MACHINEMATE

Accessories to provide a complete control solution.

Operator Station Front Panel

List Price: $3199

Part # M268

The M268 operator station front panel includes the 15” color TFT display with touch screen, the machine tool builder’s panel set of operator switches and buttons (emergency stop, machine start, cycle start, cycle stop, twelve programmable buttons) and a manual pulse generator. The depth of this panel, even allowing for a cable bend radius is less than 4” deep. A simple brochure with its mechanical details is available.

The list price for this front panel is $3199. It requires a VGA cable to connect the display to the CNC; this cable is available in 2-meter or 10-meter lengths. It also requires a 50-pin cable to connect the operator switches to the control; this cable is available in different lengths and either with a DB50 connector on both ends or with flying leads (connector on only one end).

The M267 was the previous model with a capacitive touch technology. M268 uses a resistive touch technology.

19" Machine Tool Builder's Panel

List Price: $660

Part # M319

The 19” Machine Tool Builder's Panel (MTBP) can make the operator’s panel design and implementation easier. This MTBP is built to the 19” rack-mount standard, so its width is identical to that of the MACHINEMATE control with a 19” rack-mount front panel. This consistency allows a simple layout of an operator’s station. This panel includes the minimum operator switches.

the Emergency Stop pushbutton (push in to lock, twist out to release)
feed and speed override switches
cycle start and stop pushbuttons
the machine start pushbutton
the jog + and – pushbuttons
six general-purpose pushbuttons
a molded 2-meter cable (with a 50-pin D-shell on both ends)

All of the pushbuttons except the E-stop can be illuminated. Any of the eight general purpose buttons can be custom engraved by MACHINEMATE INC for a nominal charge or clear buttons are available for the customer to provide custom button labels. A 2-meter cable (MM70 for $35), 5-meter cable (MM78 for $65) as well as even longer cable lengths.

A two-page description (in .pdf) is available for the MTBP.

When using the MACHINEMATE SERCOS interface, the included 2-meter cable is pin-compatible for an easy installation. By connecting the cable from the MTBP to the SERCOS control’s IO connector and loading the PLC application template for the MTBP I/O, it takes just a few moments to be running with the MTBP.

MACHINEMATE INC has prepared a PLC application template that includes the processing of all the MTBP inputs and outputs. It is available for download from our web site.

For analog systems, a breakout card can be obtained from MACHINEMATE to convert the 50-pin connector to terminal strip connections (this card is shown below with the connectors and adapters). Several vendors offer this card.

11.4" Machine Tool Builder's Panel

List Price: $720

Part # M309

This model matches the width of the 11.4” two-piece operator panels so it has a slightly different layout. This panel has a similar set of push buttons and switches as the 19” model, except it has a set of 12 general purpose push buttons rather than 8. A 2-meter cable (MM70 for $35), 5-meter cable (MM78 for $65) as well as even longer cable lengths.

19" Auxiliary Panel

List Price: $575

Part # M293 ( 24VDC input )

Part # M295 ( 5VDC encoder input )

For the 19” rack-mount CNC front panel configuration, an Auxiliary Panel is available. This panel has the same size as the 19” MTBP but it includes just 16 general purpose push buttons (each with an LED; these can be custom engraved for a nominal charge) and a hand-wheel (also called a manual pulse generator or MPG). The hand-wheel comes in either 5V encoder or 24VDC input models. Different cable lengths are available (the same cables as for either of the MTBP items above).

NOTE: Any of the general purpose push buttons on the panels (M268, M309, M319, M293, M295) can be custom engraved for a nominal charge (M305); the limit is up to 7 characters on each line and up to 2 lines.

Handheld Operator Station
List Price: $695

Part # M300 ( 24V input model )

Part # M316 ( 5V encoder model )

The handheld operator station provides a simple solution to the requirement for remote operator activities. This rugged pendant includes the 100 increments/rev manual pulse generator (MPG or hand-wheel), a six-position axis select switch, a three-position feed multiplier switch, two white pushbuttons (that illuminate) and the Emergency stop pushbutton (push in to lock, twist out to release). The white pushbuttons are not labeled so they could be used for axis jogging or another machine function.

This cost effective handheld operator station comes in 2 models. The IO model uses a MPG that is 25 PPR and requires 2 at 24V digital inputs to create the pulse counter. The MPG in the Encoder model is a 25 PPR differential encoder that requires 5 Volts for its power.

The dust and waterproof pendant (weighing 650g or less than 1.5 pounds) comes with its flexible cord (length is 4.26-feet, stretches to 21-feet) that is terminated with a 26-pin round connector. The bulkhead mating connector is also provided. The body of the pendant is about 8.5" long and about 3" wide at its top (where the manual pulse generator is located with its 3" dial) and about 2.25" wide at its base (where the buttons are and the cable connects); the body is about 1.625" deep (the dial is about 0.75" deep, plus its small round handle 0.75" long and 0.275" in diameter). A longer, thicker cable is also available (length is 5.9-feet, stretches to 34-feet); the list price for this combination is $818 (M336 has the 24V input MPG; M337 has the 5V encoder MPG). A two-page description (in .pdf) is available.

MACHINEMATE INC has prepared a PLC application template that includes the processing of all the MPG inputs and outputs. It is also available for download from our web site.

The manual pulse generator is also available separately with a list price of $100. M317 is the 5V encoder model and M318 is the 24V input model. This MPG comes with the handwheel (100 positions). The stand alone unit's interconnect is a 6-pin terminal strip on the back of the unit. There are three mounting screws behind the front flange. The body of the encoder is a cylinder about 2.25" in diameter, about 1" long behind the flange. The dial is about 3" in diameter (the same as on the handheld pendant above), just like the mounting flange.

Encoder Feedback Systems

Rotary Encoders
List Price: $199 - $290 (based on mounting requirements)

MACHINEMATE INC offers two ROTARY ENCODER models in NEMA 11 size, as potential candidates for replacing a resolver of the same size. One of these is a direct size replacement for a size 11 resolver, often found on older CNC machines. Rotary encoder information, including data sheets (in pdf), is available including the dimensions and signal details for each model.

Linear Encoders
List Price: Prices varies by length

MACHINEMATE INC also offers a line of LINEAR ENCODERS with an IP67 environmental rating (completely sealed) that will continue to provide accurate and reliable readings even when submerged in water, oil or coolant. The length of the small system (both the head and its tube) ranges up to 1 meter while the larger system ranges up to 11.7 meters). Linear encoder information, including data sheets (in pdf), is available.

Power Supplies

List Price: $146.95

Part # M327 ( 24V input model )

List Price: $73.35

Part # M328 ( 5V encoder model )

MACHINEMATE INC offers two power supply models. These power supplies can be used for the two common requirements in a control application – 5VDC at 25 watts for the encoders and 24VDC at 150 watts for the discrete inputs (like switches and buttons) and discrete outputs (like lights and solenoids). Both power supplies are DIN-rail mount. The 24V data sheet and 5V data sheets are available.

Connectors and Adapters

List Price: $150

Part # M302

Several connectors and adapters are available from MACHINEMATE INC. A DIN-rail mounted interface card is available to connect a 50-pin D-shell connector via terminal strips. 50-pin cables are used for several connections in a MACHINEMATE system. Cards with either a male or female connector are available. M302 is commonly used when the cable provided with one of the front panel accessories (either MTBP or the Auxiliary Panel) must be connected to an IO Module. Since the cable has a female end the terminal strip breakout must have a male connector, like the M302.

M314 is the terminal strip breakout like the M302 but with a female connector. It would be used when the SERCOS built-in 24in/16out connector must be taken to a terminal strip breakout and the alternate gender is required. M314 also has a list price of $150.

When flying lead cables (female connector on one end but just wires on the other end) are desired for the 50-pin cable applications different cable lengths are available. M372 is a 20-meter cable ($149 list), M373 is a 10-meter cable ($85 list), M374 is a 5-meter cable ($55 list), M387 is a 1-meter cable ($37 list).

The encoder connections use a 15-pin D-shell connector. A flying lead cable is available for these encoder connections (15-pin connector on one end of the 3-foot cable). The list price for this M182 cable is $25.

KVM Extender for a more distant operator front panel

A KVM (Keyboard, Video, Mouse) extender can be obtained from MACHINEMATE INC. A standard VGA cable length is limited to 30 feet. The PS/2 keyboard, PS/2 mouse and VGA video connections can be linked to a remote operator panel up to 300 feet away using a standard CAT5 UTP Ethernet cable and a KVM extender. The KVM extender model shown above is the ST-C5KVM-600 from Network Technologies Incorporated.

Drives and Motors
List Price: Prices vary

The MACHINEMATE CNC Control will work with the drives and motors from a variety of vendors. If needed, quality high-performance drives and motors can also be purchased with the control at a reasonable price for a complete automation solution. A wide variety of DRIVE AMPLIFIERS and AC MOTORS are available from MACHINEMATE INC as part of a package.

The AC motors include (motor type and feedback type):

MKD (servos, resolver feedback)
MHD (servos, encoder)
MKE (servos in potentially explosive area, resolver)
1MB (frameless spindle, encoder)
2AD (spindle, encoder)
ADF (spindle, encoder)
MBS (kit motor, encoder)

The CNC requires incremental encoder feedback from an analog drive. The Eco drives will provide that feedback signal to the CNC even if the motor’s feedback technology is not an encoder. With SERCOS drives (where the CNC closes the position loop in the drive), the CNC is not involved in the feedback technology since the axis position comes directly from the drive over the fiber optic network.

MACHINEMATE INC continues to work with other drive manufacturers so that a complete automation solution can be provided from one source. Contact the factory for possible drive/motor solutions to complete the CNC integration.

USB External Port Kit

List Price: $75

Part # M168

A kit is available from MACHINEMATE for an external USB port. Since the USB ports on the CNC industrial PC are typically accessed within a cabinet, this kit provides access to a USB connection on the outside of the cabinet. A two page pamphlet for this kit is available.

Cables, switches and other miscellaneous items.

Various cables (some have connectors on both ends while others have a single connector with flying leads) are available (these are also mentioned above at Connectors and Adapters). Push buttons (cycle start/stop, jog plus/minus) or rotary override gray-code switches (for feed rate or spindle speed) are available when a complete operator switch panel is not required (such as the MTBP models above). Hand-wheels (either 5V encoder or 24V input; these are also mentioned above at Handheld Operator Station) and other miscellaneous items are also available to assist an integrator.

CAD/CAM Package from Cadem

List Price: $2399 (must be purchased as part of a CNC shipment)

Cadem developed CAD/CAM packages called CAPSmill for milling applications and CAPSturn for turning applications. MACHINEMATE can also provide their CAM package with its CNC. The easy to use operator interface allows a part and its processing to be described quickly and efficiently using a combination of icons and graphical data entry dialogs (as shown in the example here). After describing the geometry, the MACHINEMATE part program is easily generated.

This software can be obtained from MACHINEMATE INC or from Cadem (based in India). Overviews of the feature sets in CAPSmill (3D, XYZ) and CAPSturn (2D, XZ) are available. Cadem provides information from its own web site as well.

2D CAD/CAM Package from Kartik Cad Cam Consultants

List Price: $2000 (must be purchased as part of a CNC shipment)

Kartik Cad Cam Consultants has developed a CAD/CAM package called MOST 2D, with its Material Optimization Software Technology. This CAD/CAM software supports nesting of part shapes (either from a drawing file or from a predefined shape library) and is designed for sheet metal cutting and heavy fabrication. This is 2D CAD/CAM for flat parts defined in just X and Y axes.

These CAM packages can be obtained from Kartick Cad Cam Consultants (based in India) or from MACHINEMATE INC since the package provides a good CAM package with nesting for the cutting technologies. The CAD/CAM package comes in several versions: Lite (the simplest version), Standard (most features) and Professional (full capabilities, including automatic chaining of the part shapes in the optimized 'nest'). An overview for the feature sets in each version is available in pdf. The list price for the Standard version of MOST 2D is $2000. The list price for the Professional version of MOST 2D is $3000.

CNC Software Features

Teaching and Digitizing

MACHINEMATE INC offers two optional features to help with reverse engineering jobs. Small brochures are available for each (in pdf format).

The teach feature allows an operator to teach a part easily, creating a part program that will reproduce the physical features on the original part as taught (a form of reverse engineering). The CNC teach feature uses simple functions for the operator, including the points in a profile (like a contour), points in a circle or arc (the circle/arc center will be calculated from the points that are taught) and points off the part (that will be moved at rapid traverse, which are different than those on the part when the movement will be a programmed feedrate). The feature is also extensible so if the operator requires more functions such as spindle on and off or coolant on and off actions during the teaching process, they can be added very easily. This teaching process records the activity in a part program that can reproduce the features of the part, as defined by the operator. The output part program requires minimal editing, usually just the programmed feed rates and the programmed spindle activity (either clockwise or counterclockwise at which programmed speed, and perhaps in which gear range).

The digitize feature allows an operator to automatically digitize a part, creating a part program that will reproduce the original part. The feature has a simple set up, including the resolution of the points to be captured on the part and the rough dimensions of the part (XYZ on a mill or XZ on a lathe). Upon activation, the CNC will move the machine enabling the touch probe to record the surface of the part. It will also handle a missing surface, like a hole or an outside surface that is inside the rough dimensions. This digitizing process records the activity in a part program that can reproduce the original contours, enabling the reverse engineering of a part or its features. (A simple touch probe is required for this feature; touch probes are available from a number of vendors.)

‘Dry CNC’ Software Package

MACHINEMATE INC can provide a version of the control software as a CNC simulation and the PLC development software package. This package is sometimes called ‘Dry CNC’ or ‘MACHINEMATE – no hardware’. This CNC package can run part programs in test mode without actual axis movement (as no axes are connected) and no active I/O (as none are connected). As this is a complete CNC package, any add-ons using the standard DDE connection can be exercised as well.

This product can be provided to our Value Added Customers to assist in their sales and development efforts. Please contact MACHINEMATE INC by phone or email if you are interested in obtaining this product.

CNC Hardware Specification

MACHINEMATE INC offers a CNC hardware system specification that includes the dimensions for the CNC models and the major accessories. The CNC system hardware specification can be viewed or downloaded here (in pdf, about 700KB, 21 pages).

A six-page products brochure (in pdf) is available for an overview of the MACHINEMATE INC products.

More information is available online about our CNC Controls and their Connections.

When ordering, please contact us:

MACHINEMATE INC.
100 West Larsen Drive
Fond du Lac, WI 54937-8520

Phone: 920-907-0001

Fax: 920-907-0181

Email: info@machinemate.com

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Handheld Operator Station List Price: $695