the Edit
menu item or the buttons on the Toolbar.

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MAINTENANCE MANAGER - EN 1.1 '
ENTERING A NEW INTERVAL
Selecting the Add option from the Edit menu or clicking on button:

calls up the following dialogue box for entering a new axis interval:

In this window, we select the axis to be monitored, define the upper and lower
limits of the interval and the alarm threshold.
Clicking the mouse on the heading of the table’s various columns enables you
to sort the list’s various elements.
Press the Add key to make the entry or the Cancel key to close the window
without making any changes.

EDITING AN INTERVAL
Selecting the Modify option from the Edit menu or clicking on button:

calls up the following dialogue box for editing the currently selected axis
interval.

Here we find the Salvagnini code of the axis selected, its description and
upper and lower limits of the interval.
For each component, except those entered by Salvagnini, we can edit both the
alarm threshold and value of the counter associated with it.
Press the Modify key to confirm editing or the Cancel key to close the
window without making any changes.

How to use the application - 27 -

MAINTENANCE MANAGER - EN 1.1 '
DELETING AN INTERVAL
Once you have selected a component, you can use the Delete option from the
Edit menu or click on button:

and the programme will delete the component selected after first prompting
you to confirm.

Action Table
This table contains all D&F Actions controlled by the MAINTENANCE
MANAGER programme.

The table gives:

a) Action name
b) Actor name and its description
c) Commands associated with the action
d) Counter value
e) Alarm threshold
Any action can be entered, edited or deleted in this table – with the exception
of those linked to Salvagnini maintenance events – using the Edit menu item
or the buttons on the Toolbar.

ENTERING A NEW ACTION

Selecting the Add option from the Edit menu or clicking on button:

calls up the following dialogue box for entering a new component** [sic!
probably “new action”]:

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MAINTENANCE MANAGER - EN 1.1 '

The action to be entered can be selected in this dialogue box, and the alarm
threshold established.
In addition, clicking the mouse on the heading of the table’s various columns
causes the various elements on the list to be sorted.
Press the Add key to make the entry or the Cancel key to abort the operation.

EDITING AN ACTION
Selecting the Modify option from the Edit menu or clicking on button:

calls up the following dialogue box for editing the currently selected object:

Here we find the name of the action selected, actor code and commands the
action is made up of.
For each component, except those linked to Salvagnini maintenance events,
we can edit both the alarm threshold and value of the counter associated with
it.
Press the Modify key to edit or the Cancel key to close the window without
making any changes.

How to use the application - 29 -

MAINTENANCE MANAGER - EN 1.1 '
DELETING AN ACTION
Once you have selected an action, you can use the Delete option from the
Edit menu or click on button:

and the programme will delete the action selected after first prompting you to
confirm.

WorkSpace Table
In this window, the list on the left features all existing workspaces whilst the
list on the right displays the components in the currently selected workspace
complete with relevant information.
A workspace is simply a set of a number of objects designated for monitoring
in the States table.

For each component of the currently active workspace, we can obtain the
following information:
a) Code of the object being monitored
b) Object description
c) Object type (inputs, outputs, axis states)
d) Counter type (ON/OFF)
e) Counter value
f) Alarm threshold

CREATING A NEW WORKSPACE

Selecting the Add option from the Edit menu or clicking on button:

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MAINTENANCE MANAGER - EN 1.1 '
calls up the following dialogue box for entering a new workspace:

You have to enter the name of the workspace to be created and then press
OK.

ENTERING/DELETING ELEMENTS IN A WORKSPACE

Selecting the Modify option from the Edit menu or clicking on button:

calls up the following dialogue box for entering or removing elements in the
currently selected workspace:

The pane on the left lists objects currently monitored by the programme,
which can thus be added.
The pane on the right instead lists objects currently belonging to the
workspace.
For each object, we are given the code, description and object type.
Clicking the mouse on the heading of the table’s various columns causes the
various elements on the list to be sorted.
To add components, simply select one or more objects from the list on the
right** [sic! probably “left”] and press Add; vice versa, to remove some of
the components simply select one or more from the list on the right and press
Remove.
To save changes made, press OK, otherwise press Cancel to close the
window without making any changes.

How to use the application - 31 -

MAINTENANCE MANAGER - EN 1.1 '
DELETING A WORKSPACE
Once you have selected a workspace, you can use the Delete option from the
Edit menu or click on button:

and the programme will delete the currently selected workspace after first
prompting you to confirm.

Tables and Graphs

For all SYSTEM view tables, you can activate a different view instead of the
table by selecting the Current View \ Graph option from the View menu or
by clicking on the following button on the Bar:

We are thus presented with a graph, with horizontal bars, representing the
counters’ values and alarm thresholds:

For each component, the counter’s value is represented by a coloured bar as

follows:
Green counter value is below 90% of alarm threshold value
Yellow counter value is over 90% of alarm threshold value
Red counter value has exceeded alarm threshold value
The alarm threshold, on the other hand, is represented with a bar coloured
grey.
Clicking the mouse over each object calls up a dialogue box featuring the
component code, counter value and alarm threshold value.

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MAINTENANCE MANAGER - EN 1.1 '

We can also view the graph of a subset of components shown in the various
tables. To do this, simply select the components with the mouse, keeping the
SHIFT or CTRL key pressed, and then select the Current View \ Graph
option from the View menu. In this case, the above-mentioned dialogue box
cannot be called up for information on a single component.
To go back to the table view, select the Current View \ List option from the
View menu or press the following button on the Bar:

How to use the application - 33 -

MAINTENANCE MANAGER - EN 1.1 '

Environment and configuration

Application files
These files are required for the actual application to work.
In directory $SYSCON/syscon/bin/MMngr:
! mmgr.exe: the application’s executable;
! exec_mmngr.bat: batch file for launching application;
! mmngr _*.dll: files of resources in the various languages used.

System files
These are the files contained in directory
$SYSCON\syscon\<system_name>. In this description we refer to the
“Structure of the support file system for SysCon control” document, chapter
3: "Control of machine tool". We will only point out amendments and
additions to what was originally written in this document.

DATABASE
Addition of directory mm_db containing two databases:
mm.mdb (application’s database)
mm_events.mdb (Salvagnini events database)
Addition of directory mm_db\Maintenance Docs containing the system
maintenance manual files.

CONFIGURATION
Addition of file scsfiles\scs_config\MMngr.ini: MAINTENANCE
MANUAL configuration file
Support for SysConShell:
Edit scsfiles/scs_config/sysCon.ini editing the following existing items:

dryserver = bin\MMngr\mmngr.exe
diario = bin\MMngr\exec_mmngr.bat

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MAINTENANCE MANAGER - EN 1.1 '

Glossary

Alarm
Warning that a counter associated with a given event has exceeded the
threshold established for said event.

Axis
By Axes we mean axes of electric motors, mechanical axes, encoders, i.e.
objects that can run distances or that are used to measure distances run.

Actor
Physical object performing a given action (e.g. X axis of manipulation
device).

Action
An Action is a complex operation carried out by the machine, which is
achieved by enabling/disabling some of the machine’s components (e.g.
Manipulation device X axis traverse) in a suitable sequence.

Component
Physical objects making up the machine: switches, microswitches, buttons,
relays, solenoid valves.

Axis Interval
An Axis Interval is a length run or that can be run by the axis.

States
States are variables associated with each component of the machine, which
indicate its state (ON/OFF).

Workspace
This is a subset of system components monitored by the application, grouped
together for viewing.

——!——

Glossary - 35 -
 6. EasyData
3.12. Specifiers and options

6. EasyData

S4XE.30 - S4_1553 - V20160202EN - 329 -

4 EasyData

Version 1.0

'
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2
Table of contents
Introduction ..................................................................................................................... 5
What is EasyData?................................................................................................ 5
The purpose of this guide ..................................................................................... 5
Who uses EasyData? ............................................................................................ 5
Starting from Timeout .......................................................................................... 5
Starting from Monitor........................................................................................... 6
Different viewing options ............................................................................................... 6
View diagram ....................................................................................................... 7
Search results........................................................................................................ 7
View and add photo.............................................................................................. 7
Browsing and searching .................................................................................................. 8
Structure ............................................................................................................... 8
Text searching....................................................................................................... 9
Searching and viewing pages and components .................................................. 10
Browser functions and tool bar........................................................................... 11
Installing updates .......................................................................................................... 13
CD launcher........................................................................................................ 13
Updating ............................................................................................................. 15
Viewing the PDF format..................................................................................... 17
Starting to browse the CD .................................................................................. 18

Table of contents -3-

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4
EASYDATA - EN 1.0 '
Introduction

What is EasyData?
EasyData is a diagnostic software, integrated with the numerical controller to
interactively navigate through the documentation using “web” technology
(photos, hyperlinks, part codes and automatic filters).
EasyData supplies the information relating to each component managed by
the Salvagnini numerical controller. The wiring and/or hydraulic diagrams of
the system can be consulted by the operator directly on the screen,
automatically filtered on the component being analyzed or searched for in the
documentation.
With EasyData you can also:
! add your own photos or notes to the image archive;
! obtain a paper print-out or export one or several documental diagrams
to PDF or JPG files.
EasyData does not contain any documentation relating to the components
made by other manufacturers and integrated into Salvagnini systems.

The purpose of this guide

The purpose of this guide is to explain how to use EasyData on the machine
computer. Please consult the “EasyData update” guide found in the Update
CD issued by Salvagnini for how to update the diagrams.

Who uses EasyData?

EasyData has been designed for those operators working directly on the
machine or for those managing the maintenance who need to consult the
electrical and hydraulic diagrams, as well as to quickly locate the components
of the system.

Starting from Timeout

If during any processing, the control system detects an anomalous electrical
signal, a timeout window will automatically appear. By selecting one
component and by clicking on the icon ! Photo , you will start EasyData
that automatically will show the pages that contain the component.

What is EasyData? -5-

EASYDATA - EN 1.0 '
Starting from Monitor
From the Salvagnini Monitor application, as well as for the previous
illustration, by selecting a component and by clicking on the icon ! ,
EasyData will directly display all the pages that contain the component.

Different viewing options

On the left side of the interface, there are three icons that refer to different
view commands:

View diagram

Search results

View & add photo

-6- Starting from Monitor

EASYDATA - EN 1.0 '
View diagram
This option allows you to see and browse the diagrams by clicking on the
component’s codes page references, Salvagnini codes and pressurized lines
that are connected to a hyperlink.

Search results
This option is automatically activated as a search result. For each element
found, it will show a thumbnail of the drawing’s section where this element is
present. If the element is present only inside a pdf document, the thumbnail
will just be symbolic. By clicking the thumbnail, EasyData will display the
relative page, with a view of the part on the searched element. Search results
are displayed in groups of 10 elements.

View and add photo

At first EasyData will display “Show add photo” in order to find
immediately the position of the selected sensor, from the Monitor application
or from the Timeout window.
By activating this option after a search (Search option), you will see the list
of the image’s thumbnail (1 in next fig.) related to the search that has been
carried out. Double click on the thumbnail to enlarge the image.
You can also add new images in the following way:
" click on Click here... (2) to open the window from which you have to
upload the new image.

View diagram -7-

EASYDATA - EN 1.0 '
" specify the name of the component (3) that the new image refers to; the
component name will have to be the one predefined as a signal in the
Monitor application or timeout message.
" from “my computer”, press browse (4) to select the file of the image to
upload.
" confirm by pressing OK (5).

Browsing and searching

Structure
The main window is structured in four rows:
a. system data: part number, supply order and customer
b. diagrams are structured into modules in relation to their typology:
electrical, hydraulic, or other pdf documents
c. page list of the module selected from row “b”; by selecting the page, you
will open it in ‘show diagrams’ mode
d. list of components (object or signal code) that result from your search; by
selecting a component, you will be able to see a list of the pages that
contain it

-8- Structure
EASYDATA - EN 1.0 '

Text searching
You can search for texts within the diagrams, by proceeding as follows:
" Insert the word you have to find in the search box of the second row
" Choose the search type:
! simple to find strings having also the word
! exact to find strings having only the word
" Press search

Text searching -9-

EASYDATA - EN 1.0 '
The list of pages having the word you are searching for will appear in ‘show
search results’ mode.

Searching and viewing pages and components

The third and fourth rows of the main interface enclose the page list, and the
components respectively, of the whole electrical and hydraulic systems. By
using the search filters, you can restrict the page list and the components
displayed, in relation to the search criterion that you have adopted.
From the third row, in the box [Title], by entering a word of the page title
you will find only the list of pages having that word. You can also search
within titles in the first language used for the diagrams [First Language],
or in a second language usually defined together with the user [Second
Language].
By entering the page number in the [Page] box, confine the display within
that page.
The function [VIEW COMPONENTS] is to view, in the fourth row, the list
of components present in the diagrams.
The function [VIEW CODES] is to view the list of Salvagnini codes present
in the diagrams.
The function [VIEW ALL] is to view the list of both codes and components.
In the forth row the function [SEARCH] limits the view to those codes or
components having the search key entered in the [Object] box.

- 10 - Searching and viewing pages and components

EASYDATA - EN 1.0 '

Browser functions and tool bar

As for the diagrams, just one component can be connected with parts of the
circuit distributed in different pages. EasyData makes dynamic browsing of
the diagrams easier through hypertext links. You can recognize hypertexts by
the different form of the pointer, when you move the mouse on the diagram.
By clicking once on the hypertext, you will obtain immediately the list of
pages related to it.

In view mode, there are different icons relating to different commands; some
of them can be enabled also through the function buttons here listed:

Back to main window structured in four rows

View previous page[back]

View next page[End]

Save diagram page in dwf format

Print page on default printer

View page in pdf format, within a new browser window

Browser functions and tool bar - 11 -

EASYDATA - EN 1.0 '
View page in image format, within a new browser
window
Drag the drawing within the view area

Zoom the diagram by moving the mouse and keeping the

left button pressed
Zoom an area of the diagram

Reset the original size of the diagram[ Home]

Online help

View previous pop-up menu page[ Page Up]

View next pop-up menu page[ Page Down]

The tools are not all activated simultaneously. The conditions that make them
enabled or not are as follows:
" the viewing mode
" the type of diagram visualized: electrical or hydraulic
" whether any searches have been previously carried out

A pop-up menu with a list of the components that are inside

the page. By selecting a component, you modify the
visualization so that it will move in the center of the screen.

A pop-up menu with the list of the codes present in the

page.

A pop-up menu with a list of the pressurized lines on the

page. Enabled only for hydraulic diagrams.

- 12 - Browser functions and tool bar

EASYDATA - EN 1.0 '
Searches for any text inside all the pages of the drawing.
See p. 9.

Displays, in direct or inverse sequence, the pages found

whose number is indicated in the Result field. The number
in brackets indicates that you are viewing that particular
page among those identified in the search. In the example,
you are viewing the 8th page of the 14 that have been found.

Saves all the views of a part in the diagram, assigning a

name in the relative entry box. The views saved in this way
can be selected in order to promptly view the details of
particular interest.

Installing updates
Whenever there are some modifications of the electrical and hydraulic
systems by the manufacturer, a CD to be installed on the machine is released,
in order to allow you to view the updated version of the diagrams.
The updating is carried out on workstations where Easydata has already been
installed and set up. See the “Install EasyData” guide for the first
installation of the EasyData application.

CD launcher
Log on to the computer with the Administrator account.
Insert the EasyData CD in the CD-Rom drive.
Wait for the CD launcher installation window to appear on the screen.
Note: if the installation window does not automatically appear after inserting
the CD, you can start it manually by double-clicking on the starter.bat
file present in the CD.

CD launcher - 13 -
EASYDATA - EN 1.0 '

After checking the environment variables and licences of the EasyData

software, you can do the following:

start the browser to consult the diagrams directly on the

CD without installing the update

update the software present in the folder

C:\usr2\syscon\bin\EasyData\Systems o
C:\EasyData\Systems

view the folder on the CD containing the diagrams in

PDF format, either to consult or to print them

If the CD launcher does not find a valid licence for using EasyData, only
the View PDF function, which allows the drawings in PDF format to be
viewed, will be activated.

- 14 - CD launcher
EASYDATA - EN 1.0 '
If the licence controllers and base files for using the CD have not been
installed in the workstation, the Start function, which starts up the browser
for consulting the diagrams directly on the CD, will be disabled. Proceed with
the Install function to update the software libraries. Consult the Install
EasyData guide.

Updating
The updating procedure is guided by the messages that appear in sequence in
the various phases.

Automatic
configuration of
environment
variables, system
requirements check
and “CD launcher”
script start-up

Updating - 15 -
EASYDATA - EN 1.0 '
Main window

Warning: if you click on

“OK”, all the files present The process is asking if
in the “C:\usr2\syscon\ “C:\usr2\syscon\bin\
bin\EasyData\Systems” EasyData\Systems” is
default folder will be the installation folder
overwritten

For the P4 **16, the

installation folder is
C:\EasyData\Systems

File update in progress:

wait until it finishes

Warning: if you click on

“OK”, all the files present
in the “C:\EasyData\
Systems” folder will be
overwritten
The updating process
has been completed
correctly

- 16 - Updating
EASYDATA - EN 1.0 '
Viewing the PDF format
If you insert the CD in any computer provided with the minimum
requirements 1 for using EasyData, you will be able to consult the diagrams in
pdf format (Portable Document Format). If you click on ViewPDF, a new
window will appear showing the contents of the PDF folder on the CD. From
the pdf file it is possible to give the order to print directly all the diagrams or
parts of them.

During the first installation procedure or during the update, the diagrams in
pdf format are copied to the folder
“C:\usr2\syscon\bin\EasyData\Systems\pdf”, or to the folder
“C:\EasyData\Systems\pdf” for the P4**16 bending systems.

1
Pentium(R) 3 or equivalent (or greater) with 256 Mb (or greater) RAM (with at least 128 Mb available).
Microsoft Windows 2000 Professional - SP 4 or Microsoft Windows XP Professional - SP 1 (or greater);
Internet Explorer 6.0 (or greater);
Adobe Reader 5 (or greater);
Autodesk DWFViewer 6.0.0.200;
Screen resolution, minimum 1024 x 768 pixel.

Viewing the PDF format - 17 -

EASYDATA - EN 1.0 '
Starting to browse the CD
If the computer is provided with a licence, it is possible to use EasyData
directly from the CD, even without performing the update procedure.

Please consult the on-line guide to find out all the functions offered by the
application.

——!——

- 18 - Starting to browse the CD

6. EasyData
3.12. Specifiers and options

- 348 - S4XE.30 - S4_1553 - V20160202EN

 7. VisualStacker
3.12. Specifiers and options

7. VisualStacker

S4XE.30 - S4_1553 - V20160202EN - 349 -

7 VisualStacker

Version 2.4
 This page has been left blank intentionally.

-2-
Contents
Introduction 5
What is VisualStacker?.................................................................................................... 5
Who uses VisualStacker? ................................................................................................ 5
What is State Shell Interface? .......................................................................................... 5
Who uses State Shell Interface? ...................................................................................... 6
Conventions ..................................................................................................................... 6
Reference systems ........................................................................................................... 6
Ordinary stack ....................................................................................................... 7
To stack ........................................................................................................................... 8

VisualStacker 9
Unloading with a Cartesian manipulator ......................................................................... 9
Description of the user interface .................................................................................... 10
Simulation mode window .............................................................................................. 14
3D mode window .......................................................................................................... 14
Stacks list box................................................................................................................ 15
File Menu ...................................................................................................................... 15
Expert user .......................................................................................................... 15
Open file ............................................................................................................. 16
Print .................................................................................................................... 16
Print preview....................................................................................................... 17
Exit ..................................................................................................................... 17
View menu..................................................................................................................... 17
Toolbar ............................................................................................................... 17
Status bar ............................................................................................................ 17
Server messages .................................................................................................. 17
Stack info ............................................................................................................ 18
Show menu .................................................................................................................... 18
Parameters .......................................................................................................... 18
Easy parameters .................................................................................................. 19
Zone Editor ......................................................................................................... 19
Pick-up configurations ........................................................................................ 19
Zones to use ........................................................................................................ 23
Sub-zones to use ................................................................................................. 25
General Parameters ............................................................................................. 27
Manual modifications ......................................................................................... 30
Operation menu ............................................................................................................. 31
Recalculate simulation ........................................................................................ 31
Reset calculation ................................................................................................. 31
Calculate simulation with trajectory ................................................................... 31
Start calculation with status file .......................................................................... 31
Save current zone status ...................................................................................... 31
Start from real status ........................................................................................... 31
Reset all private parameters ................................................................................ 31
Simulation menu ............................................................................................................ 32
Calculate data...................................................................................................... 32
Manipulator config. ............................................................................................ 32

Contents -3-
 Help menu ..................................................................................................................... 32
Online help.......................................................................................................... 32
About VisualStacker ........................................................................................... 32

StateShell 33
Description of the user interface .................................................................................... 33
3D mode window .......................................................................................................... 34
Stacking report area ....................................................................................................... 34
File menu ....................................................................................................................... 35
Load zone from file............................................................................................. 35
Save zone to file.................................................................................................. 35
Exit ..................................................................................................................... 35
View menu..................................................................................................................... 36
Toolbar ............................................................................................................... 36
Status bar ............................................................................................................ 36
Bounding box...................................................................................................... 36
Tools menu .................................................................................................................... 36
Toggle expert user .............................................................................................. 36
StackAdd ......................................................................................................... 37
StackModify.................................................................................................... 37
StackChange quantity...................................................................................... 37
StackRemove Stack......................................................................................... 37
StackFree zone ................................................................................................ 38
StackFree all zones ......................................................................................... 38
Help menu ..................................................................................................................... 39
Help on line ........................................................................................................ 39
About StateShell ................................................................................................. 39

-4- Contents
VISUALSTACKER S4 - EN 2.4

Introduction

The activity of unloading-destacking for the automatic Salvagnini systems is

run by VisualStacker and State Shell Interface applications.
The graphics of both modules enables the user a preliminary simulation of the
unloading process and afterwards the visualization of the ongoing process
during production.

What is VisualStacker?
VisualStacker is an application that permits to set up those criteria and
parameters necessary to optimize the process of sheet metal handling and to
check its effectiveness by a simulation.
The criteria aims to provide some operating instructions of the system, for
example: use modality for the space in the unloading areas, type of stack, etc.

Who uses VisualStacker?

The VisualStacker application has been developed for use by production
supervisors and machine operators.
Production supervisors use the program when planning production; machine
operators use it while running production.
The aim is to program and monitor the way in which unloading is managed
automatically.

What is State Shell Interface?

State Shell Interface visualizes in real time the stacks created by the
machine.
It also permits to modify some data of the stacks that have been created,
whenever the graphical representation does not correspond to the real
situation.

Introduction -5-
VISUALSTACKER S4 - EN 2.4

Who uses State Shell Interface?

The State Shell Interface application is used by machine operators.
Usually operators use the program each time there is a production process to
carry out.
The aim is to check the condition of the unloading areas recognized by the
machine.

Conventions
The term "stack" indicates a group of objects laid one on top of the other.
The term "unloading zone" indicates a surface (pallet, boxes etc.) on which
the parts that have been processed are stacked.
The term "unloading area" indicates a group of several unloading zones.
If there is only one unloading zone, the unloading area will be the same as the
unloading zone.

Reference systems
A reference system is a group of elements (axis origin and unit of
measurements) which is used to associate an analytic entity (numbers and
operations) with each geometric entity (flat figures and solids).
The position of an object in space is represented by the co-ordinates and
orientations of one of its points with respect to a known reference (x, y, z
coordinates and angles a, e, r; usually only angle "a" that is the angle of
rotation around the z axis, is taken into consideration.
The position of an object is indicated by specifying the relative positions of
the two reference systems. (absolute reference system and relative reference
system).
For the punching system only standard stacks are used and the reference
system of the parts correspond to the one of the stack; therefore you only need
to know the stack position with respect to the unloading zone.
N.B. Generally the reference system of the part has its origin in the center of
the part and the x axis is parallel to the last side programmed.
The following conventions have been adopted to differentiate the various
reference systems:

Type of arrow/color Reference system

Stack

Unloading zone

-6- Introduction
VISUALSTACKER S4 - EN 2.4

View of the work area of an S4 system

Loading connection y Unloading

S4 worktable connection

Ordinary stack
y

In this type of stack the parts are parallel to the support surface.
The reference system of the stack coincides with that of the first part stacked.
The reference systems of the subsequent parts lie on top of that of the first.
The position of their reference system is therefore:
x=0
y=0
z=(thickness+correction) x no° of parts.

Introduction -7-
VISUALSTACKER S4 - EN 2.4

To stack
Salvagnini’s automatic sheet processing system manages the unloading and
stacking conditions by itself.
If operators want to change the stacking parameters they can use
VisualStacker.
If you want to check that the stacking has been programmed correctly, you can
use the graphics simulation offered by VisualStacker.

Select the program in the Production Management

window of Salvagnini Console interface and from the
Production menu press Stacking

If Cartesian manipulator is present, we recommend that you

perform the Calculation of simulation with trajectory
before calculating the simulation, selecting this item from
the Operation menu.

Calculate the simulation by

pressing the proper button

Modify and save parameters by

using the proper buttons.

If the result is not

the one expected
Check simulation

If the result is correct

Start production by pressing the

proper button

-8- Introduction
VISUALSTACKER S4 - EN 2.4

VisualStacker

Unloading with a Cartesian manipulator

If the S4 or S4+P4 system’s sheet stacking occurs through a Cartesian
manipulator, there is a conveyor with brushes (CTS), placed downstream the
S4 conveyor.
This station, divided into two belts in sequence, is equipped with only one
unloading centering guide and two cross-travel retractable sheet stops (central
sheet stop and finale sheet stop).
If the parts can be gripped by the suction cups and can therefore be stacked by
the Cartesian manipulator, they will be stacked on tables, placed on the CTS
conveyor sides (see the figure below).

VisualStacker -9-
VISUALSTACKER S4 - EN 2.4

If the parts are very small or very thin and long strips that cannot be stacked by
the Cartesian manipulator, the centering guide moves and drops them into
some bins located on the side of the CTS belt conveyor (see figure below).

Description of the user interface

When you start to use this application, the following user interface appears:

1. Main menu bar.

2. Command button bar or tool bar: these buttons perform the same
functions as some of the items in the menu.

- 10 - VisualStacker
VISUALSTACKER S4 - EN 2.4

3. View of the stacking zone: this area shows the unloading zones that are
configured in the system. The perimeter of the unloading zone under
examination is shown in red.
Selecting a part in the graphical area and clicking the right-hand mouse
button, a pull down menu with the following commands shall appear.

Select one of the commands to view the related window. The part you
selected before in the graphical area shall be highlighted.
4. 3D view: shows the unloading zone in 3D.
5. Bar that shows the progress made with the processing. By positioning
the cursor on this bar during the processing, you can see the estimated
remaining time.
6. View options:
 All zones: shows all the unloading zones;
 3D window: shows the unloading area in 3D environment;
 Only contour of pieces: visualizes only the contour of the
pieces present in the unloading zone, without showing the
different processing (embossing, holes);
 Grid: shows a reference grid that makes the perception of the
piece dimensions better;
 Opt images: shows images of the optional devices: double sheet
feeler-pins, pallets and/or stacking sub-zones;
 Manipulator: shows the position of the manipulator holding
devices;

VisualStacker - 11 -
VISUALSTACKER S4 - EN 2.4

 Stacking free area: represents the non-collision area of the

manipulators when they are stacking on the selected zone;

 Movement free area: represents the non-collision area during

the Cartesian manipulator movement, from the CTS (conveyor
with brushes) to the unloading zone.

- 12 - VisualStacker
VISUALSTACKER S4 - EN 2.4

 Reachable area of manipulator: represents the limits of reach

from the center of the manipulators.
The two black arrows indicate the origin of the reference system
of the Cartesian system.

7. Program data area:

Group: identifies the work group containing each program to process;
Program: indicates the single program to produce.
Double click on the program present in this area to view its code.
8. Quantity: indicates the number of times that the program (or program
list) must be processed.
9. Area listing unloading zones: shows the stacking zone list configured in
the system.
10. Area listing stacks in unloading zone.
11. Status bar.
12. X and Y co-ordinates: shows the position of the mouse cursor in the
unloading zone(3), either with reference to the origin of the unloading
zone (when a single zone is displayed) or the origin point of the
Cartesian manipulator (when all the unloading zones are visualized).
13. Stacking simulation management: by using the buttons of this area, you
can manage the simulation of the stacking phase one step at a time.

VisualStacker - 13 -
VISUALSTACKER S4 - EN 2.4

Simulation mode window

The Simulation mode window is used to run the simulation one step at a
time. The simulation is controlled by using the appropriate scroll buttons of
the different phases.

The two counters Step and Pallet indicate, respectively, the stacking phase in
progress and the number of pallet changes that have been performed until that
simulation step.
The stacking phase can be: unloading a part or freeing a zone (e.g. performing
a table change).

3D mode window
This window shows the stacking area in 3D.
By positing the pointer in the area, if you keep one of the 3 buttons pressed
and move the mouse, you can modify the view of the unloading area.
The following views can be obtained:
 The left-hand button is used to change the angle from which the stacking
area is viewed;
 The middle button is used to zoom in on the area shown;
 The right-hand button is used to move the “origin” of the reference axes.
The mouse can also be used to move or enlarge the view window by pressing
the left-hand button and dragging the mouse to the position or view desired.

- 14 - VisualStacker
VISUALSTACKER S4 - EN 2.4

Stacks list box

This box describes the stacks that are present in the unloading zone during the
current step of simulation.
The following information is given for each stack:
 Quantity: number of parts present in the stack during the current step of
simulation;
 GROUP: the group that the program selected belongs to;
 Program: gives the name of the program containing the part present in
the stack;
 Code: name of the part present in the stack;
 Job: identifies the production order associated with the part;
 X and Y: co-ordinates of the origin of the stack reference system in the
unloading zone reference system;
 Layer: the layer to which the selected part belongs, when there is a
multilayer-stacking.

File Menu
If you position the pointer on File, the following pull-down menu will appear:

Expert user
If you select this option and enter a password, a number of functions normally
available to Salvagnini technical personnel will be enabled.

VisualStacker - 15 -
VISUALSTACKER S4 - EN 2.4

Open file
If you select Open in the File menu, the following window will appear:

From this window, you can select the program or list of programs you want to
open.
1. Groups area: this box is used to select the group required;
2. Programs area: this box is used to select the program required among
those present in the group;
3. OK: opens the selected program;
4. Cancel: closes the window;
5. Area used for filtering programs according to the name;
6. Clean up before opening: it allows you to delete all the information
associated with the selected program:
All the parameters saved before shall be lost and the program shall be
opened using only the default settings;
7. Open and execute: if enabled, it allows you to open and
automatically calculate the selected program, without having to click on
the “Calculate” button in the scroll bar.

Print
The Print function from File menu enables you to print what has been
displayed in area 3 indicated on p. 11.

- 16 - VisualStacker
VISUALSTACKER S4 - EN 2.4

Print preview
The Print Preview function from File menu enables you to see a preview of
what will be printed.

Exit
The Exit function from File menu closes the application.

View menu
If you position the pointer on View, the following pull-down menu will
appear:

Toolbar
If ticked, it shows the toolbar.

Status bar
If ticked, it shows the Status bar.

Server messages
It opens the following window:

It shows the messages that have been received from the server (configuration
initialization, the connection made, etc.).
If you press the Close button, you close the window, whereas by pressing the
Clear button you delete the contents of the window.

VisualStacker - 17 -
VISUALSTACKER S4 - EN 2.4

Stack info
This item shows the following window:

This window contains information about the stack (the group it belongs to, the
name of the program, the maximum number of parts in the stack etc.)
Press Close to close the window.

Show menu
If you position the pointer on Show, the following pull-down menu will
appear:

If the blank unloading from S4 system occurs through a Cartesian manipulator,

the Fix & Move function is disabled.

Parameters
This function is only available to Salvagnini technical personnel.

- 18 - VisualStacker
VISUALSTACKER S4 - EN 2.4

Easy parameters
This function is only available to Salvagnini technical personnel.

Zone Editor
This function can only be used by Salvagnini skilled personnel.

Pick-up configurations
If you select Pick-up configurations in the Show menu, the following
window will appear (it shows the suction cup’s configuration):

Window pick-up configuration

This window enables the operator to modify the pick-up point and/or activate
or deactivate the suction cups on the pick-up devices.
The window is divided into the following areas:
1. Parts: this area is used to select the part for which you want to see and/or
modify the pick-up; if you modify a part of this window, you
automatically change also any similar1 part present in the program.
2. View area: in this are you can see the part selected, the manipulator used
and the suction cups enabled to carry out the gripping.
If you press the left mouse button and move the cursor in this area, you

1
Two parts are similar if they have the same geometry , the same name, and have been programmed with the same
rotational movement.

VisualStacker - 19 -
VISUALSTACKER S4 - EN 2.4

will be able to translate the manipulators.

If you press the “Ctrl” button, the mouse cursor will turn from an arrow to
a hand; if you press the left mouse button at the same time, you will be
able to move the graphics present in this area.
3. Suction cups: by selecting a part from area 1 you enable, in this area,
only the suction cups of the manipulator used to perform the gripping.
The list on the left is about all the gripping device’s suction cups of the
manipulator on the left (2); those ones that are being used are highlighted.
The list on the right is about all the gripping device’s suction cups of the
manipulator on the right (1).
In this area you cannot choose the manipulator to use, but only a
modification of the suction cup’s configuration of the manipulator
selected: by clicking on each suction cup of the list you can enable or
disable them for the part being processed.
For long parts, that have to be gripped by both manipulators, you will
have to enable the suction cups of both manipulators.
4. Pick-up correction: modifies the position of the holding devices. You
can set some corrections in the X and Y directions as well as an angular
correction.
The pick-up corrections can be obtained also by clicking the mouse on the
graphical area:
Left button : X-Y transfer
Middle button: activate/deactivate suction cups
Right button: rotation

Backward centering: if there are some parts with notches that do not
permit a proper centering at the bottom of the two stops of the CTS
(conveyor with brushes), by enabling this function (valid only for the
manipulator on the right) you can obtain the backward movement of the
conveyor’s belt of the manipulator in respect to standard motion; the
blank leans on the CTS central sheet stop.

- 20 - VisualStacker
VISUALSTACKER S4 - EN 2.4

CENTERING DEVICE ON
TRANSFER WITH BRUSHES
(CTS)

CORRECT CENTERING
If the part to stack does not have particular
notches, the blank is centered correctly.

INCORRECT CENTERING
If the part to stack has particular notches
causing the blank stop in a incorrect
position, you need a further centering
procedure.

BACKWARD CENTERING
By enabling the “Backward centering”
option, the right belt turns counter-
clockwise until the blank is centered
against the central sheet stop.
This option cannot be applied to the left
belt as there is not a sheet stop at the
beginning of the belt to block the sheet.

VisualStacker - 21 -
VISUALSTACKER S4 - EN 2.4

5. Ignore embossing: if enabled, it allows you to activate the suction

cups without taking into account the embossings present on the sheet.
6. Centering Sequence: Specifies the sequence of the conveyor and
centering guide movements.
7. Update suction cups: enables automatically all the suction cups
placed inside the edge of the part being picked up. By enabling “…while
move”, you automatically select the suction cups that have to pick up the
part during the gripping corrections.
8. Green light  Secure pick-up: the pick-up is secure;
Yellow light  Pick-up too de-centered: the pick-up is not secure
and the picked up part can fall while moving as the suction cups enabled
on the part are too few or dislocated inconsistently on the part;
Red light  Pick-up impossible: shows that the pick-up will not be
carried out as the number of suction cups enables on the part are not
enough to pick it up.
9. Save: saves the configuration that you have just created.
10. Close: closes the “pick up configuration” window.
If you have modified any parameter of this window and attempt to exit
without saving them, the following window will appear:

To save all the changes you have made, click Yes; to exit without saving
them, click No. If you do not want to exit, click Cancel.
11. Loading image bar: it may take a long time to open a program that
contains lots of parts.
A window will open for each part, with a progress meter to indicate the
time being taken to read its geometrical characteristics:

The user can choose whether to interrupt the loading process (by pressing
Cancel) or to skip the part being loaded (by pressing Skip), to allow him
to modify the parameters without waiting for the end of the process.
If the geometry of the part selected is incomplete, the bar will appear in
red together with the following message: “WARNING: Part image
INCOMPLETE!”; otherwise, it will appear in green.

- 22 - VisualStacker
VISUALSTACKER S4 - EN 2.4

12. Mixed Manipulator / Standard Manipulator: indicates whether the

manipulator’s gripping device is configured with both magnets and
suction cups (Mixed Manipulator) or only with suction cups (Standard
Manipulator).
This parameter is defined by the user selecting the Manipulator config.
option in the Simulation menu.
13. Zoom: cursor used to increase/decrease the dimensions of the part shown
in the view area; the same can be done using the mouse wheel.
14. Save for both: this button is only active if the right-hand manipulator is
selected.
The right-hand manipulator is located further from the S4 punching
machine and its movement is limited by the parts of the machine present
on the right, whereas the left-hand manipulator doesn’t have to respect
any such limits.
If you press this button, all the modifications made on the right-hand
manipulator will be applied to the left-hand manipulator too.

Zones to use
If you select Zones to use in the Show menu, the following window will
appear:

This window is used to select the unloading zone and is composed as follows:
1. Parts area: this box is used to select the part for which you want to
define the unloading area:
Part: it is the name of the part;
R: indicates the rotation;
Order: identifies the production order associated with the part;

VisualStacker - 23 -
VISUALSTACKER S4 - EN 2.4

2. Piece preview: shows the geometry of the part selected:

3. All: selects all the unloading zones;

4. None: deselects all the unloading zones;
5. Zones to use: Shows all the zones available for unloading and is used
to select those required;
6. Scroll arrows: they are used to modify the stacking sequence by
changing the order of items;
7. Save to all: saves the unloading configuration created for all the parts
present in the part area;
8. Close: closes window;
9. Save: saves the unloading configuration created only for the part
selected.
10. Save to order: it allows you to save the selected zone to use, on all
the parts belonging to the same job.
11. Enable multiple configuration: allows you to simultaneously select
zones belonging to different configurations from that being used.
Before exiting from this window, you must save in order to activate the
configuration that you have selected. If you exit without saving, the window
described earlier will appear to remind you to save the new configuration.

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VISUALSTACKER S4 - EN 2.4

Sub-zones to use
If you select Sub-zones to use in the Show menu, the following window
will appear:

This window is used to configure a number of unloading sub-zones. It is

composed as follows:
1. Parts list: this area is used to select the part for which you want to
define the sub-zone;
2. Zone: this area is used to show the sub-zone that has been set and to
modify its dimensions.
Position the cursor of the mouse on any of the sides of the rectangle
drawn and then drag the pointer while you press the left mouse button.
Dragging the corners the resizes both the length and the height of the
sub-zone, whereas dragging a side changes the length of that side alone;
3. Sub-zones list: this box lists the sub-zones that have been defined;
4. Add a new sub-zone: this button is used to add a sub-zone to the
unloading zone selected from the pull-down menu under the Zone area.
The sub-zone created has a red frame around it;
5. Remove the selected sub-zone: this button is used to delete the
sub-zone selected from the Sub-zones list;
6. Remove all sub-zones: this button is used to delete the sub-zones
selected for each part present on the Parts list;

VisualStacker - 25 -
VISUALSTACKER S4 - EN 2.4

7. Remove all sub zones on this zone: this button is used to delete
all the sub-zones present on the Sub-zones list;
The following buttons are used to force the use of a specific sub-zone from
among those available in the zone selected:
8. Set sub-zone for selected part: sets a given sub-zone for the part
selected;
9. Set sub-zone for all parts: sets a given sub-zone for all the parts;
10. Reset sub-zone for selected part: eliminates the sub-zone set for
the part selected;
11. Reset sub-zone for all parts: eliminates the sub-zone set for all the
parts;
The reserved sub-zone will appear in the list of sub-zones, highlighted with the
string (FORCED).
To enable the buttons relating to the functions just described, please contact
Salvagnini.
12. Save only for selected parts: this button is used to save only the set
sub-zones only for the part selected in the Parts list;
13. Save for all parts: this button is used to save the set sub-zones for all
the parts present in the Parts list;
14. Used to set the parameters that define the sub-zone;
15. Close: this button is used to exit from the window;
The sub-zone concerned is shown by a red rectangle, whereas the unloading
zone is shown by a blue rectangle; any other sub-zones present are shown in
blue, with a line thinner than that representing the edge of the unloading zone.
Before exiting from this window, you must perform a save in order to activate
the configuration you have defined. If you exit without saving, the window
described earlier will appear to remind you to save the new configuration.

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VISUALSTACKER S4 - EN 2.4

General Parameters
If you select General parameters the following window will appear:

This window is used to modify the stacking mode. The window is composed
as follows:
1. Parts: this area is used to select the part of which you want to set
General Parameters:
Parts: it is the name of the part;
Q: indicates the number of the part selected in the whole program/job;
R: indicates the rotation of the part;
Order: identifies the production order associated with the part.
2. Maximum number of stacks of this part in zone: indicates the
maximum number of stacks of this part that can be stacked in a given
unloading zone;
3. Maximum number of stacks in zone: indicates the maximum
number of stacks that can be produced in a zone;
4. Area filling algorithm: The filling algorithm area establishes the
criterion by which the space available on each zone will be occupied.
The algorithm available are as follows:
- On the vertexes

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VISUALSTACKER S4 - EN 2.4

- On the medians
- In matrix form (depending on the configuration)
The second field presents some variations of the algorithm chosen:
- Right - Bottom, the part is initially being moved all the way to the
right and then all the way down, obviously to the point where there
is space available;
- Bottom - Right, the part is initially being moved all the way down
and then all the way to the right, obviously to the point where there
is space available;
- etc..
5. Stack spacing: if there is more than one stack you can set the
minimum distance between axis (x, y);
6. Possible rotations of the stack: this section is enabled only if the
parts unloading occurs by a Cartesian manipulator and shows the
sequence of rotations to undertake.
If the rotation set in the field “Start rotation” does not generate a correct
position of the part that has to be stacked, you have to move to “Second
rotation” and so on. You can enter up to four different rotations;
7. Scatter on all zones: by enabling this option, you scatter the
production an all the pallets equally; by disabling it, you will load one
pallet before moving on to the next one;
8. Suppose all zones empty at start: if enabled, it considers the
unloading zones free at the start of the program or list;
9. Link all: if enabled, it keeps all the tables chained, in order to avoid a
request of confirmation by the operator during any chaining cycle in
unmanned processing;
10. If the system is in line with a P4 panel bender, one of these two options
will appear, depending on the type of part selected:
if “.P4”, then P4 in line will appear: this option allows the operator to
choose whether the part will be moved to the panel bender or stacked on
a generic device downstream of the S4 system.
if “.S4”, then out of the line will appear: if enabled, the selected part
is not stacked but sent to a generic connection downstream of the S4.
11. Group by order: special stacking in relation to a job number;
12. Avoid different programs on the same table: if there is a list of
production, as the program changes, a table change is also carried out;
13. Avoid overlapping: the manual mode for stacks shift, avoid different
parts to overlap;
14. P4 report: enables the creation of reports to send to the P4 panel
bender, when this machine is in line;
15. Multilayer stacking.
Enable multilayer stacking: with this option, the stacking does not
take place per pile but per layers and it is possible to set the number in
the Layers field.
16. Special stacking cycle: enables the selection of special cycles;
17. Opening corrections for deviators in end position:
Permits to modify the position of the two diverters; by entering a
positive number you move them away from the part, whereas by
entering a negative number you move them closer.
Deviate using RIP enables to deviate sheets outgoing from the S4 by
using RIP.
18. Save to all pieces: saves the current configuration on all the pieces
present in area 1;

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VISUALSTACKER S4 - EN 2.4

19. Save only the changes: saves only the parameters that have been
modified, on all pieces;
20. Close: closes the window;
21. Save: saves the current configuration only on the selected part;
22. Send to MVP: if enabled, the part to be stacked is sent to the MVP
store;
23. Alternate turnover: this option is activated only if a turnover unit is
present. If enabled, it allows you to stack the parts overturning them in
an alternate way;
24. Superimpose job: it allows you to superimpose parts belonging to
different jobs;
25. Conveyor dynamics: it is possible to modify the speed, acceleration
and deceleration parameters of the conveyor during the stacking. If you
modify these values, you shall also modify the values present in the
machine cycles;
26. Thickness correction: it is used for parts with embossings and
allows you to set the thickness of the embossing to take into account
during the stacking (the sheet thickness is not included in this value);
27. Save for the entire job: it allows you to save the modified
parameters for all the parts belonging to the same job.
28. Use magn. manip.: the part selected will be picked up using
magnets.
29. Order: production order.

Before exiting from this window, you must perform a save in order to activate
the configuration you have defined and re-elaborate the calculation. If you exit
without saving, the window described earlier will appear to remind you to save
the new configuration.

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VISUALSTACKER S4 - EN 2.4

Manual modifications
If you select Fix & Move from Show, the following window will appear:

In this environment you can modify the position of each stack within the same
zone or move a stack from one zone to another.

Save: saves the new configuration.

Restart from the latest save: sets the configuration of the latest save.

Reset automatic calculation: closes “Manual modifications” window and

resets the automatic mode.

Cancel stacks : cancels the stack selected.

New stack: permits to insert a new stack equal to the one selected.

Move to next area: moves the selected stack to the next unloading area.

Quantity: determines the maximum number of pieces possible for the stack
selected.
Movement: The large arrows permit to move stacks at right angles, whereas
the small arrows move stacks as described on point “4” p. 28. It is possible to
set the movement step (expressed in mm).
Rotation: disabled.
The right window is about information on stacked parts:
If the quantity in stacks exceeds the maximum quantity set up, next to
Sub-code a red circle will appear to indicate the need to change pallet, in
order to stack all pieces.
When a green circle appears next to the code, this means that all pieces will
be stacked on the same unloading area.

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VISUALSTACKER S4 - EN 2.4

Operation menu
If you select the Operation menu, the following window will appear:

Recalculate simulation
The option Recalculate simulation from Operation menu recalculates the
stacking simulation by considering the algorithms for stacking and the
parameters set up.

Reset calculation
This option is enabled only during the calculation of simulation.

Calculate simulation with trajectory

This option is activated only if the Cartesian manipulator is present.
It calculates the simulation of the staking stage taking into account the
trajectories of the manipulator holding devices. It allows you to check whether
the program is feasible.

Start calculation with status file

Function used only by Salvagnini engineers.

Save current zone status

Function used only by Salvagnini engineers.

Start from real status

The Start from real status option is used to start the stacking simulation
from the current status of the stacking devices.

Reset all private parameters

Resets all the values modified and restores all the original values.

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VISUALSTACKER S4 - EN 2.4

Simulation menu
If you select Simulation, the following window will appear:

Calculate data
Function used only by Salvagnini engineers.

Manipulator config.
The user defines whether the manipulator used is Mixed (suction cups and
magnets) or Standard (just suction cups).

Help menu
If you select Help, the following window will appear:

Online help
Shows this manual online.

About VisualStacker
If you select About VisualStacker a window with information on the
program will appear.

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VISUALSTACKER S4 - EN 2.4

StateShell

Description of the user interface

If loading/unloading stations shared between more than one system are
present, please consult the State Shell Interface appendix at the end of this
chapter.
To activate the StateShell application, select and click on the program from
the Applications menu of the Salvagnini Console:

When the application starts, the user interface is as follows:

StateShell - 33 -
VISUALSTACKER S4 - EN 2.4

1. Main menu bar.

2. Command button bar or tool bar: these buttons perform the same
functions as some menu items.
3. Representation of the stacking or feeding zone: in this area you can
view the unloading zones that are configured in the system.
4. List of stacking zones: it displays the list of the stacking zones that are
configured in the system.
5. Report area: it lists the stacks present in the unloading zone selected in
zone 4.
6. Displays all unloading zones.
7. 3D view of the unloading area.
8. Status bar.
9. X and Y coordinates: it shows the position of the mouse cursor in the
unloading zone (3), referred to the origin of the unloading zone or to the
origin point of the Cartesian manipulator (if present).

3D mode window
This window provides a 3D view of the stacking area.
Position the mouse on the area, keep pressed one the 3 buttons and move the
mouse to modify the view of the unloading area.
The views that can be obtained are as follows:
 Use the left-hand mouse button (MB1) to rotate the sight angle of the
stacking area;
 Use the middle mouse button (MB2) to perform a zoom on the viewed
area;
 Use the right-hand mouse button (MB3) to shift “the origin” of the
reference axes.
It is also possible to use the mouse to move or amplify the display window: to
do this, position the mouse on the window, keep the MB1 pressed and move
the mouse to the position or view desired.

Stacking report area

The items indicated in the list area identify the stacks present in the unloading
zone.
Each Stack is identified by:
 Quantity: number of parts currently present in the stack;
 Group and sub-code: identify the part stacked.

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VISUALSTACKER S4 - EN 2.4

File menu
Press MB1 with the pointer positioned on File to open the following pull-
down menu:

Load zone from file

Function used only by Salvagnini engineers.

Save zone to file

Function used only by Salvagnini engineers.

Exit
The Exit item of the File menu, allows you to exit from the StateShell
application.

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VISUALSTACKER S4 - EN 2.4

View menu
Position the pointer on View of the menu bar to open the following pull-down
menu:

Toolbar
It displays the tool bar.

Status bar
It displays the status bar.

Bounding box
If selected, it displays the outline of the part without showing any machinings
(embossings, holes etc.).

Tools menu
Position the pointer on Tools of the menu bar to open the following pull-
down menu:

Toggle expert user

This item and a password are used to enable some functions used only by
Salvagnini engineers.

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VISUALSTACKER S4 - EN 2.4

StackAdd
Function used only by Salvagnini engineers.

StackModify
Function used only by Salvagnini engineers.

StackChange quantity
Select the stack whose quantity you want to change and press the MB1 on
Change quantity to open the following window:

The only box in the window where it is possible to write is the Quantity box.
Select the item and enter the new quantity.
This function allows the user to correct any errors either in the stacking
program or if the operator picks up parts from a stack.

StackRemove Stack
Select Remove from the Stack menu to cancel a stack in the unloading zone.
To cancel a stack, select it in the unloading zone and activate Remove. The
following window will appear:

The only active functions are:

 Cancel, used to cancel the stack removing operation;
 OK, used to confirm that the stack has been removed.

StateShell - 37 -
VISUALSTACKER S4 - EN 2.4

StackFree zone
Press the MB1 button when the pointer is positioned on Free zone of the
Stack menu.
This function allows you to empty an unloading zone.
Select the zone that you want to free and activate the function. The following
window will appear to confirm that all the stacks in the selected zone have
been removed.

Press Yes to empty the zone, No to interrupt the operation.

StackFree all zones

Press the MB1 button when the pointer is positioned on Free all zones in
the Stack menu.
This function allows you to free all unloading zones.
The following window shall confirm that all the stacks present in each zone
have been deleted (flat, dwn, etc..).

o
Press Yes to free all zones, press No if you want to interrupt the operation.

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VISUALSTACKER S4 - EN 2.4

Help menu
Press MB1 with the pointer positioned on Help to open the following
window:

Help on line
This function allows you to view this manual.

About StateShell
Press MB1 with the pointer on About StateShell to open the window
containing the information about the program:

————

StateShell - 39 -
 8. SimulX
8.1. Preface

8. SimulX

8.1. Preface

8.1.1. What is SimulX?

SimulX is an application that simulates the machining process for
panels on S4 punching machines.

8.1.2. Who uses SimulX?

SimulX is used by two categories of user:
• machine operators;
• programmers.
The programmers can use SimulX to check the punching programs
without effectively running them on the machine. Numerous graphical
options show the sequence of the machinings and the final aspect of
the parts produced. It shows the programmer if any scrap has been lost
or if any embossings have been crushed by the rotator clamp or the
shear’s blankholder.
SimulX allows the operator to quickly identify whether the part being
produced requires any changes and where to make them.
Thanks to the print option, SimulX also allows you to generate a paper
archive which connects the product code with its graphical
representation.

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8. SimulX
8.2. User interface

8.2. User interface

8.2.1. General description

1 Machine movements 3 Information

2 Panel processing 4 List of operations

Areas (1) and (2) have variable points of view that can be managed
using the pull-down menu located in the top right-hand corner of both
areas (click on if the menu is hidden).
This menu allows you to carry out the following operations:

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 8. SimulX
8.2. User interface

Zoom in on the centre of the work area.

Zoom in on a selected area.

Increase the current zoom.

Decrease the current zoom.

Zoom in on the area of the panel where machining is in process.

Show the second transfer, if present.

Change the opacity of the panel.

Rotate by 180 degrees the view in the area showing the machine's
movements (1).

[CTRL key] + mouse movement

translates the view.
[CTRL + Shift keys] + mouse movement
rotates the model in a 3D view.

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8. SimulX
8.2. User interface

8.2.2. Tool bar

File management
Closes the application.

Opens a saved project.

Loads the file being simulated from the beginning.

Opens the print report panel.

Opens the settings panel.

View
2D or 3D view.
/
Opens the dimensions window.

Manages the view (show/hide) of the various parts of the

machine in the machine movements window (1).

Opens the head configuration window.

Allows you to obtain information about the processing.

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 8. SimulX
8.2. User interface

Allows you to choose one of the three types of view for the
panel being processed.

Allows you to change the simulation reproduction speed.

Allows you to manage the view (show/hide) of the various

parts of the graphical interface.

Navigation
It allows you to accurately and quickly move to any stage of the panel
processing. The positioning can be done as follows:

Starts the simulation.

Interrupts the simulation.

Moves forward by one operation.

Move backward by one operation.

Goes to the end of the simulation.

Goes to the beginning of the simulation.

Goes to the next rotation.

Goes to the next regripping operation.

Goes to the next part unloading operation.

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8. SimulX
8.2. User interface

8.2.3. View area

Machine movements

This area shows the movements of the main parts of the machine
during processing.
You can also choose between a normal 2D view and a 3D view (by
pressing buttons or ).

Panel processing

This shows the panel complete with all the machinings applied.

Additional features
1. You can obtain information about the machinings (punchings,
embossings and so on) by acting directly on their graphic
representations.

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 8. SimulX
8.2. User interface

To do this, just activate the Select punch [Select Punch]

function by pressing the button on the toolbar and click on a
punching or embossing in the machining view.
The selected item will be highlighted and the data related to the
selected operation will be displayed in the information window.

2. There is a constant connection between the status of the simulation

and the source program related to the panel. Clicking on the
icon in the low part of the window allows you to select the line
related to the current operation of the simulation in the source code
of the program.
Once you have selected an operation, three new buttons with the
following functions will be enabled:

• ; in the source code of the program related to the panel, this

button selects the line containing the definition (PUN instruction) of
the punch used for the selected operation.

• ; in the source code of the program related to the panel, this

button selects the line containing the request (XYP instruction) for
the selected operation.

• ; it moves the simulation to the exact point in which the

selected operation is applied to the panel.
3. Pressing the button on the toolbar allows you to choose
between three different types of view: outlines, full view and full
view with highlighted parts.

Information
The information area is situated at the bottom right and it offers some
useful measurement tools and submenus with information about the
machine used (head configuration) and the statistics related to the
processing.

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8. SimulX
8.2. User interface

Measure
If you click on the button on the toolbar, the Measure window will
appear.
It displays the type of measurement (vertical, horizontal, gravitated) and
a variety of information (distance on X, distance on Y, angle).

Click with the left-hand mouse button to select the start and end points
of the measurement.

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 8. SimulX
8.2. User interface

Statistics
This window displays the statistics related to the current status of the
simulation such as the number of punchings, shearings and rotations.

The part of the window related to the use of the punches allows you to
view the information about the various uses of the punches.

Finished panel
The lower part of the Information (3) area always features a
representation of the finished panel.

Unloaded parts
You can also obtain the representation of the of the last part that has
been unloaded and the information about the dimensions, destination
and code (you can save it clicking with the right-hand mouse button).

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8. SimulX
8.2. User interface

List of operations
The window below lists the operations performed during the simulation.
Use the cursor (indicated by the arrow) or double click directly on a line
in the list to view the simulation corresponding to the selected operation
in the Machine movements area.

The bar located in the bottom left-hand corner of this area shows the
current progress of the simulation.

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 8. SimulX
8.2. User interface

8.2.4. Head configuration

You can explore the head configuration by pressing the button on
the toolbar and activating the relative window. Selecting a punch in the
head you can obtain all the information related to the punch definition:

From the processing window you can also select the position of a punch
within the head by clicking on the line related to the punch.

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8. SimulX
8.2. User interface

8.2.5. Settings
Pressing the button on the toolbar you can view the settings window.
This window allows you to configure many functions of the application
such as the windows that are shown when the simulation starts up or
the colours given to each type of processing.

8.2.6. Printing a report

The print configuration window is displayed by pressing the button
on the toolbar. It allows a title, additional notes and the company logo to
be added. It also allows you to decide whether to print the data for each
single part unloaded, the head configuration or the head configuration
taking into account only the punches used.

This is an example of what a report extract looks like:

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8.2. User interface

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8. SimulX
8.2. User interface

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 9. Store Manager Shell
9.1. Preface

9. Store Manager Shell

9.1. Preface

9.1.1. Terminology
Pack data
Number of sheets or height, dimension in X, dimension in Y, thickness,
specific weight and name/code of the material.

Server
Application that provides a particular service and is able to satisfy the
requests of other applications called "client".

RCM table
Mechanical device that allows you to load or unload a pallet of sheets.

9.1.2. What is Store Manager Shell?

Store Manager Shell is an application that allows the management of
the following activities:
• loading (from the RCM table to the shelves)
• unloading (from the shelves to the RCM table)
• moving (from shelves to shelves)
the packs of sheets on one or several store shelves.
Generally it allows you to manage one or several stores feeding the
Salvagnini system.

9.1.3. Who uses Store Manager Shell?

The Store Manager Shell is used by the system operator, whose task is
to keep the situation of the store(s) that feed the Salvagnini system
updated.

9.1.4. How to use the application?

The Store Manager Shell application is activated by means of the
“Applications / Feeding store” function of the application that controls
the Salvagnini system.

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9. Store Manager Shell
9.1. Preface

9.1.5. Typographical conventions

The images used in this manual show the English version of the Store
Manager Shell application.
In the descriptions, the exact English nomenclature is given in square
brackets after each reference to a parameter, command and/or button.
This is to help the reader identify the positions of the commands in the
images and therefore in the application interfaces.

Example:

Figure 49: Store Manager Shell Interface menu

The reference to the New function is indicated as follows:

New [New]

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 9. Store Manager Shell
9.2. User interface

9.2. User interface

9.2.1. General description

1. Menu bar
2. Toolbar
3. Identifier of the store being used
4. Graphical representation of the store
5. RCM table area
6. Identifier of the number of sheets present on the shelf or RCM table

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9. Store Manager Shell
9.2. User interface

7. Area showing the data relating to the pack selected in the graphical
representation.
8. Indicator of the current action
9. Indicator of the operation mode (Manual/Automatic)
10. Status bar

Menu bar
Allows you to activate the functions offered by the Store Manager Shell
application.
Some menu functions do not directly perform an action, but allow you to
activate or deactivate an option. The activation status in indicated with
the symbol next to the function.

Toolbar
The control buttons allow you to perform some frequent functions of the
menu bar in a fast and intuitive way:

1. It has the same function as Exit [Exit] in the File menu [File]
2. Function disabled
3. It has the same function as Load [Load] in the Packs menu
[Packs]
4. It has the same function as Unload [Unload] in the Packs menu
[Packs]
5. It has the same function as Move [Move] in the Packs menu
[Packs]
6. It has the same function as Compose Packs [Compose Packs]
in the Packs menu [Packs]
7. It has the same function as Abort [Abort] in the File menu
[File]
8. It has the same function as New [New] in the Packs menu
[Packs]
9. It has the same function as Modify [Modify] in the Packs menu
[Packs]
10. It has the same function as Delete [Delete] in the Packs menu
[Packs]
11. It has the same function as Print [Print] in the File menu
[File]

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 9. Store Manager Shell
9.2. User interface

12. It has the same function as About SmShell [About SmShell] in

the Help menu [Help]
for further information, please see the paragraph on Menu bar [} 408].

Graphical representation of the store

This area schematically shows:
• the feeding store structure;
• the number of sheets on each shelf.

Using the mouse, the operator can select a shelf or a pack of sheets.
The selected shelf is yellow and the pack is light blue. The data relating
to the selected pack are given in the area where the characteristic pack
data are shown.
Double-clicking on the selected pack displays the Modify pack
[Modify pack] window, which is explained below.

RCM table area

The RCM table is used in the activities of loading/unloading between
the shelves and the packs of sheets on the pallet.

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9. Store Manager Shell
9.3. Menu bar

This zone is not present in the TIVOX store management.

9.3. Menu bar

9.3.1. File menu

Refresh [Refresh]
This function realigns the store status and the data of the sheet packs
present on the shelves.

Update sheets quantity [Update sheets quantity]

This function is only available for TIVOX stores and it allows the
software to control and realign the data present in the store.

Abort [Abort]
This function allows you to stop a loading or unloading operation or the
operation of moving packs of sheets.

Print [Print]
This function allows you to print the data relating to the packs of sheets
present in the store (length, width, thickness, specific weight, type of
material and quantity), divided per shelves.

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 9. Store Manager Shell
9.3. Menu bar

The same function can be activated by means of the button.

Print preview [Print Preview]

This function provides a print view before printing.

Print setup [Print Setup]

This function allows you to define the print options for the printer
selected.

Exit [Exit]
This function closes the application and does not affect any movements
in progress in the store, which are controlled by the control system.

The same function can be activated by means of the button.

9.3.2. Packs menu

Load [Load]
This function allows you to load a pack of sheets from the RCM table to
a store shelf.
The following window appears:

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9. Store Manager Shell
9.3. Menu bar

The operator must enter the shelf and the number of sheets to handle.
The operator can select an alternative shelf: if the number of sheets to
load is greater than the maximum number of sheets that can be placed
on the shelf selected, the sheets in excess do not remain on the RCM
table, but are placed on the alternative shelf.
To perform the operation press the Start cycle illuminated green button
on the MD store's control panel, to stop the cycle use the Abort
[Abort] function from the File [File] menu.
This function is only enabled for the Salvagnini MD store.

The same function can be activated by means of the button: .

Unload [Unload]
This function allows you to unload a pack of sheets you have selected
before with the mouse from a store shelf to the RCM table.
The operator must enter the number of sheets to unload.

The operator will be prompted to confirm the unloading operation in

progress.
To perform the operation press the Start cycle illuminated green button
on the MD store's control panel, to stop the cycle use the Abort
[Abort] function from the File [File] menu.
This function is only enabled for the Salvagnini MD store.

The same function can be activated by means of the button: .

Move [Move]
This function allows you to move a pack of sheets from one shelf to the
other.

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 9. Store Manager Shell
9.3. Menu bar

The operator must enter the start shelf, the destination shelf and the
number of sheets to move.
To perform the operation, press the Start cycle illuminated green
button on the MD store's control panel, to stop the cycle use the Abort
[Abort] function from the File [File] menu.
This function is only enabled for the Salvagnini MD store.

The same function can be activated by means of the button: .

Compose packs [Compose Packs]

When enabled, this function allows you to move the packs of sheets
from the shelf to the RCM table of the store, selected by means of the
following interface:

Defrag [Defrag]
This function allows you to reorder the store according to the option set
in the Options > Store defrag [Options > Store defrag] menu.

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9. Store Manager Shell
9.3. Menu bar

New [New]
This function allows the operator to enter the data of a pack of sheets in
the database.

This operation does not provoke any physical movement of the store.
The options present in this window are enabled according to the system
configuration.

The same function can be activated by means of the button: .

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 9. Store Manager Shell
9.3. Menu bar

Edit [Modify]
This function allows the operator to edit in the database the data of the
pack of sheets selected.

This operation does not provoke any movement in the store.

The same function can be activated by means of the button: .

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9. Store Manager Shell
9.3. Menu bar

Delete [Delete]
This function allows the operator to delete from the database the data of
the pack of sheets selected.

Press Yes [Yes] to continue, press No [No] to cancel the operation.

This operation does not provoke any movement of the store.

The same function can be activated by means of the button or

pressing "Canc" on the keyboard.

9.3.3. View Menu

Store 1 [Store 1]
The Store Manager Shell application can manage up to 5 stores of the
same type (MD or Tivox), connected in parallel to one or several
Salvagnini systems.
From this menu you can select the store you want to use.

Toolbar [Toolbar]
The symbol indicates that the toolbar view has been enabled.

Status bar [Status Bar]

The symbol indicates that the status bar view has been enabled.

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 9. Store Manager Shell
9.3. Menu bar

9.3.4. Options Menu

Alternate feeding [Alternate feeding]

It enables an option that allows the system to use alternatively the
sheets from two packs with the same characteristics.
This option is used to obtain homogeneous feeding of several packs
with the same characteristics.

Store defrag [Store defrag]

It allows you to set how to reorganize the store. Once you have selected
the option, use the Defrag [Defrag] function of the Packs [Packs]
menu to perform the defragmentation:

WARNING
This operation provokes several store movements and can be very
long. The application must not be closed during this operation.

The defragmentation can be performed in 2 ways:

1. By sheet quantity [By Sheet Quantity]: Store Manager Shell
tries to create homogeneous packs with a greater quantity of
sheets;
for instance, if there is a pack with quantity 5 and a pack with
quantity 2 of the same material (or size), it will move the 2 sheets to
the shelf with quantity 5.

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9. Store Manager Shell
9.3. Menu bar

2. By packs position [By Packs Position]: there are two cases:

– if there is an empty shelf near the RCM table, the Store
Manager Shell will try to bring the packs of the same material
(or size) to that shelf;
– if there is no an empty shelf near the RCM table, the Store
Manager Shell will try to bring all the sheets of the same
material (or size) to the shelf nearest to the RCM table;

NOTICE
The pack search mode within the Store Manager Shell is not affected
by this option and is always carried out from the RCM table towards
the top shelf or from the shelf specified by the loading cycle upwards
and if not found from the RCM table towards the top shelf.

Material code [Material Code]

It allows you to define the material codes that the user can decide to
use when creating or editing a pack.

User data [User Data]

It allows you to define the User Data that the user can decide to use
when creating or editing a pack.

Supplier code [Supplier Code]

It allows you to define the supplier codes that the user can decide to
use when creating or editing a pack.

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 9. Store Manager Shell
9.4. Diagnostics

9.3.5. Help Menu

Help topics [Help Topics]

View this manual.

About SmShell…[About SmShell…]

It displays a window with the information about the program:

9.4. Diagnostics

9.4.1. Messages
"The pack management server is no longer responding"
This error message is displayed when the communication between the
Shell Store Manager and the server application, which manages pack
handling in the store, has been interrupted due to a network overload or
server failure.
Please contact the Salvagnini Italia S.p.A. Customer Service.

"The store server has not accepted the request"

This error message is displayed when the Shell Store Manager sends a
request that cannot be satisfied by the server which controls pack
handling in the store.
Try again later.

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9. Store Manager Shell
9.4. Diagnostics

"The MD interface cycle has not run the initialization

procedure"
This error message is displayed when the part of Real Time software
has not run the initialization procedure.
To solve this problem, press the Stop button in the control application
window of the Salvagnini system.

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 10. CTM Editor
9.4. Diagnostics

10. CTM Editor

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14 CTM Editor

Version 1.1

'
 This page has been intentionally left blank.

-2-
Summary
An introduction to CTMEditor 5
What are Machine Constants (CTM)? ............................................................................ 5
What is CTMEditor? ....................................................................................................... 5
Who uses the Machine Constants editor? ....................................................................... 5

CTMEditor Main Characteristics 6

The machines .................................................................................................................. 6
The groups....................................................................................................................... 6
The cycles........................................................................................................................ 7
The software applications................................................................................................ 7
Users and access levels ................................................................................................... 8

User interface 9
The variables tree .......................................................................................................... 10
The attributes................................................................................................................. 11
The toolbar .................................................................................................................... 12
The status bar ................................................................................................................ 12

Main menu commands 13

File menu....................................................................................................................... 13
Logon.................................................................................................................. 13
New Ctm............................................................................................................. 15
Save .................................................................................................................... 15
Download ........................................................................................................... 16
Import/Export from UNIX DB ........................................................................... 16
Compact DB ....................................................................................................... 17
Exit ..................................................................................................................... 17
Edit menu ...................................................................................................................... 18
Find..................................................................................................................... 18
View Menu.................................................................................................................... 20
Cycles List .......................................................................................................... 20
Toolbar ............................................................................................................... 21
Status Bar............................................................................................................ 21
Tools menu.................................................................................................................... 21
Options ............................................................................................................... 21
Help Menu..................................................................................................................... 22
Help Topics ........................................................................................................ 22
Information about CTM Editor…....................................................................... 22

Environment and configuration 23

Start-up from Salvagnini Console ................................................................................. 23
Start-up using an MS Dos command line...................................................................... 24
Application files ............................................................................................................ 24
“groups.ctm” file ................................................................................................ 25
“messages_<lang_ext>.ctm” file ........................................................................ 25
“applications.ctm” file ........................................................................................ 26

Summary -3-
 “last_values.ctm” file.......................................................................................... 26
Precautions ......................................................................................................... 26

Glossary 27

-4- Summary
CTM Editor - EN 1.1 '

An introduction to CTMEditor

What are Machine Constants (CTM)?

MACHINE CONSTANTS (often called by the acronym CTM) are parameters
memorised in the computer, used by regulating their numerical value, to
obtain the correct operation of the system and/or of the correlated software
applications.
The CTM are recorded in a file with a Data Base structure (a term which will
be abbreviated to DB hereinafter) and they describe many aspects of the
Salvagnini system, the physical position of the mechanical components, some
behavioural preferences of the software applications and other aspects.
Each single CTM has different attributes: their progressive numbers and
names for identification, a value that must be between the minimum and
maximum set values, the measurement unit, access level, indications of the
system functional groups and/or of the software whose operation is influenced
by the CTM value and other attributes described further on.

What is CTMEditor?
CTMEditor is a software application for CTM management. It supplies a
graphic representation of the Data Base: the variables are distributed on the
nodes of a tree and it is possible to see and modify their attributes by clicking
on the corresponding node.
CTMEditor also graphically indicates if a machine constant is used by the
machine cycles or by the software applications.
With CTMEditor changing the variables is only permitted to users with
suitable permission. The editor also permits the DB of several machines to be
interrogated or modified, without having to leave the application. The
application can be launched from Salvagnini Console or directly from the
command line with the suitable parameters.

Who uses the Machine Constants editor?

CTMEditor is used by persons wishing to consult or modify machine
constant values.
ATTENTION: changing machine constants is an EXTREMELY
DANGEROUS activity that can compromise correct system operation. It
must therefore only be performed by competent and qualified
technicians.

An introduction to CTMEditor -5-

CTM Editor - EN 1.1 '

CTMEditor Main Characteristics

The machines
CTMEditor permits the contemporaneous access to the DB of the machine
constants of all the machines installed.
The data of several machines, even of different types and with different
operating systems may be present in the workstation CTMEditor is installed
in. This is the case for example of a machine computer that manages a
warehouse with MV trays, its movement/lifting device and a single sheet
SMD feeder.
As the DB of different types of machines anyway have the same structure,
CTMEditor can manipulate them without any problems.

WARNING: if an office workstation is connected to one or more systems, as

a general rule we advise against changing the original DB recorded in the
machine computer from the office.

The machine computer DB is the main one. A copy of this is made using the
special Salvagnini Console utilities in the office workstation because the two
DB must always be aligned, or in other words they must be the same.

The groups
Before intervening on a part of the machine using CTM, it is important to
know which other CTM have an influence on that part. In other words, how
they are correlated. For this purpose CTMEditor permits the CTM to be
associated in Groups, permitting access to variables per group and to see the
groups each constant belongs to. A group represents a set of variables and a
variable can belong to several groups.

-6- CTMEditor Main Characteristics

CTM Editor - EN 1.1 '
The cycles
Some variables are used by the cycles, in other words by the software
components that supervise machine movements in real time.
CTMEditor lets us know if a constant is used by the cycles of a machine, to
see the list of these cycles, and to rapidly access their content. The variables
used by the cycles are highlighted in the tree by a small yellow gear:

The software applications

Salvagnini software is composed of a group of software applications, whose
behaviour and results can be conditioned by the values of one or more CTM.
If a user changes the value of one of these constants, all the outputs
previously produced by an application and that use that CTM are no longer
updated. It is therefore important to know which applications use a certain
machine constant and vice versa, which CTM are used by a certain
application. CTMEditor supplies this information by permitting access to the
constants, ordered per application and to see the applications that use it for
each CTM.
Several applications called "compilers" (SDEX, PDEX, LDEX, …)
generate binary data used by the Salvagnini system, starting from a user
program (name.S4, for example) The CTM used by a compiler are highlighted
in the tree by the letter E:

CTMEditor Main Characteristics -7-

CTM Editor - EN 1.1 '
Users and access levels
CTMEditor is protected against unauthorised modification. In other words, it
can be used in different access or protection ways (user levels). The
application always permits the consultation of all the attributes of a CTM,
whatever the current access level is.
The access levels are as follows:
• Standard user;
• Expert user;
• Administrator

CTMEditor can modify several variable attributes, only if it finds itself in a

higher or equal access condition to the protection status attributed to that
variable.

-8- CTMEditor Main Characteristics

CTM Editor - EN 1.1 '

User interface

This chapter describes the various functional areas of the CTMEditor graphic
interface and their characteristics and functionality.

Fig. 1 Main window

To the left, there is the machine constant tree (3), to the right (4), the
attributes of the variables. The most frequent actions permitted by the menu
(1) can be performed from the Toolbar (2). The messages of each constant are
visible in the sliding window (5), while the status bar (6) shows the activities
in progress.

User interface -9-

CTM Editor - EN 1.1 '
The variables tree
To the left, below the toolbar, we find the variables tree (zone 3 of Fig. 1) that
permits a determinate variable to be selected and to consult or change its
attributes. The tree lets us see which variables are used by the various
applications, how they are grouped and gives a complete list of them, ordered
in a growing number.
The variables are displayed as the nodes of a tree and the same number of
trees appear for the number of installed machines. Each tree has a root node
with the machine name and three offshoot nodes. The offshoot nodes are:
• Applications
• Groups
• All the variables
The Applications node can have offshoot nodes, with an application
corresponding to each of them; the variables of the machine in question used
by that application correspond to the offshoots of this node.
The Groups node has at least the “In no group” offshoot node. This node can
have numerous offshoots: a variable that does not belong to any group
corresponds to each offshoot of this node. The groups node can also have
other offshoots, each corresponding to a group of variables.
The All the variables node has as many offshoots as the number of variables
machine X has. Each variable node is labelled with a string that contains the
variable number, name and value.

The variables have nodes with different icons. If there is an E present in the
icon, this means that the variable is used by an application called compiler.
If a small gear is present, this means that the variable is used by a cycle. In
this case, we can see the list of cycles the variable is used in by double
clicking on its node. A variable can concern processing and cycles at the same
time: in this case, its icon has both a small gear and an E.

- 10 - User interface
CTM Editor - EN 1.1 '
The attributes
The attributes area (zone 4 of Fig. 1) is found under the toolbar to the right.
Almost all the fields of this area correspond to a field in the DB. If the field
corresponding to an attribute is enabled (white background), it can be
changed. By saving the value written in this field, it is assigned to the
corresponding attribute of the variable selected in the tree.
The fields present in this area are:

• Number
• Value
• Name
• Minimum value
• Default value
• Maximum value
• Measurement unit
• Class
• Type
• Groups
• Axes
• Level
• Last change date
• Previous value
• Applications
• Description

The fields with a coloured background cannot be changed, but only consulted.
Whatever they are depends on the access level used.
The Applications attribute contains the list of the applications to which the
variable belongs. The Last change date contains the date of the last change.
The Previous value attribute contains a copy of the “value” and
“measurement unit” set before the last change.

User interface - 11 -
CTM Editor - EN 1.1 '
The toolbar
To speed up system use, several operations possible via menus are also shown
on a command bar located immediately below the main menu.

Corresponds to the File / Exit menu item

Corresponds to the File / Save menu item

Corresponds to the File / Download menu item

Corresponds to the Edit / Search menu item

Corresponds to the Help / About CTM Editor... menu item

The following buttons do not have any corresponding menu items:

Shows the documentation for the CTM selected
It permits a pdf file containing the list of all the machine constants
with related parameters and descriptions to be opened.
Machine cycles logic analyzer
It starts the “Machine cycles logic analyzer” application that
permits the cycles that use the machine constant selected to be
viewed.

The status bar

In the status bar, either information about the button the mouse is located on
or information about the operation the CTMEditor is performing, appears.

- 12 - User interface
CTM Editor - EN 1.1 '

Main menu commands

This chapter reviews all the Menus and their items and explains their
functions. To activate a function, it is sufficient to open the drop-down menu
it appears in and to select it with the mouse.
Several items do not directly perform an operation, but permit an option to be
activated or deactivated: in this case, a selection button is shown next to the
item indicating the activation status of that option.

File menu

Logon
By clicking on the Logon item, the application is taken to the level of a given
user. If a tick sign appears ( ) next to this item, CTMEditor is already in
the level of a certain user, otherwise it is in the 0 default level.
To connect (in technical jargon “login” or “logon”) just select the File /
Logon menu.
A window appears in which it is possible to insert the User name and
Password of a certain user, defined in the Salvagnini Console interface.

Main menu commands - 13 -

CTM Editor - EN 1.1 '

To disconnect (in jargon “logoff”) and to return to the application in the 0

status, just use the File / Logon menu again
Having done this, we can now connect again as another user.
Changing particular machine constants can seriously damage the machine.
Therefore, some parameters can only be changed at “Expert user” or
“Administrator” user level.
Because the possibility of changing the attributes of a variable depends on the
level of the variable and on the privileges assigned to the Username, Password
pair, after login, several fields concerning variable attributes may or may not
be active depending on these two pieces of information. In the figure below,
we see which fields can be changed, depending on the user name and
therefore according to the access level attributed.

Status of the CTMEditor application

Standard user Expert user Administrator

The user can only enter a value in The user can only change the All the fields concerning the
the Num field to view the attributes following fields: attributes of all the variables can be
of a new CTM. Value, Minimum value, Default changed. The “Last change” and
value and Maximum value. “Previous value” fields are updated
automatically.

- 14 - Main menu commands

CTM Editor - EN 1.1 '
New Ctm

It can only be activated by Administrator and permits a new machine

constant to be defined.

Save
The Save item becomes active only if the value of a field/s has been changed.
By using this item, the new field values are saved in the database.

Main menu commands - 15 -

CTM Editor - EN 1.1 '
Download
This is understood as the immediate transfer of the CTM values to the
numerical control. In this way, the changes to the CTM read by the machine
cycles become immediately operative, otherwise, they become operative the
next time Salvagnini Console is started.
To execute the transfer (Download) of the DB values into the machine, just
use the File / Download menu.

Import/Export from UNIX DB

These are useful items when CTMEditor is installed in an office workstation

connected to Salvagnini systems with a Unix operating system. In this case,
the Unix DB - imported as a copy from the machine computer – must be
converted into the MS Access format before the Salvagnini applications are
launched. Examples here are the compilers for S4, P4, AutoNest, etc.
Confirmation is requested before performing the conversion. The two items
are always active, independently of the application level, as long as the
existence of a Unix DB is recognised.
If the Import UNIX DB is active and used, the database in UNIX format is
converted into the MS Access format and any previous copy of the MS
Access data base is overwritten.

- 16 - Main menu commands

CTM Editor - EN 1.1 '
If the Export UNIX DB is active and used, the data base in UNIX format is
converted into the MS Access format and any previous copy of the MS
Access data base is overwritten.

Compact DB

It can only be activated by Administrator and permits the DataBase to be

reorganized reducing the space occupied on disc.

Exit
By activating the Exit item, we can leave CTMEditor. An exit confirmation
window appears and control boxes labelled Save and Download may be
presented. The boxes can appear as disabled (with a grey background) and not
selected or as enabled (with a white background) and selected ( ). If they
are enabled, the user can remove the control. The operations marked with a
tick ( ) are executed on exiting.

Save is enabled if we exit after changing a field and not saving it afterwards.
Download is enabled if we exit after changing the field value, successively
saving and still not having made the transfer.

Main menu commands - 17 -

CTM Editor - EN 1.1 '
Edit menu

Find
By using the Find item in the Edit menu, it is possible to find constants with
determinate characteristics in the DB. When Find is used a window appears
permitting the search by number or by the partial string of the name or by
value or by partial string of the message. The search by partial string can be
done in a “Case Sensitive” way (sensitive to Capital/small characters) or
not, depending on whether the corresponding box is ticked or not.

The type of search is decided by activating the boxes in the Criteria area. If
the search is executed by number or by value, the Case Sensitive box is
deactivated, otherwise it is activated.
If the search is made by number, we write the number of the variable we want
to find in the field on the bottom left. Selecting the tree of that variable takes
us to the node of that variable in the All Variables subdirectory of the
current machine and all the attributes of the variable appear in the main
window.

- 18 - Main menu commands

CTM Editor - EN 1.1 '

The search by number can also be performed using the Num field in the
attributes area.

If the search is performed by name or by message or by value, if we press the

Find button to the left, all the variables with the string inserted in the field on
the bottom left respectively as the partial string of the name, of the value or of
the message, appear in the list box. Therefore, by clicking on one element of
the list, the tree selection will go to the node of that variable in the All
Variables subdirectory of the current machine and all the attributes of the
variable will appear in the main window.

Main menu commands - 19 -

CTM Editor - EN 1.1 '

View Menu

Cycles List
The Cycles List item is only active if the current variable is one used by a
cycle. Its icon therefore has a small gear in the variables tree. In this case, if
we click on this item, we can see the list of cycles that use that variable.

By selecting a cycle we can see its content:

- 20 - Main menu commands

CTM Editor - EN 1.1 '

Toolbar
Toolbar activation if needed:

Status Bar
Status Bar activation if needed:

Tools menu

Options

These options permit the machine constants tree view in area 3 in Fig. 1 to be
changed.

Main menu commands - 21 -

CTM Editor - EN 1.1 '
Help Menu

Help Topics
Permits us to see this manual.

Information about CTM Editor…

Shows the panel with information about the program version.

- 22 - Main menu commands

CTM Editor - EN 1.1 '

Environment and configuration

Start-up from Salvagnini Console

The CTM application can only be enabled from the Tools menu by an
“Expert user”.

Environment and configuration - 23 -

CTM Editor - EN 1.1 '
Start-up using an MS Dos command line
CTMEditor can also be launched from the command line using the following
syntax:

CTMEdit <machine name> [-l <lang_ext>] [-c <num_CTM>] [-a]

• The <machine name> parameter is the name of a machine present

in the PC from which the program was launched. This machine is
called the main machine.
• -l <lang_ext> is the extension of the language with which we
want to use the application. If the option -l, is missing, CTMEditor
starts in the Salvagnini.ini. language. E.g. .ita, .eng, .fra, …
• -c <num_CTM> activates the application positioning the cursor on
the CTM specified <num_CTM>;
• The option –a enables the management of several machines in
CTMEditor.
If the CTMEditor application has been launched from the Salvagnini
Console interface, it manages only the machine constants of the system that is
being controlled.

Application files
The information shown by CTMEditor is memorised in these files:
• ctm.mdb
• groups.ctm
• applications.ctm
• messages_<lang_ext>.ctm , where <lang_ext> is the extension of the
language with which the application was launched by, or if the
application is launched without any language, the extension is
Salvagnini.ini. language.
• last_values.ctm
ctm.mdb file is essential; other files may not be present.

- 24 - Environment and configuration

CTM Editor - EN 1.1 '
“groups.ctm” file
This contains the list of the groups to which every variable belongs to.
The information read from the file and its modification is saved in the file. If
this file is missing when the machine node is first expanded, it is created from
ctm.mdb. It is possible to import this information into ctm.mdb using the
Import groups menu. This is a text file that can be edited, even manually.
The file may not concern all the variables. In this case the variables not
considered by the file are considered as not belonging to any group. When the
file is produced by ctm.mdb, it concerns all the variables.

A group name can contain dots, but it cannot start or end with a dot and it
cannot contain two adjoining dots. The possible values for the Groups
attribute are all the lists of group names, divided by the character ‘,’ .

“messages_<lang_ext>.ctm” file
This contains the message attribute value for every variable. This value is read
by the file and every time it is changed, it is saved on the file. If this file is
missing when the machine node is first expanded, it is created from ctm.mdb.
It is possible to import this information into ctm.mdb using the Import
groups menu. This is a text file that can be edited, even manually. The file
may not concern all the variables. In this case the variables not considered by
the file are considered as not belonging to any group. When the file is
produced by ctm.mdb, it concerns all the variables.

Environment and configuration - 25 -

CTM Editor - EN 1.1 '
“applications.ctm” file
This is read only when the application starts and it is not modified by
CTMEditor. It contains a list of applications and the list of the variables that
each application uses. For each application it contains information concerning
whether or not it belongs to the compilers class. It is a text file that can be
edited, eve n manually.

“last_values.ctm” file
This file contains information about the value and the measurement unit of the
variables before the last change to this pair of attributes. In particular, when a
variable is saved, if the pair of attributes (value, unit) has changed, the old
pair value is saved in this file. If the file does not already exist, it is created.
When a variable is consulted, the value of this pair is read and shown in the
Previous value field of the window. If the file does not exist, or the variable
does not appear in the file, this field contains the “none” string.

Precautions
CTMEditor uses a DB in MS Access and/or UNIX format and a group of
support files. These files can be edited using the corresponding editors, but we
recommend doing this solely using CTMEditor.

- 26 - Environment and configuration

CTM Editor - EN 1.1 '

Glossary

Application
Synonym for software program.

Title bar
This contains the window title. The position of the window on the screen can
be changed by positioning the pointer on the title bar and by holding MB1
down.

Editor
An application (or software program) permitting texts to be written or data to
be inserted into the computer.

Group
A group of CTM with criteria chosen by the user.

Host
(Host). An auxiliary computer or a host computer connected in a
communications network.

Icon view
The operation to minimise a dialogue window. The window closes and an
icon appears on the screen. To re-open the window, position the pointer on
the icon and double click.

List box
A window permitting the components of a list to be displayed and selected.

Login
The user name: a word or an alphanumerical code that defines the user base or
the user.

Glossary - 27 -
CTM Editor - EN 1.1 '
MB1
Left mouse button

MB2
Central mouse button

MB3
Right mouse button

Mouse
A device for controlling the pointer on the screen.

Program
Document (or file) containing a group of instructions.

Pointer
An arrow (or vertical line) that moves on the screen when the mouse is
moved.

Push button
(Button). To permit passage to the next step of the function connected to the
button. To activate it, position the pointer on it and press MB1.

Network
A data transfer system between computers permitting dialogue between the
workstation and the machine.

SiX
This is the computerised numerical control system applied to Salvagnini,
machines. It was developed by the “Automation and Control Systems
Division” in synergy with other international companies specialised in the
sector.

Salvagnini Console
The user interface by which the user can interact with the SiX control system.

Workstation
A multi-function and multi-user work station (computer)

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- 28 - Glossary
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