An Overview of TrueMotion Technology
State of the art Mechatronic Automation system
TrueMotion is an ICAM or Integrated Computer Assisted Manufacturing device with "Draw and Go" capability. It is possible with TrueMotion to make a component or engrave something just by drawing or typing text on your PC screen!
This might seem to good to be true, and for many systems it takes users months to become productive due to the sheer amount of technology that has to be taken on board. TrueMotion is easy to use and comprehensive, it has been designed by users for users and not by engineers wanting to impress their management with useless bells and whistles that get in the way of getting the job done.
A QDS 500 Auto-router, Control Unit situated at the front left hand side.
TrueMotion ICAM kits enable engineers to automate their existing machines and drive new equipment without having to have advanced electronic knowledge.
Generating Simple Work Files
Two software packages are provided, firstly a CAM device that enables the user to put on a PC screen a drawing and or text using any of the resident fonts on the computer. The drawing or text is set to scale using the rulers on screen. In the instance above an engraved sign is being prepared, the text is a celtic font and positioned centrally within in the rectangles. the outer edge is the "extent" or outline of the slate stock and the inner line a border.
Composing the design is easy as the CAD program allows the text to be streched, or morphed to sit within the framed limits. It is very easy to stylize text by re-shaping individual letters, or add art work, and patterns, it is also easy to scan photos and generate line drawings. The depth of cut can be changed to improve contrast, shadowing can be added along with other effects. The CAD component generates a file when the job is saved and this consists of a series of co-ordinates, each pair of co-ordinates describes a line, the line might be several centmetres long or less than 1/1000 of a mm. A circle or curve might appear to be perfectly smooth on the drawing and indeed on the machined article but it is still made up of a series of short lines. Circles can be set to have a specific number of nodes, they can have so few that they are drawn as a polygon, however a default setting of 200 will render a smooth circle less than 15cm diam. Selecting a value of 1000 or more will produce a smooth edge on large machines.
The CAD screen can feature an engineering drawing possibly imported from a library with an additional "tool path" layer over. This and other layers can be applied with representation of cutter dimensions. Having this facility makes complex profiles and sinks easy to organise with direct reference to the master document.
When the CAD work has been completed the file generated is then read by the CAM program running in tandem, the CAM presentation is a passive device in that it cannot modify the drawing, it only shows what is going to be produced and the extents of the drawing. Once the operator is satisfied that the correct item to be made is screened and the stock on the machine is large enough the run button can be moused to initiate the machine operation.
The file to be run might be a singular operation or the file might be part of a sequence of files that are pre-programmed to be executed in a set order possibly with different depths or cutters etc. When the "run" button is activated the PC downloads the sequence of co-ordinates to the CAM to run the job. When a file is run it is often required to have the sequence of events in the correct order. We can say that an event is the machining of a single line or associated group. If for example the file details text, then letters will be machined in the order they were typed, no problem. However if a cut-out or release action is included it must be at the end of the file otherwise the part being machined will be cut from the stock and float free before the letters are machined resulting in a lost job.
Sequencing files is easy with a drag and drop operation with the addition of depth of cut, type of cutter etc. for entry level systems the depths are set manually and files selected and run singularly. Programmable operation is seldom required for signage and engraving or for simple auto-router operations. Simple layered machining is very easy to do and is known as 2.5D. It is also possible to swap drive Y for the Z drive and produce "3D" topography.
Advanced Production and Prototyping
Engraving, turning, and simple auto-router procedures are the domain of the entry level automation kits. However if there is a requirement for complex machining then the programmable ICAM device is required. With the full automation kit complex components can be made and prototypes produced quickly.
Running a Machine
TrueMotion can run many types of machines from lathes to auto-routers. Whatever machine is being driven the means of controlling its operation is critical, at any time the operator must be able to take over control. With TrueMotion a control unit is included as an integral part of the system. This unit affords several functions and we can run through a simple operating sequence.
The PC screen is the starting point, once the CAM "Run" button on screen has been "moused" the file(s) to be run are despatched to the machine manual mode is selected then the data is held in a buffer to await selection. If during machining the operator needs to stop the progress then selecting the manual mode halts the task, switching back then sets it to continue. Using the control unit the 3 drive axes can be operated and all machine functions accessed.
A joy stick or momentary switches are used to position the head, other controls include pneumatic set down, sole plate pressure, Z depth, machining mode ie. terrain following, auto-routing, or flying. There are other system functions including wait, continue, abort, re load etc.
In addition to the auto and manual modes there is also a facility for entering "go to" instructions via the keyboard to control the progress and position of the head.
Limit and safety switches are also linked to the control unit; status indicators also feature.
Cut and Fold a simple 2D to 3D move for plastic, composites, MDF and more!
PCB's, track cut without using chemicals
Machine Interfacing
TrueMotion kits are available as a collection of units selected to suit the requirement. Developers can purchase just the Cam software and the TM Micro Unit while constructors will require a more comprehensive kit.
The TrueMotion system is a software based device, the "real world" manifestation of the technology is made possible by embedding the program in a micro chip. The micro chip is supported by a minimal amount of hardware components. Reliability of a system is seen as inversly proportional to the amount of hardware (the unreliable part of a proved system). TrueMotion is software rich and hardware lean so the system presents as extremly reliable, more, the core hardware is guaranteed for years! Compared with a traditional servo systems the hardware component count is around 50 times less and very much more efficient. Digital systems like TrueMotion do not need to be tuned up or configured like servo systems, they also use a lot less power, it is interesting to note most servo systems use a lot of power just to stay still!
TrueMotion is a low voltage system commonly using voltages between 12 and 40v DC, various types of DC motor can be driven. Portable machines driven by a Laptop can be used for field work.
There is a wide diversity of motors, encoders actuators and pneumatic devices connectable to the TrueMotion core drive units.
Large Auto-Router kit with Flat motor units
Machine Heads
The most complex part of most bridge mills or auto routers is the machine head. this unit normally runs on an "X" beam (left to right) the beam also traverses along the "Y" axis (forwards and back). The head therefore moves in the horizontal plane with a tool advance in the "Z" axis (up and down). Vertical displacement of the cutting or milling device may be controlled manually or by the PC via the micro. Other actuations and displacements of sole plates and guides etc. are also taken care of within the machine head in order to process the stock material.
Advanced Micro Solutions can help you with your project if you are designing and building a new machine for a specific task or if you are upgrading or automating an existing piece equipment. We would point out that TrueMotion technology is a commercially orientated system, reliable, dependable, powerful yet easy to use, it has been developed for prototyping and manufacturing and presents as a flexible and agile automation device. The system is used for the most part by small businesses, entrepreneurs engineers and prototyping. In conclusion we can say that it is a very flexible and cost effective manufacturing system.
Advanced Micro Solutions will be giving potential customers a chance to have a 'hands on" appreciation of TrueMotion technology during the late spring of 2010 when machines equiped with the technology will be available for demonstration. Further information is available by accessing our TrueMotion kits page.
Design and Build with TrueMotion
