LTEK Industries, Inc.

E232 Photograph on a HAAS VF-2 CNC Mill

P0 --- A typical installation on a HAAS VF-2

e-mail info@beta-a2.com

CNC Communication

• Do you run a job or production shop with constantly changing programs in your CNC or NC machines?
  
• Should you backup programs but do not because of the time involved to do so?
  
• Is program loading and saving a bottleneck?
  
• Do you want simple and easy procedures?
  
• Do you want centralized storage of your CNC programs with direct connection to your CNC machines to avoid errors resulting from using floppies or other loose media with outdated data, and/or floppy drives that do not work correctly?
  

How do we differ from the competition?

Compared to a direct Ethernet link into the CNC machine we provide most of the same features of a network system, but will probably have a somewhat slower transfer rate.  However, we may be lower in cost and one software package can work with different machine brands.  Our system philosophy may make CNC program transfer simpler, and to transfer many short programs we may be faster.

Compared to a direct RS-232 communication we can operate at high baud rates and moderately long distances.  Pure direct RS232 does not provide some of the features of a networked system.  Also our system philosophy provides convenience.

Compared to other Ethernet to RS232 systems our simplicity and operator convenience will be the differentiating features.

The E232 System goal is Simplicity, Ease of Use, and Speed.

We want to save you time and provide a simple procedure to perform the necessary communication functions.

To send or receive CNC programs requires very few keystrokes, and very little time.

This system provides a moderately high speed transfer of CNC programs to or from a central computer (server) to the RS-232 serial input on your CNC machine. Different kinds of machines can be on the same network (net). Thus, both HAAS and Fanuc Control type machines could be on the same network and be communicated to with the same software.

An internal Ethernet connection in your CNC is not used and not required, rather we connect thru the RS-232 port.

Communications in both directions, RS232 to Ethernet or Ethernet to RS232 is provided.

Individual machines are identified by a 3 digit number in the range 101 to 250. There is no inherent limit of 150 machines, it is simply an arbitrary value for the present. Each machine is identified by an absolute IP address of which the last three digits are the machine number.

When sending CNC programs from the CNC to the central computer the need to type a filename at the central computer for each program received from the CNC is eliminated. This tremendous time saver is a result of our semi-automatic generation of the received filename. It is almost impossible to overwrite a previous identical file.

Thus, you are more likely to backup programs on your machines because of the greatly reduced time to do so.

Up to 115.2 kbaud transmission speed.

Data can be sent at high rates, up to 115.2 kbaud, over long distances. Usually your CNC machine is the determining factor for baud rate. On the Ethernet side of the system the CAT-5 cable limit is 100 meters (328 ft), and for fiber optic cable the distance is much greater, about 2000 meters. The thruput on the Ethernet side is vastly higher than on the RS-232 side. The Ethernet side can transfer 10 or 100 megabits/sec on a 10/100 base system over this 100 meter cable.  This is 100 to 1000 times faster than 115.2 kbaud.

As an illustration of the speed of saving programs from a CNC to a central computer we used a HAAS lathe with 110 programs totaling 147 kilobytes to run an experiment at 115.2 kilobaud. Most of the programs were 1 to 4 kilobytes. It took 2 minutes and 33 seconds to save the 110 programs individually, and useful filenames were generated. Using conventional techniques this would take many hours. The HAAS "send all" of these same programs was 13 seconds. The difference between 13 seconds and the 2 minutes and 33 seconds is operator response time and button pushing for 110 programs. Note 147 kbytes in 13 seconds is 1.5 minutes per megabyte.

High baud rates, up to 115.2 kilobaud, are possible with the E232 Box because it is located at the CNC machine and only a short (three foot) RS-232 cable is used. Generally an RS-232 connection will fail at about 6 feet (2 meters) at 115.2 kilobaud. Typically the standard Ethernet CAT-5 cable part of the system specifies and allows 100 meters (note that experimentally we see total failure of Ethernet CAT-5 communication at about 150 meters of cable without repeaters). Thus, all machines must be within a 100 meter radius from their Ethernet switch. Two machines could be 200 meters apart if the switch was centered between the two. Additional switches allow machines to be spaced farther apart.  Switches can be located up to 100 meters between each other with CAT-5 for up to about 4 switches. Longer spacing between switches if fiber optic cable is used. Note, 100 meters equals 328 feet.

Simplicity of Sending and Receiving files with HAAS.

When sending files (CNC programs) to a HAAS CNC it is not necessary to reset the CNC to receive mode for each file sent. You simply use ALL RECV. Once sending is initiated at the central computer you simply pick files in Windows Explorer to send the files. At the end when all files have been sent you do a termination function. The different CNC programs can be in different subdirectories (folders).

When sending programs from HAAS you simply initiate receive at the central computer, then pick one program at a time at HAAS and push SEND, or select HAAS ALL and push SEND once. At the end you quit the receive function. As mentioned previously the filenames are semi-automatically generated. Also in the process the filenames are made unique so that you can not overwrite a previous similar file.

Hardware and Software Components of the E232 System.

The Betatronics E232 System consists of hardware and software to provide a simple means to send and receive CNC programs between a CNC machine RS-232 port, and a Personal Computer (PC) using 10/100 BASE-T Ethernet for communication, one or more standard Ethernet switches, CAT-5 Ethernet cables, and a Betatronics Ethernet to RS-232 box at each CNC machine. This can be done at the highest baud rate of the CNC up to 115.2 kilobaud, and long distances over the Ethernet.

We have had total failure to provide a reliable link to an include   .pfd   file of a system block diagram in this site.  If you e-mail us with a fax number we will fax a copy to you. 

This system is designed around HAAS and Mori-Seiki (Fanuc), RS-232, Ethernet, and has been tested with Windows ME and XP. You can mix HAAS and Fanuc controls on the same network and our program will communicate with either one or both or others that are compatible.

The RS-232 interface uses 7 data bits, 1 stop bit, Even parity, and RTS/CTS hardware handshake. The baud rate is selectable from 50 baud to 115.2 kilobaud at standard values. However, 4800 baud probably would be the lowest you might use. The 7 data bits corresponds to 10 bits in the asynchronous serial signal, or at 115.2 kbaud this is 11.5 kbytes/second. This consists of 1 start, 7data, 1 parity, and 1 stop bit, total equals 10. If you were to use 8 data bits your thruput would drop about 10%. Eight bits are not needed so 7 bits is optimum.

When you send and receive CNC programs there is no concern about the baud rate and other serial parameters, because these are preset once in each E232 Box. One machine can be 4800 baud and another at 115.2 kbaud. This has no effect at the personal computer other than the time to transfer a given size file. Further, you set the serial parameters in your CNC and they remain fixed.

This Betatronics system works with one or more Betatronics E232 Boxes (the E232 boxes and software are our unique components to the system). For efficient operation one E232 Box is required at each CNC machine. Normally we would supply only the software and E232 boxes, and you would use whatever you wanted for the other parts.

The Betatronics software in the PC and E232 Box are designed to work together.

We are often asked about DNC ("drip mode"). Yes, it will work but it is not recommended. If this is really important to you, then tell us your needs. This type of application should have its own dedicated computer probably running a very robust operating system, like Free BSD (few crashes over weeks or months).

Single Keystroke Sending of a Group of Programs.

For production applications where a number of CNC programs are associated with a particular part (classified as a "Group of Programs") we have a simple single operation procedure for sending this group. This group method can reduce errors and setup time where the same part is batch run many times. Further, it can provide a means to document what programs were used at a given time, and this could be valuable under recall conditions.

Prices and Specifications.

Prices are quoted based on your application. Prices and specifications are subject to change without notice.

Other Betatronics programs and custom products are:

Some other useful programs and products of ours are EXTRACT, GROUP, and TIMELOG.

TIMELOG is a high priced stop watch. Actually it is much more. Each box can simultaneously monitor 16 binary inputs and record transition times with a resolution of 1/100 (.01) second. This allows finding random errors you might never find otherwise. On a production assembly line TIMELOG provides means to detect bottleneck conditions. TIMELOG can do measurements a time study person cannot. A time study person is obvious to station operators, thus, operators may be on good behavior while being observed or may try to fool the time study person. TIMELOG is not obvious to the operators and can run continuously over long periods to study variations over time. However, a time study person can study an operator's motions which TIMELOG cannot.