Automation Office

Technical Documentation
AU-049/04N

Title: Extra functions for the work table

Rev: 2.2
Date: 15/09/2005
Issued by: Cristiano Vampa

Previous document versions

Rev. Date Description

1.0 21/10/2004 First issue.
1.1 02/12/2004 Renamed variable PUNI in PUNC.
1.2 18/02/2005 Renamed table WTPIANI in WTPIA1.
"Multipositioning" replaced by "multizone locking".
New arrangement of chapters.
1.3 22/04/2005 The parameters for launching cycle GWTEXE have
been defined thoroughly.
1.4 27/04/2005 A “Summary of parameters for launching cycle
GWTEXE” has been added.
2.0 27/05/2005 The documentation regarding the newly implemented
Dynamic Multizone Locking function has been
completed.
First release in English.
2.1 14/07/2005 Adjustments on dynamic multizone locking.
2.2 15/09/2005 New INFOMACC\StPrgAn datum documentation.

Contents

1. Ripositioning and commands regarding the objects that compose the work table ............ 3
Introduction ............................................................................................................. 3
ISO Programming...................................................................................................... 4
Examples ................................................................................................................. 6
Summary of parameters for launching cycle GWTEXE ................................................... 11
Errors .................................................................................................................... 12
Fixed cycle GWTEXE ................................................................................................ 12
2. Extension of the locking logic ............................................................................................ 13
Introduction ........................................................................................................... 13
Debug ................................................................................................................... 16
3. Multizone Locking............................................................................................................... 19

4. Static multizone locking .......................................................................................................... 20

Use of the remote console ........................................................................................ 20
Data configuration ................................................................................................... 22
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Activation of a zone configuration. ............................................................................. 23

Examples of configuration......................................................................................... 24
Configuration of 16 vacuum zones and 16 uniclamp zones........................................................ 24
Configuration of 4 vacuum zones in Y direction ....................................................................... 25
Configuration of 4 vacuum zones in X direction and 4 uniclamp zones in Y direction ..................... 26
5. Dynamic multizone locking ................................................................................................ 28
Transfer of information towards the PLC ..................................................................... 28
Pendular machining ................................................................................................. 30
How the software is organised in the machine ............................................................. 30
Piece locking cycle ................................................................................................... 36
Configuration of machine data................................................................................... 39
6. Comparing the two implementations of multizone locking ............................................... 40

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1. Ripositioning and commands regarding the objects that compose the work
table

Introduction
ISO instructions are available for carrying out different types of operation on the objects
making up the work table.
The commands to activate for each type of operation must be described in matrix type
program variables according to the following table:

Type of operation Name of command variable Values

Enable/disable vacuum PVAC (work table, carriage) -1=no command,
(standard/auxiliary) 1=on, 0=off
Uniclamp PUNC (work table, carriage) -1=no command,
activation/deactivation 1=on, 0=off
Bar unloaders PBSP (work table, carriage) -1=no command,
activation/deactivation 1=up, 0=down
Enable/disable front stops PFST (work table, row) -1=no command,
1=up, 0=down
Enable/disable side stops PLST (work table, row) -1=no command,
1=up, 0=down
Positioning master carriages PCR (work table, carriage) Target position
Slave carriage definition PCRS (work table, carriage) 1=carriage slave for which
PCR() has been defined,
0=non slave
Positioning tables PNOX (work table) Target position

The movement commands also include the necessary release/lock commands.

The following definitions will help understand the significance of PCR() and PCRS():
• master carriage is a carriage that is positioned by the motor,
• slave carriage is a carriage that is positioned by the movement of a master
carriage to which it is connected through the piece locked onto them.

Each array of commands has an extra line and column than that required. The offset for
accessing the commands of each object is 1: this means that the first element is at position
1,1 if the array is two-dimensional, while it is at position number 1 if the array is
monodimensional.
Element 0,c is used to “broadcast” the command specified for all the index c carriages of all
the tables, while element p,0 is used to broadcast the command specified for all the carriages
of table p.
Element 0,0 is used to “broadcast” the command specified for all the carriages of all the
tables.
These indications also apply to PFST() and PLST() where the second number is not a carriage
but a row.
The broadcast is not managed for PNOX() in that, for example, command PNOX(0)=100 would
signify “move all tables to position 100” which is physically impossible!

As regards the PBSP() array of commands for the bar unloaders, the command orientated
towards the carriage has been used. In practice, as the plant is currently used for semiareas,
the command can be given by simply using the table broadcast: PBSP(1,0)=1 activates the
plant on table 1, which is the same as the left-hand area.

NB: If a value other than –1, 0 or 1 is assigned to an array element for binary type
commands, the “ING 206 > Cannot execute program line runtime; Machine data write error
(incorrect setting of RDM parameters)” error is generated.

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ISO Programming
The commands specified are activated when fixed cycle GWTEXE is called and they must be
preceded by a call to fixed cycle GWTINIT1.
The structure of cycle GWTEXE is as follows:

• Copies each array in the corresponding machine data table2.

• Executes instruction M, which enables all the commands and only returns a step completed
when the commands themselves have been completed (tables positioned, carriages
positioned and locked, stops down, delay time expired in the case of commands to objects
without sensors, …).

Initialising a matrix after it has been copied to the table ensures that only the commands for
the objects requiring a status change need to be specified before the next GWTEXE fixed cycle
call. The only exception being vectors with carriage positions (PCR) and table positions
(PNOX): in these cases, if the current position of an object is confirmed, the command is not
enabled.

Of all the commands received, the PLC only enables those relating to the objects used for
locking the piece or the various pieces associated to the program (dimensions specified in the
program). The function is therefore independent of the locking sequences used (standard or
multi-panel).

Furthermore, the vacuum ON/OFF commands and uniclamp ON/OFF commands are only
activated if they are compatible with the status of the selector that enables either one or the
other of the two piece locking systems.

It is possible to include parameter PDLY in the cycle, which represents the delay introduced
after the execution of the requested commands. The delay time is expressed in seconds.
Unless specified otherwise, the default value of 0 seconds is used.

Warning

In any case it is good practice to specify all parameters required for launching cycle
GWTEXE, even when this parameter is not used.
For instance, if no delay needs to be entered for parameter PDLY, it is better to set it to
= 0 especially if it is not sure whether this parameter is used in other parts of the
program:
N20 L=GWTINIT
…
…
N100 L=GWTEXE PDLY=0

Through parameter PINC it is possible to specify that the movements set for the carriages and
work tables are incremental (value 1). If the parameter is not specified or not set to 0, the
movements of the carriages and work tables are absolute.
For example:
N20 L=GWTINIT
N30 PCR(1,1)=120

1
If this rule is not followed, PLC locking error 9691 is displayed.
2
When the program starts, the arrays are initialised by the FIRST fixed cycle by the call to the GWTINIT fixed
initialisation cycle. This cycle defines the various arrays and initialises the elements representing the binary commands
at –1 and the elements representing the target positions at 99999.

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N40 L=GWTEXE PINC=1 PDLY=0

means that 120 is incremental and not absolute.

The GWTEXE cycle is the basic component required to execute more complicated cycles such
as, for example, the uniclamp positioning cycle for "machining all the sides of a piece for door
and window frames”.
Execution of a block of instructions included between the calls to the two fixed cycles GWTINIT
and GWTEXE is not locking. This means that during execution of the actions and movements
programmed, the execution of a program goes to the lines below the line containing the call to
cycle GWTEXE. In practice it is possible to run a tool change or to activate a spindle during the
execution of the actions and movements programmed.
It is possible to use instruction M233 to wait for the end of the execution of a block of
instructions included between GWTINIT and GWTEXE.

Table and carriage movement commands

The PCR() and PCRS() arrays are used to position the carriages of each single table, while
PNOX() is used to position each single table.

The carriages for which a position has been defined using PCR() are positioned using the belts
of the table to which they belong, while tables for which a position has been defined using
PNOX() are positioned using the relative motors.

There are three possible cases:

1. a position is defined for each carriage and each table using PCR() and PNOX()
respectively,

2. PCR() is defined for some carriages only,

3. PNOX() is defined for some tables only,

The first case is used for retooling the entire work table during the execution of a program
and without locked pieces.
The current EPS movement logic of the locking cycle is used.

The second case is used to move some carriages as required during the machining of pieces
for door and window frames using uniclamps or as required when "opening" a piece that has
been previously cut into two parts.
The carriages for which PCR() (masters) has been specified are commanded simultaneously.
On completion of the movement, the positions of the carriages for which PCRS() (slaves) has
been specified are updated in line with the movements made by the master carriages.

The third case is used to move some tables only.

The tables for which PNOX() has been specified are commanded simultaneously.

It is not possible to command some of the carriages and some of the tables simultaneously.

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Examples

Example 1: repositioning uniclamps when machining a piece for door and window
frames
If, for example: You want to pass from the initial situation to the final situation as indicated in
the following figure.

1 2 3 1 2 3

Y = 200
Row

Y = 500

Row
Initial situation Final situation

The intermediate situation is that in which both rows of uniclamps lock the piece.

The ISO instructions to use are the following:

…
…
; *** end machining on sides 1, 2 and 3 ***
;
; *** approach uniclamp row 2 ***
;
;preparation of commands for raising uniclamp row 2
N90 L=GWTINIT
N100 PUNI(1,2)=0 PUNI(2,2)=0 PUNI(3,2)=0
;activate command
N110 L=GWTEXE
;preparation of commands for positioning carriages row 2
N115 L=GWTINIT
N120 PCR(1,2)=500 PCR(2,2)=500 PCR(3,2)=500
;activate command
N130 L=GWTEXE
;preparation of commands for lowering uniclamp row 2
N135 L=GWTINIT
N100 PUNI(1,2)=1 PUNI(2,2)=1 PUNI(3,2)=1
;activate command
N150 L=GWTEXE ; piece also clamped on side 2
;
; *** retract uniclamp row 1 ***
;
;preparation of commands for raising uniclamp row 1
N155 L=GWTINIT

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N160 PUNI(1,1)=0 PUNI(2,1)=0 PUNI(3,1)=0

;activate command
N170 L=GWTEXE ; piece only clamped on side 2
;preparation of commands for positioning carriages row 1
N175 L=GWTINIT
N180 PCR(1,1)=200 PCR(2,1)=200 PCR(3,1)=200
;activate command
N190 L=GWTEXE
;
; *** start machining side 4 ***
;
…
…

An alternative to these instructions is to use broadcast commands, as follows:

…
…
; *** end machining on sides 1, 2 and 3 ***
;
; *** approach uniclamp row 2 ***
;
;preparation of commands for raising uniclamp row 2
N90 L=GWTINIT
N100 PUNC(0,2)=0
;activate command
N110 L=GWTEXE
;preparation of commands for positioning carriages row 2
N115 L=GWTINIT
N120 PCR(0,2)=500
;activate command
N130 L=GWTEXE
;preparation of commands for lowering uniclamp row 2
N135 L=GWTINIT
N140 PUNC(0,2)=1
;activate command
N150 L=GWTEXE ; piece also clamped on side 2
;
; *** retract uniclamp row 1 ***
;
;preparation of commands for raising uniclamp row 1
N165 L=GWTINIT
N170 PUNC(0,1)=0
;activate command
N180 L=GWTEXE ; piece only clamped on side 2
;preparation of commands for positioning carriages row 1
N185 L=GWTINIT
N190 PCR(0,1)=200
;activate command
N200 L=GWTEXE
;
; *** start machining side 4 ***
;
…
…

This second example is more general. The GWTEXE cycle asks the PLC to activate the
commands specified for all the objects (uniclamps and carriages) on rows 1 and 2 of all the
tables. The PLC will only activate the commands for objects on the tables being used by the
program, thus allowing a single program to be used for pendular work (command broadcasting
renders the program independent of the work origin).

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In practice, the program can be written in a more compact manner by removing the comments
and defining the various arrays of commands on the same line on which the GWTEXE cycle is
called:

…
…
N90 L=GWTINIT
N100 PUNC(0,2)=0 L=GWTEXE
N105 L=GWTINIT
N110 PCR(0,2)=500 L=GWTEXE
N115 L=GWTINIT
N120 PUNC(0,2)=1 L=GWTEXE
N125 L=GWTINIT
N130 PUNC(0,1)=0 L=GWTEXE
N135 L=GWTINIT
N140 PCR(0,1)=200 L=GWTEXE
…
…

NOTA BENE: in the present-day plants, carriage release causes the uniclamp to move up,
while carriage locking causes the uniclamp to move down. That is why the code above can be
further reduced as follows:

…
…
N90 L=GWTINIT
N100 PCR(0,2)=500 L=GWTEXE
N110 L=GWTINIT
N120 PCR(0,1)=200 L=GWTEXE
…
…

or:

…
…
N90 L=GWTINIT
N100 PCR(0,2)=500
N110 L=GWTEXE
N120 L=GWTINIT
N130 PCR(0,1)=200
N140 L=GWTEXE
…
…

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Example 2: opening a piece previously cut into two parts in Y.

If, for example: The front piece obtained from cutting the original panel in two is to be moved
away. The front piece is to be moved in direction Y+.

1 2 3

2
cut
3

The ISO instructions to use are the following:

…
…
; *** end cut that divides the panel in two ***
;
;define the target position of carriage 4 of each table
N90 L=GWTINIT
N100 PCR(0,4)=1200
;define the slave carriage of each table
N100 PCRS(2,3)=1 ; carriage 3 of table 2 is a slave, it will move due to the
effect of the movement of another carriage to which it is connected, in that the
piece is locked onto both of them
N110 PCRS(3,2)=1 PCRS(3,3)=1 ; carriages 2 and 3 of table 3 are slaves
;activate commands
N110 L=GWTEXE
;
; *** panel “open” ***
;
…
…

It could be said that in the example, each of the three tables has just one master carriage (4),
there are no slave carriages on table 1, on table 2 carriage 3 is a slave, on table 3 carriages 2
and 3 are slaves.

The rules to follow when programming the opening of the piece are as follows:
1. each table can have more than one master carriage3,

3
If the following is programmed:
N10 L=GWTINIT
N20 PCR(1,4)=1200
N30 PCR(1,3)=800
N40 L=GWTEXE
It is declared that there are two master carriages on table 1: 3 and 4. In this case, PLC locking error 9678 is
generated. The error message ends with the number of the table on which the programming error has been made.

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2. a total of at least one master carriage must be defined4,

3. each table can have no master carriages,
4. each table can have no slave carriages,
5. the target position programmed for each master carriage must be such that induces each
carriage to move the same amount and in the same direction. 5.

Each time a carriage is programmed, a collision check is carried out before the movement is
effected6.

Warning: in a particular case in the second example, only master carriages may be present
(no carriages are moved by the piece). In this case, in order to be able to indicate that the
master carriages must be moved of the same amount as specified in rule 5, parameter
PSYN=1 must be passed on to the GWTEXE fixed cycle. This forces the PLC to check that the
rule in question is respected even if there are no slave carriages (if there are slave carriages,
rule 5 is always checked).
When there are no slave carriages and PSYN has not been defined or PSYN=0 has been
explicitly defined, the rule in question is not checked. In this way, in the first example, the
start position of each uniclamp of row 2 does not need to be the same as the other clamps
which will be moved together.

4
If no master carriages are programmed but only slave carriages are defined, PLC locking error 9688 is generated. For
example:
N10 L=GWTINIT
N20 PCRS(1,4)=1
N30 PCRS(1,3)=1
N40 PCRS(2,3)=1
N50 PCRS(4,3)=1
N60 L=GWTEXE

5
If this rule is not followed, PLC locking error 9681 is generated.

6
In the case of a collision, PLC error 9682 is generated. The error message ends with the number of the table and the
number of the carriage on the table that would collide. The error is a locking error and the collision is avoided.

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Example 3: opening a piece previously cut into two parts in X.

If, for example: The right piece obtained from cutting the original panel in two is to be moved
away. The right piece is to be moved in direction X+.

1 2 3 4

cut

The ISO instructions to use are the following:

…
…
; *** end cut that divides the panel in two ***
;
;define target position of table 3
N90 L=GWTINIT
N100 PNOX(3)=1300
;define target position of table 4
N110 PNOX(4)=1600
N120 L=GWTEXE
;
; *** panel “open” ***
;
…
…

Summary of parameters for launching cycle GWTEXE

Parameter Meaning
PDLY This is the delay introduced after execution of the commands
specified in PVAC(), PUNC(), PBSP(), PFST(), PLST() variables. It
is expressed in seconds. If there is no need to specify it, then it is
advisable to set to 0.
PINC If it equals 1, it indicates that the PCR() carriage quotes or the
PNOX() table quotes are incremental, otherwise if it equals 0, it
means that the quotes are absolute.
PSYN If it equals 1, PLC must make sure that all the carriages with a
quote programmed using PCR() move of the same amount, even
if they have not been defined as slave carriages.

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Errors
The following errors are possible:

PLC 9678 More than one carriage have been requested to move onto the same mobile support
(table)

PLC 9679 Some mobile supports (tables) and some carriages have been requested to move at the
same time.

PLC 9680 Carriage or mobile support positioning request: case not included in the commands
received from ISO.

PLC 9681 At least two carriages belonging to different mobile supports have target quotes that
imply movement of different entities (each carriage must be moved with the same
entity).

PLC 9682 On a mobile support, the programmed quote for a carriage implies a collision with an
adjacent carriage (table, carriage)

PLC 9688 No carriage movement has been requested

PLC 9691 Programming error: the call to cycle GWTEXE is not preceded by the call to
cycle GWTINIT

PLC 9702 Warning: the programmed quote for a carriage is the same as its position. The
movement requested has been cancelled. Carriage, work table
(<carriage>,<work table>)

Fixed cycle GWTEXE

The commands codified by the array type variables are sent to the PLC via the copy of their
values in table WTDATIPM. Each column of the table corresponds to a work table.

The data present in the table are as follows:

Data Array
PVAC1, ..., PVAC4 PVAC (work table, carriage)
PUNC1, ..., PUNC4 PUNC (work table, carriage)
PBSP1, ..., PBSP4 PBSP (work table, carriage)
PFST1, ..., PFST6 PFST (work table, row)
PLST1, ..., PLST6 PLST (work table, row)
PCR1, ..., PCR4 PCR (work table, carriage)
PCRS1, ..., PCRS4 PCRS (work , carriage)
PSCR1, ..., PSCR4 PSCR (work table, carriage)
PNOX PNOX (table)

This means that command PVAC(1,1) is copied in data item PVAC1 of the first column of table
WTDATIPM, that quote PNOX(3) is copied in data item PNOX of the third column, etc.

The cycle is arranged in the following phases:

1. copies each command array in the corresponding section of table WTDATIPM,

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2. reset of each array (-1 for binary commands, 99999 for position commands) via the call to
fixed cycle GWTINIT7,
3. execution of instruction M232 which activates all the commands. M232 reads the
commands from table WTDATIPM and executes them. Blocks the execution of the steps
until activation of the commands received is completed.

In addition to array-type parameters, the cycle also receives the following parameters in input:
• PNUP: number of mobile tables defined in table PIA_MOB
• PNUC(PNUP): number of carriages for each table
• PDLY: Delay introduced after execution of commands (in seconds)

Variables PNUP and PNUC(PNUP) are only defined at the first execution of fixed cycle GWTINIT
at the beginning of the program, whereas PDLY can be specified each time fixed cycle GWTEXE
is called.

The following names of variables: PVAC, PUNC, PBSP, PFST, PLST, PCR, PCRS, PSCR, PNOX,
PNUP, PNUC are therefore reserved for this application and cannot be used for other purposes
inside programs, subprograms and fixed cycles.

2. Extension of the locking logic

Introduction
In view of the applications for the work table and the possibility to have a work table where
each carriage has its own independent outputs for:
• standard vacuum,
• uniclamp and
• release of carriage from table,
PLC has been modified.

Table PIA_MOB must now also be set for non EPS machines. Just set data item AreaMas to
associate a single work table to its own semi-area and data item NumVen to specify the
number of carriages present on the table.
If the machine is fitted with a traditional vacuum system, i.e. with 2 or 4 independent areas, it
is not necessary to set any other data.

In the case where the machine has new carriages with the characteristics described above
(independent outputs for standard vacuum, uniclamp and release) or it has the carriages
grouped in locking zones, then it is necessary to set the new tables correctly as follows:

WTVUOSTD Table for vacuum electrovalves (standard)

Field name Values Description
Enable 0, 1 Flag to enable (1) or disable (0) the electrovalve.
O_On -1…n Number of activation outputs.
O_Off -1…n Number of deactivation outputs.

This table contains the data of all the standard vacuum electrovalves. Each column
corresponds to an electrovalve. An electrovalve can be associated to a single carriage or to a
group of them.

7
Cycle GWTINIT is used to initialise the array-type arrays. defines these arrays at the first execution.

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WTUNICL Table for uniclamp electrovalves

Field name Values Description
Enable 0, 1 Flag to enable (1) or disable (0) the electrovalve.
O_On -1…n Number of activation outputs.
O_Off -1…n Number of deactivation outputs.

This table contains the data of all the uniclamp electrovalves. Each column corresponds to an
electrovalve. An electrovalve can be associated to a single carriage or to a group of them.

WTPIA1 Table for the work table carriages and for the configuration
of the locking zones 1
Field name Values Description
ZonaVu1, 0…n Vacuum locking zone (standard) to which the carriage belongs.
ZonaVu2,
ZonaVu3,
ZonaVu4
ZonaUn1, 0…n Uniclamp locking zone to which the carriage belongs.
ZonaUn2,
ZonaUn3,
ZonaUn4
VuoStd1, 0…n Number of the vacuum electrovalve (standard) associated to the
VuoStd2, carriage if it is greater than zero (number of the column in table
VuoStd3, WTVUOSTD). If it equals zero, it means that no independent
VuoStd4 electrovalve is associated to the carriage: so the carriage receives
from its own semi-area the inputs for the standard vacuum (from
data AREELAV\O_VenON and AREELAV\O_VenOFF).
Unicl1, 0…n Number of the uniclamp electrovalve associated to the carriage if it is
Unicl2, greater than zero (number of the column in table WTUNICL). If it
Unicl3, equals zero, it means that no independent electrovalve is associated
Unicl4 to the carriage: so the carriage receives the uniclamp inputs from its
own semi-area (from data AREELAV\O_UniON and
AREELAV\O_UniOFF).

This table contains the data of all the carriages.

It is the main table in which, for every carriage of every work table, it is possible to specify the
number of the vacuum electrovalve (number of this column in table WTVUOSTD), the number
of the uniclamp electrovalve (number of this column in table WTUNICL) associated to the
carriage.

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NB: Each and every carriage must have a data item indicating the zone to which each
carriage belongs (ZonaVu1, ZonaVu2, …, ZonaUn1, ZonaUn2, …) and a data item indicating
the number of electrovalves (VuoStd1, VuoStd2, …, Unicl1, Unicl2, …).

If the work table is divided into zones (not into independent carriages), the data has the
same meaning in that several carriages with the same electrovalve belong to the same zone.

If the work table is divided into independent carriages then more carriages with
different electrovalves can be associated to a locking zone.

As far as the CAD/CAM is concerned, data ZonaVu1, ZonaVu2, …, ZonaUn1,

ZonaUn2, … is the data that indicates how the various locking zones are arranged
according to their type (vacuum and with uniclamp).

WTPIA2, … Table for the configurations of locking zones 2-15

WTPIA15
Field name Values Description
ZonaVu1, 0…n Vacuum locking zone (standard) to which the carriage belongs.
ZonaVu2,
ZonaVu3,
ZonaVu4
ZonaUn1, 0…n Uniclamp locking zone to which the carriage belongs.
ZonaUn2,
ZonaUn3,
ZonaUn4

These tables contain the data to define the configurations of the locking zones from 2 to 15.
Refer to section Static multizone locking.

The “carriage orientated” management has also been implemented for:

• ancillary vacuum,
• piece lifting bars,
• side stops,
• front stops.

Tables WTVUOAUX is used for ancillary vacuum, table WTBARRE is used for lifting,
WTBATFR is used for front stops, WTBATLAT is used for side stops and all of these tables
can be used just like tables WTVUOSTD and WTUNICL. To associate a carriage to one of the
electrovalves, data WTPIA1\VuoAux, WTPIA1\Barre, WTPIA1\BatFr, WTPIA1\BatLat having the
same meaning as data WTPIA1\VuoStd and WTPIA1\Unicl must be entered for each carriage.
At the moment, given the fact that there are no practical advantages to using these
electrovalves independently for each carriage, the tables as well as the connection data in
table WTPIA1 are not displayed with password below level 16. The management exists but the
data cannot be viewed so as not to complicate things too much for the final user (Biesse
Technician), at least until it is not necessary to use such data.

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Debug
A new table WTDEBUG has been introduced to indicate the status of the inputs present for
each of the six electrovalves managed at WTPIA1 [Link] in this case, the electrovalves do
not actually exist yet and so have data with a level 16 password.

NB: The output status is updated only if these outputs are controlled through the functions
dedicated to the carriage that retrieve data from tables WTBATLAT, WTBATFR (WTVUOAUX,
WTBARRE, WTBATFR and WTBATLAT).

Below is an example of this table defining the various standard vacuum electrovalves. The
“photo“ shows the situation in which the panel is blocked (it is long in the example).
Information “O800=1, O801=0” means that activation output O800 is active, whereas
deactivation output O801 is disabled.

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The definition of the standard vacuum electrovalves is highlighted in table WTVUOSTD shown
below:

The association between each carriage and its own standard vacuum electrovalve is
highlighted in table WTPIA1 shown below:

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Messages are also printed on file [Link] for the [Link] message is BBOX_73 indicating
the command on one of the [Link] has four parameters with the following meaning:
• 1st parameter table number,
• 2nd parameter carriage number,
• 3rd parameter command,
• 4th parameter type of electrovalve (0=standard vacuum, 1=uniclamp, 2=ancillary
vacuum, 3=bars, 4=side stops, 5=front stops).

An example of message printed is as follows:

PLC : BBOX_73([Link])[11845]  ON command on carriages 1, 2 and 3 of the first table

PLC : BBOX_73([Link])[11845]
PLC : BBOX_73([Link])[11845]
PLC : BBOX_73([Link])[11845]  ON command on carriages 1, 2 and 3 of the second table
PLC : BBOX_73([Link])[11845]PLC : BBOX_73([Link])[11845]PLC :
BBOX_73([Link])[11845]  ON command on carriages 1, 2 and 3 of the third table PLC :
BBOX_73([Link])[11845]PLC : BBOX_73([Link])[11845]…
…

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3. Multizone Locking

Introduction
The multizone locking mode allows the locking of more pieces associated to the same
program inside a unique locking cycle: all the pieces are locked and so machining can start
with a unique program on a unique origin with the added advantage that tool change can be
optimised.
The CAM can optimise the machining operations regarding individual pieces and will generate
an ISO list in which the machining operations are optimised in a unique program.
LPX and LPY will be programmed in such a way as to include all the machining operations on
all the pieces; as for the standard management, only the active objects on the work table are
those relating to the origin selected and to the LPX dimension described in the program.
The execution of the program will be possible only if the origin is the same for all the objects;
alternatively some start buttons configuring KA variable in line N10 of the program will have to
be disabled.

Tooling system input data

The tooling system must know the actual resting points in the machine and the respective co-
ordinates (origins) and must show a grid on which to load the pieces
This information can be found in the NC origin table.

The tooling system must also know how to control the electrovalves of vacuum and uniclamp
systems so as to prevent any piece loading operations that could be incompatible with the
machine actual locking possibilities.
Table (WTPIA1) will be made available listing every carriage of every work table and
indicating which electrovalve and which zone control the activation of the vacuum and which
control the activation of the uniclamps..

Example 1: machine with 4 traditional independent areas and 8 work tables:

WTPIA1

1 2 3 4 5 6 7 8
ZonaVu1 1 1 2 2 3 3 4 4
ZonaVu2 1 1 2 2 3 3 4 4
ZonaVu3 1 1 2 2 3 3 4 4
ZonaVu4 1 1 2 2 3 3 4 4
ZonaUn1 1 1 2 2 3 3 4 4
ZonaUn2 1 1 2 2 3 3 4 4
ZonaUn3 1 1 2 2 3 3 4 4
ZonaUn4 1 1 2 2 3 3 4 4

In the case described there are only four vacuum electrovalves and four uniclamp
electrovalves (work tables 1-2, 3-4, 5-6 and 7-8).

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Example 2: machine with independent carriages and 8 work tables:

WTPIA1

1 2 3 4 5 6 7 8
ZonaVu1 1 5 9 …
ZonaVu2 2 6 10
ZonaVu3 3 7 …
ZonaVu4 4 8
ZonaUn1 1 5 9 …
ZonaUn2 2 6 10
ZonaUn3 3 7 …
ZonaUn4 4 8

In the case described there is a vacuum electrovalve and a uniclamp electrovalve for each
carriage.

Generally speaking the number of vacuum electrovalves could be different from the number
of uniclamp electrovalves.

There are two ways to manage their coexistence on the same machine:

• static multizone locking by which it is possible to associate pre-set combinations of

locking zones to a piece,

• dynamic multizone locking by which it is possible to associate any set of carriages to a

piece (compatibly with the carriage electrovalves).

4. Static multizone locking

This implementation consists of extending the management already available before this
software release whereby the work table was divided into vacuum/uniclamp zones.
In the previous version there was only one zone configuration and that was dependent from
the work table electrovalves, whereas it is now possible to choose between 15 zone
configurations..

The data configuration tables are the same as for the dynamic multizone locking mode.

Use of the remote console

When the remote console is configured, only one of the two selector consoles should be used
to manage the vacuum/uniclamp zones based upon table ZONE_BL. The remote console is
used instead of the [Link] the console it is possible to:
• associate the left side central stops with one another.
• associate the right side central stops with one another,
• associate the external side stops with one another,
• associate one or more rows of front stops to row 1,
• select the locking zones with vacuum,
• select the locking zones with uniclamps,
• select the zone configuration.

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These functions can be used from the "Locking" menu on the console, which has the following
structure.

Item Function
Associate stops This item generates a new submenu for associating the side stops
and front stops.
Select zones This function enables and disables each single locking zone. When
this item is selected, a display appears as shown in the following
figure:

The symbols “[1]” and “[0]” represent the selectors associated to

each single zone: “[1]” indicates that the selector is enabled, while
“[0]” indicates that the selector is disabled.
The UP ARROW, DOWN ARROW, LEFT ARROW and RIGHT ARROW
keys are used to move the cursor from one selector to the next.
Pressing ENTER changes the status of the selector at the position of
the cursor (from [0] to [1] and from [1] to [0]). If the
vacuum/uniclamp mode selector on the electric cabinet is disabled,
this means that the commands set by the selectors refer to the
vacuum locking zone, otherwise if it is enabled, this signifies that
the commands set by the selectors are for the uniclamp locking
zone.
Select zone conf Activates a zone configuration. When this item is selected, a display
appears as shown in the following figure:

The UP ARROW and DOWN ARROW can be used to set the zone
configuration to activate. Press ENTER to confirm the selection
made.

Selecting item “Associates stops” displays a menu structured as follows:

Item Function
Left side Associates the left side stops with each other.
Right side Associates the right side stops with each other.
External side Associates the outer side stops with each other.
Front Associates a row of front stops with row 1.
When this item is selected, a display appears as shown in the
following figure:

The symbols “[1]” and “[0]” represent the selectors: “[1]” indicates
that the selector is enabled, while “[0]” indicates that the selector

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is disabled. There is a selector for each half-area and for rows 2, 3

and 4.
The first line selectors associate row 2 of the front stops with row
1. The second line selectors associate row 3 of the front stops with
row 1. The third line selectors associate row 4 of the front stops
with row 1.
The UP ARROW, DOWN ARROW, LEFT ARROW and RIGHT ARROW
keys are used to move the cursor from one selector to the next.
Pressing ENTER changes the status of the selector at the position of
the cursor (from [0] to [1] and from [1] to [0]).

Data configuration
To make the configuration uniform through PLC tables, this new version allows for the data to
be configured with table WTPIA1 and both WTVUOSTD and WTUNICL tables. This is valid only
in case the remote console is used.
Data item INFOMACC\Si_zoneY must be set to 2. .
In case of machine update with this application (without the console), configuration takes
place with the already existing and configured table ZONE_BL.

In table WTPIA1 it is possible to associate each carriage to the locking zone to which it
belongs. Data ZonaVu1, ZonaVu 2, … can be used to specify the zone to which the carriage
belongs as regards vacuum locking, whereas data ZonaUn1, ZonaUn2, … can be used to
specify the zone to which the carriage belongs as regards uniclamp locking.
Table WTPIA1 contains the data to define configuration 1 of zones (ZonaVu1, … ZonaVu4 e
ZonaUn1, …, ZonaUn4). The next configurations from 2 to 15 are defined using tables WTPIA2,
…, WTPIA15 which only contain the data to define the zones that are different from the ones of
table WTPIA1 in that it also contains information on the electrovalve connected to each
carriage.

Each vacuum and uniclamp system is associated to both outputs of their own electrovalve by
means of table WTVUOSTD and WTUNICL. Connection between carriage and electrovalve is
performed by means of data VuoStd1, …, VuoStd4 and Unicl1, …, Unicl4.

Each locking zone has a number according to the actual position associated to the zone. The
following layout indicates the numbers associated to each one of the 16 zones managed ( 16
vacuum + 16 uniclamp).

left area right area

SX1 SX2 DX2 DX1

1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

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Activation of a zone configuration.

The configuration can be selected without any execution problem, from the application on the
console as already described above. In addition to the parameter box of a program, it is
possible to specify the configuration by means of field LOCKING ZONE [Link]
0 indicates that the program is not associated to any configuration. During execution, the last
active configuration will be used (either from program or from remote console). Value from 1
to 15 indicates which configuration to use (in practice it means which table WTPIA1, …
WTPIA15 to use to group carriages in zones).

Variable PMZS must be defined in line N10 of the program file to contain the zone
configuration number. The contents of variable PMDS must be copied on bit 10 to 13 of KA
[Link] is an example:

[PARAMETRI01]
N10 … PMZS=13 … KA=13312 …

If a configuration not defined using table WTPIA is activated from console and program, then
<n> the following error appears “PLC 9703 Number of zone configuration wrong”.

The active default configuration is number 1.

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Examples of configuration
Let us see some examples of configuration of tables WTPIA1, WTVUOSTD and WTUNICL
according to existing vacuum or uniclamp zones.
What was said for table WTPIA1 also applies to tables WTPIA2, … WTPIA15: the only difference
between the table associated to configuration 1 and those associated to the remaining
configurations is the fact that these latter ones only contain data ZonaVu1, …, ZonaVu4,
ZonaUn1, …, ZonaUn4 for the definition of the zones.
Let us assume to have a machine with 8 extrusions and 4 carriages for each extrusion.

Configuration of 16 vacuum zones and 16 uniclamp zones

In this case we have all the possible vacuum and uniclamp zones.
Table WTPIA1 must be set as follows:

1 2 3 4 5 6 7 8
ZonaVu1 1 1 5 5 9 9 13 13
ZonaVu2 2 2 6 6 10 10 14 14
ZonaVu3 3 3 7 7 11 11 15 15
ZonaVu4 4 4 8 8 12 12 16 16
VuoStd1 1 1 5 5 9 9 13 13
VuoStd2 2 2 6 6 10 10 14 14
VuoStd3 3 3 7 7 11 11 15 15
VuoStd4 4 4 8 8 12 12 16 16
ZonaUn1 1 1 5 5 9 9 13 13
ZonaUn2 2 2 6 6 10 10 14 14
ZonaUn3 3 3 7 7 11 11 15 15
ZonaUn4 4 4 8 8 12 12 16 16
Unicl1 1 1 5 5 9 9 13 13
Unicl2 2 2 6 6 10 10 14 14
Unicl3 3 3 7 7 11 11 15 15
Unicl4 4 4 8 8 12 12 16 16

Table WTVUOSTD must be set as follows:

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Enable 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
O_On # # # # # # # # # # # # # # # #
O_Off # # # # # # # # # # # # # # # #

Table WTUNICL must be set as follows:

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Enable 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
O_Dw # # # # # # # # # # # # # # # #
O_Up # # # # # # # # # # # # # # # #

The virtual selectors appearing on the remote console display are those indicated in the
following figure:

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Each selector can be used to select a vacuum and uniclamp locking zone.

Configuration of 4 vacuum zones in Y direction

In this case we have the zones indicated in the following layout:

left area right area

1 13

2 14

Table WTPIA1 must be set as follows:

1 2 3 4 5 6 7 8
ZonaVu1 1 1 1 1 13 13 13 13
ZonaVu2 1 1 1 1 13 13 13 13
ZonaVu3 2 2 2 2 14 14 14 14
ZonaVu4 2 2 2 2 14 14 14 14
VuoStd1 1 1 1 1 3 3 3 3
VuoStd2 1 1 1 1 3 3 3 3
VuoStd3 2 2 2 2 4 4 4 4
VuoStd4 2 2 2 2 4 4 4 4
ZonaUn1 0 0 0 0 0 0 0 0
ZonaUn2 0 0 0 0 0 0 0 0
ZonaUn3 0 0 0 0 0 0 0 0
ZonaUn4 0 0 0 0 0 0 0 0
Unicl1 0 0 0 0 0 0 0 0
Unicl2 0 0 0 0 0 0 0 0
Unicl3 0 0 0 0 0 0 0 0
Unicl4 0 0 0 0 0 0 0 0

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Table WTVUOSTD must be set as follows:

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Enable 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0
O_On # # # # # # # # # # # # # # # #
O_Off # # # # # # # # # # # # # # # #

Table WTUNICL must not be set.

The virtual selectors appearing on the remote console display are those indicated in the
following figure:

zone 1 selector zone 13 selector

zone 2 selector zone 14 selector

Configuration of 4 vacuum zones in X direction and 4 uniclamp zones in Y direction

Let us assume that the vacuum zones are arranged as follows:

left area right area

1 5 9 13

and that the uniclamp zones are arranged as follows:

left area right area

1 13

2 14

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Table WTPIA1 must be set as follows:

1 2 3 4 5 6 7 8
ZonaVu1 1 1 5 5 9 9 13 13
ZonaVu2 1 1 5 5 9 9 13 13
1 1 5 5 9 9 13 13
ZonaVu3
ZonaVu4 1 1 5 5 9 9 13 13
VuoStd1 1 1 2 2 3 3 4 4
VuoStd2 1 1 2 2 3 3 4 4
VuoStd3 1 1 2 2 3 3 4 4
VuoStd4 1 1 2 2 3 3 4 4
ZonaUn1 1 1 1 1 13 13 13 13
ZonaUn2 1 1 1 1 13 13 13 13
ZonaUn3 2 2 2 2 14 14 14 14
ZonaUn4 2 2 2 2 14 14 14 14
Unicl1 1 1 1 1 3 3 3 3
Unicl2 1 1 1 1 3 3 3 3
Unicl3 2 2 2 2 4 4 4 4
Unicl4 2 2 2 2 4 4 4 4

Table WTVUOSTD must be set as follows:

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Enable 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0
O_On # # # # # # # # # # # # # # # #
O_Off # # # # # # # # # # # # # # # #

Table WTUNICL must be set as follows:

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Enable 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0
O_Dw # # # # # # # # # # # # # # # #
O_Up # # # # # # # # # # # # # # # #

The virtual selectors appearing on the remote console display are those indicated in the
following figure:

vacuum zone
selector

uniclamp zone
selector

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5. Dynamic multizone locking

Transfer of information towards the PLC

For each piece, the CAD/CAM will write the information required by the PLC to lock each single
piece in the corresponding zone onto the final ISO file. The information needed for each piece
is:
the origin to which the piece refers (the PLC will then activate the side and front stops of
that particular origin),
the list of carriages to use to lock the piece (the PLC will act upon the vacuum or uniclamp
electrovalves of these particular carriages).

The information must be saved in the CUSTOM section of the program file as indicated in the
following example:

[CUSTOMSEZ01]

<MULTIPAN>
; first piece on origin 1 using carriages 1, 2 and 3 of work tables 1 and 2
GROUP=1
ORIGIN=1
SUPPORT=1
CARRIAGE=1
CARRIAGE=2
CARRIAGE=3
SUPPORT=2
CARRIAGE=1
CARRIAGE=2
CARRIAGE=3

; second piece on origin 5 using carriage 4 of work tables 1 and 2

GROUP=2
ORIGIN=5
SUPPORT=1
CARRIAGE=4
SUPPORT=2
CARRIAGE=4
<MULTIPAN>
%

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The meaning of the tags is as follows:

<MULTIPAN> Limiting the information section for the PLC.

<MULTIPAN>

GROUP Indicates the number of the carriage group (each group corresponds
to a piece to lock).

ORIGIN Indicates the actual resting point of the piece.

FRONTSTOPS Indicates the number of the front stop row requested by the piece.
Row 1 is the rear row. This data item is used only if ORIGIN is not
defined or if ORIGIN equals 0.

SIDESTOPS Indicates the number of the side stop row requested by the piece.
The numbers of the rows are:
• row 1 is the left external row,
• row 2 is the left central row,
• row 3 is the right central row,
• row 4 is the right external row,
This data item is used only if ORIGIN is not defined or if ORIGIN
equals 0.

SUPPORT Indicates the number of mobile supports (extrusion of the work

table) to which the carriages specified in the next lines belong.

CARRIAGE Indicates the number of carriage belonging to the last mobile

support specified in the previous line.

; Can be used to start a comment line.

On the basis of the information passed onto section MULTIPAN, it is possible to activate the
stops as per the following criterion.

If tag ORIGIN equals 0 then stops specified in tags FRONTSTOPS and SIDESTOPS are used.

If tag ORIGIN is greater than 0 the stops used are specified in the follow table:

Origins

1 2 3 4 5 6 7 8 9 10 11 12 13 14 …
Front stops raw 1 1 1 1 2 2 2 2 3 3 3 3 4 4 …
Side stops raw 1 2 3 4 1 2 3 4 1 2 3 4 1 2 …

the side stops raws are:

• 1 is the external left raw,
• 2 is the central left raw,
• 3 is the central right raw,
• 4 is the external right raw.

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Pendular machining
To perform pendular machining, the CUSTOM section can contain descriptions of all the pieces
to be machined on different origins. The PLC will use the data regarding the pieces that are on
the carriages according to the origin selected and the semi-areas engaged.
Here is an example. Let us suppose we want to lock pieces 1 and 2 when working on the left
and pieces 3 and 4 when working on the right as indicated in the following figure.

1 2 4 3

The CUSTOM section will be as follows:

GROUP=3
<MULTIPAN> ORIGIN=4
GROUP=1 SUPPORT=8
ORIGIN=1 CARRIAGE=1
SUPPORT=1 CARRIAGE=2
CARRIAGE=1 SUPPORT=7
CARRIAGE=2 CARRIAGE=1
SUPPORT=2 CARRIAGE=2
CARRIAGE=1
CARRIAGE=2 GROUP=4
ORIGIN=3
GROUP=2 SUPPORT=5
ORIGIN=2
SUPPORT=4 CARRIAGE=1
CARRIAGE=1 CARRIAGE=2
CARRIAGE=2 CARRIAGE=3
CARRIAGE=3 CARRIAGE=4
CARRIAGE=4 <MULTIPAN>
%

How the software is organised in the machine

The information described in section CUSTOMSEZ of the ISO program file is sent to the PLC by
means of an external process using exchange signals for the synchronism between the two
processes and a table of machine data to write the information. The application is called
PrgAnalyser and is started together with all the other NC processes.

This working mode is selected from the program parameter box by means of option DYNAMIC
MULTIZONE LOCKING.
This data item can be:

• 0 mode not selected,

• 1 mode selected: at the beginning of the locking cycle, all the stops (front and side)
are active,
• 2 mode selected: at the beginning of the locking cycle, only the side stops are active.

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In line N10 of the program file, variable PMZD must be defined to contain the values described
above. The contents of variable PMDZ must be copied on bits 25 to 26 of KA instruction. Here
is an example:

[PARAMETRI01]
N10 … PMZD=1 … KA=33554432 …

If the program requires this locking mode, the PLC will activate the external process at the
beginning of the locking cycle.
In data item PLCTRAN\NomeProg, the PLC writes the full name of the ISO program file that
must be processed in order to extract the information on dynamic multizone locking from
section CUSTOMSEZ. The external process writes the information read in PLC table MULTIPAN.

name of the machine

data file
PLCTRAN\NomeProg

PLC PrgAnalyser

table MULTIPAN with the

information of section
CUSTOMSEZ

PLC
A symbol of a set of traffic lights is used to synchronise the PLC and PrgAnalyser whereby the
external process is suspended until the PLC sends a request. When output table MULTIPAN is
ready, the exchange signal ACK_DATPAN informs the PLC (logic level high).

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During locking phase the PLC behaves as represented in the following layout.

How the PLC works.

no
START origin
pressed

yes

ye
ACK_DATPAN=1

no

Copy the name of the program file

associated to the locking cycle
in PLCTRA\NomeProg.

Wake-up of external process by

activating the dedicated traffic
light wake_pr1.

no
ACK_DATPAN=1

ye

ye no
ERR_DATPAN=0 error

Reading data from table MULTIPAN.

ACK_DATPAN=0

ok

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Any errors during data reading phase is codified on exchange signal ERR_DATPAN.
ERR_DATPAN takes the following values:

ERR_DATPAN Meaning
0 No error: data correct.
1 Error during opening of program file.
2 Error during reading of program file.
3 Section CUSTOMSEZ not found in program file.
4 Section marked incorrectly: one of the two tags <MULTIPAN> or
</MULTIPAN> is not present or is corrupted.

If ERR_DATPAN indicates an error, the following message is displayed:

PLC 9678 Error during access to program file to read the data needed for the locking cycle

The value of signal ERR_DATPAN appears between brackets at the end of the message.

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PrgAnalyser application
The application behaves as represented in the following flow chart. This application can also
analyse section CUSTOMSEZ to provide the PLC with information on the Excel xp 600 mobile
stops [Link] topic will not be dealt with in this document.

How external process

PrgAnalyser works.

Connection with machine data

server and request for keys of
exchange signals to PLC.

no
Wake-up from
traffic lights

ye

ye no Management of
other
COD_APP=1 applications.
If COD_APP=2, the
section regarding
the positioning
of Excel XP600
mobile stops will
be searched for
Reading information from file in the file.
specified in PLCTRAN\NomeProg.

ACK_DATPAN=1

no
Reading
without errors ERR_DATPAN=error code

ye
ko
ERR_DATPAN=0

Writing information for the PLC

in table MULTIPAN.

ok

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The application can be started with launch option –SiLogStdout to activate printing of logs on
file home\d_xnc\logfile\[Link]. A typical sequence of these prints is as follows:

PrAn : Suspension on traffic lights...

PrAn : Wake-up process...
PrAn : Rover multipanel application...
PrAn : CUSTOMSEZ=000000692 in /WNC/home/d_xnc/p_p/prog/MULTIPAN/MP1
PrAn : <MULTIPAN>
PrAn :; Piece on origin 1 using carriages 1, 2 and 3 of work tables 1 and 2
PrAn : GROUP=1
PrAn : ORIGIN=1
PrAn : SUPPORT=1
PrAn : CARRIAGE=1
PrAn : CARRIAGE=2
PrAn : CARRIAGE=3
PrAn : SUPPORT=2
PrAn : CARRIAGE=1
PrAn : CARRIAGE=2
PrAn : CARRIAGE=3
PrAn :; Piece on origin 2 using carriages , 1 and 2 of work tables 3 and 4
PrAn : GROUP=2
PrAn : ORIGIN=2
PrAn : SUPPORT=3
PrAn : CARRIAGE=1
PrAn : CARRIAGE=2
PrAn : SUPPORT=4
PrAn : CARRIAGE=1
PrAn : CARRIAGE=2
PrAn : <MULTIPAN>
PrAn : Suspension on traffic lights...

It is possible to view the version of the application in the NC version box. The line containing
the version of this application looks like the following text:

PrAn (1): [Link] [29/09/2004 14:35:06] lib:[Link]

Table MULTIPAN
This table contains the information retrieved from section CUSTOMSEZ of the program and
used by the PLC to perform the locking cycle.
Each column contains the information regarding one of the pieces that will be locked and on
which the nest program will be run.
Here below is the data contained in this table.

MULTIPAN Table of data for dynamic multizone locking

Field name Values Description
Enable 0, 1 Value 1 indicates that the piece belongs to the part of the program
about to be run.
Orig 0, 1, 2, … If it is greater than 0, it indicates the origin on which to lock the
piece.
MskCaP1, They are the masks of the carriages used on each table. MskCaP1
MskCaP2, corresponds to table 1, MskCaP2 corresponds to table 2, etc.
… For instance, value MskCaPi1=3 (20+21) indicates that carriages 1
(20) and 2 (21) are going to be used on table 1.
FilaBaFr 0, 1, 2, … Number of front stop row specified in FRONTSTOPS.
FilaBaLa 0, 1, 2, … Number of side stop row specified in SIDESTOPS.

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In particular, data item Enab is set by the PLC. It equals 1 only for pieces that will be locked
with the current part of the program, otherwise it equals 0.
If for example:
• some pieces on the left and some pieces on the right are associated to a program and
• the dimensions in X take only one area and
• if start 1 is selected on the left
then only the columns corresponding to the pieces on the left will have Enab equal to 1. The
application on remote console needs this information (see next paragraph) for the piece
selection mode that must make it possible to select only those pieces that can actually be
locked according to the dimension in X of the program and of the origin on which the program
will be run.

Piece locking cycle

Use the Locking/Select piece application on remote console to select the piece on which to
activate the locking/release controls from the pedal. The application looks as follows

The number between symbols “< >” indicates the piece currently selected, i.e. to lock (10 in
the example). The name of the origin to which the piece refers appears in the line under the
number of the piece selected.
Each time a select origin button is pressed to reserve the origin for a new program, piece 1
and relating origin are selected on the display of the remote console. Press right arrow to
increase the number of the piece selected and press left arrow to decrease the [Link] the
current program does not provide for the dynamic multizone locking mode, the console display
looks like this:

When a program has section CUSTOM correctly set and one of the two dynamic multizone
locking modes has been activated in the Parameter Box (through option DYNAMIC MULTIZONE
LOCKING), the locking sequence of each piece associated to is as follows:

1. origin selection button pressed with light switched on,

2. parking of operating section,
3. positioning of tables and carriages (automatic or manual),
4. The button light starts flashing to indicate that the piece locking cycle can start (it will
flash at this speed during the whole locking cycle).
5. reference carriage and table are defined for each piece.
6. side stops and bar supports are activated, if requested, for each piece; if dynamic
multizone locking mode is 1, then the front stops are also activated; if the mode is 2,
then the side stops are activated but only for the piece selected.
7. act on the pedal to activate vacuum or uniclamp on the carriage group for the piece
selected (press pedal to deactivate locking, whereas release pedal to activate it).
8. change the number of the piece selected to lock all the pieces associated to the
program following the previous point, or to release and lock again a piece already

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locked; when a new piece is selected and the mode is 2, then also the front stops for
that piece move up.
9. when all the pieces have been locked at least once, the light flashes at higher speed
which, as for the standard locking cycle, indicates that it is possible to press the origin
selection button to start running the program.
10. press origin selection button to deactivate all the stops.
11. execution of the program
12. at the end of the program, all the pieces are released and the bar supports are
activated if requested.

When a piece is locked, the bar supports are disabled. When a new piece is locked that shares
the same bar support electrovalve as the piece just locked, the bar supports are not activated
as otherwise they could hit the piece already locked.

When a piece is locked (pedal released), the following messages are printed in the log file
([Link]):

…
…
CicloMultipan: pezzo 2 bloccato
CicloMultipan: 2 pezzi bloccati (3 rimanenti)
…
…

The first message indicates which piece has been locked, whereas the second one indicates
how many pieces have been locked at least once and how many remain to [Link] the
example, the messages indicate that the second piece has just been locked, that two more
have been locked and that three remain to be locked (so the program has associated five
pieces).

When the last piece is locked, the following messages are printed:

…
…
CicloMultipan: pezzo 5 bloccato
CicloMultipan: tutti i pezzi sono bloccati
…
…

If definition of reference carriage or table fails then the cycle is interrupted and the following
message appears:
“PLC 9748 Dynamic multizone locking : error in the data of section CUSTOM of the
program (<number of piece>)”.

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If the number of the side stop row is lower than 1 and greater than 4, the cycle is
interrupted and the same message appears. The following message is printed in the log file:

…
…
MultiPanLetturaDati(): valore <numero fila> non ammesso per MULTIPAN\FilaBaLa (pezzo=<numero pezzo>)
…
…

If the number of the front stop row is lower than 1 and greater than 6, the cycle is
interrupted and the same message appears. The following message is printed in the log file:

…
…
MultiPanLetturaDati(): valore <numero fila> non ammesso per MULTIPAN\FilaBaFr (pezzo=<numero pezzo>)
…
…

If the number of origin is lower than 1 and greater than 24, the cycle is interrupted and the
same message appears. The following message is printed in the log file:

…
…
MultiPanLetturaDati(): valore <numero origine> non ammesso per MULTIPAN\Orig (pezzo=<numero pezzo>)
…
…

The same message is printed if from the remote console the number of piece to be selected
were greater then the total number of pieces associated to the program. This situation is
practically impossible in that the application on the console makes sure that the number of
piece is between one and the total number of pieces associated to the program.

If an origin is selected for the execution of a program, but on the work tables involved there
are no pieces of the dimension in X of the piece, then the cycle is interrupted and the following
message appears:
“PLC 9749 Dynamic multizone locking: no piece to lock with regards to the origin
selected for the program”.

Warning

1. The only M instruction that can be used for suspension is the M212 which
commands suspension without the release of the piece. If the other instructions
are given, the program is interrupted with error message “PLC 9019 Instruction
Incompatible”.

2. No dynamic multizone locking cycle is available yet with clamps and with
vacuum used together with the clamps.

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Configuration of machine data

Configuration of dynamic multizone locking is based upon the same data as for static
multizone locking.

It is therefore necessary to:

• set INFOMACC\Si_zoneY=2,
• set INFOMACC\AreeInd=4,

• configure data VuoStd1, …, VuoStd4, Unicl1, …, Unicl4 in WTPIA1 for the vacuum and
uniclamp electrovalves of each carriage,
• configure the outputs of the vacuum and uniclamp electrovalves for each carriage in
tables WTVUOSTD, WTUNICL,

as for the static multizone locking mode.

To start PrgAnalyser application it’s necessary:

• set INFOMACC\StPrgAn=1.

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6. Comparing the two implementations of multizone locking

Dynamic multizone locking

• It is possible to associate any combination of carriages to a piece; if the table has

independent carriages, only those carriages needed for the piece will be [Link]
only condition is the availability of origins (at the moment the logic can manage 24 of
them maximum arranged on 6 rows of 4 origins, whereas physically there can be 16 stop
origins in that there are only 4 rows of stops).

• The program must be generated with section CUSTOMSEZ as specified (any programs
already made with previous versions of the software must be adapted).

Static multizone locking

• The program does not have to be generated with section CUSTOMSEZ as specified (any
programs already made with previous versions of the software do not have to be
adapted). The program can therefore be generated without any reference inside as to
how the pieces must be locked.

• It can manage a total of 16 vacuum zones and 16 uniclamp zones.

• If the work table has independent carriages (independent vacuum and uniclamp for each
single carriage), all that needs to be done is statically group together the carriages in
locking zones by means of data ZonaVu1, ZonaVu2, … ZonaUn1, ZonaUn2, … in tables
WTPIA1, …, WTPIA15.

Comparison of both implementations shows that the first one is really useful when the work
table has independent carriages and a single piece needs to be associated to any configuration
of [Link] the other hand, the second implementation can also be used when the work
table has independent carriages, but it does not allow a piece to be associated to any
combination of carriages (it is possible to choose among the zones of the 15 configurations).

Warning

If a zone configuration is activated in a program (static multizone locking) and the

dynamic multizone locking mode is also activated, the PLC will only take into account
the latter in that these two types of locking are not compatible with one another on the
same program.

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