Some of
the major advantages of the Gen2 SuperControl:
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- Overview
- More accurate motion
- Easier programming & program execution
- Communication
- Other features
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Advancing computer technology is driving the development of a new generation of CNC controls. Thermwood is a leader in implementing next generation control technology and has been granted more patents on CNC router technology than all other CNC router manufacturers in the world, combined.
CNC router manufacturers have reacted in two ways to changes in control technology. One group attempts to save money by offering limited first generation controls. First generation controls simply play back CNC programs, much like a player piano. Thermwood has chosen another path, incorporating advanced next generation features into its CNC control using the most advanced, modern technology available.
You might think the first approach results in lower cost systems that are easier to use, but the exact opposite is true. Operating a CNC machine in the real world involves more than just running a program. It requires a multitude of disciplines including, among others, tooling, maintenance, configuration, error handling, adjustment and support. First generation controls don’t do any of this so you must handle it all yourself. This requires a high level of skill and training plus a lot of downtime as you fumble with problems. Next generation controls have systems for quickly and easily handling all this, many times automatically in the background. First generation controls are less productive, requiring more effort, more time and more training generally resulting in more downtime, missed schedules and more frustration. All these problems in an effort to save a little money and yet the difference in cost is insignificant compared to the cost of a typical CNC router.
Actually, you can argue that Thermwood’s next generation control is lower cost than limited first generation controls. The lower cost comes from the fact that next generation controls perform functions internally that require separate software packages and additional steps for first generation controls. The additional software and less efficient functioning of the first generation approach are substantially higher cost than the advanced processors needed for next generation features.
When you move into more advanced applications, machining complex CAD generated surfaces or three-dimensional volumetric compensation of large envelope machines, no other control can match the Gen2 SuperControl. It easily executes multi-gigabyte programs that choke other controls, creating complex surfaces to unheard of accuracies. There are even higher level functions reserved for highly experienced programmers and research labs to handle the most sophisticated applications. Whether you are making simple cabinets or the most sophisticated scientific project, no CNC control will outperform Thermwood’s Gen2 SuperControl.
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More
complex motion algorithms - The high speed processors allow
more complex motion calculations resulting in smoother machine
motions and faster speeds
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Three-dimensional
axis compensation - Good
quality first generation controls provide for lead screw
compensation, that is, they use a table to compensate
for any position inaccuracy along an axis. The table
is created by measuring precise actual position along
an axis using a laser. The only problem is that moving
along one axis may cause inaccuracies on the other two
perpendicular axes. Any slight mechanical variation or
natural flex can cause these movements and there is no
way to eliminate them through mechanics or structure.
First generation compensation only corrects pitch error
on each axis, ignoring any effect on the perpendicular
axes. Next generation controls compensate all three axes
at every position within the working envelope. Every
inaccuracy or misalignment, regardless of its source,
is automatically corrected.
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Control
can accept raw design files in addition to CNC programs - First
generation controls are primarily playback devices, much
like a player piano. They require that the programmer not
only design the part but also perform a series of additional
functions including CAM, nesting, and post processing in
order to generate a precisely formatted program that the
control can execute. Next generation controls such as Thermwood’s
Gen2 SuperControl can, in addition to standard CNC programs,
also accept raw design files directly from design software
without the additional processing. It automatically performs
any program preparation necessary to machine the part.
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Control is directly compatible with virtually all design software - DXF files from any CAD or design software can be sent directly to a Gen2 SuperControl - Thermwood’s Gen2 SuperControl accepts data base file output from all major cabinet design software packages, then nests the parts and creates a program to run them. It can also accept and include in the nest DXF files from any CAD or design software that can output standard layer names. In fact, the control can accept input from multiple design packages and multiple DXF files and combine them all into a single job, right at the control.
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Combine
files from multiple software sources in a nest - The control creates nests of parts internally and can
combine parts from multiple sources in the same nest.
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A
single job file can contain hundreds of parts rather than
requiring hundreds of separate CNC programs for a job -
Including all the parts for a job in a single file can
dramatically reduce file handling and improve productivity
of the machine. The control nests the
parts on the appropriate material, tells the operator how
many sheets of material are needed for the job and tells
him what material to load. In fact, it guides him through
the entire process, step by step. This file also contains
information for machining the back or flip side of certain
parts. It prints a label for each part. Parts that require
flip operations have a bar code on the label. When the
operator scans the bar code, it identifies the part to
the control which automatically retrieves the correct program.
From the operator’s
standpoint the whole process is simple, load one file and
follow instructions. In a first generation control, the
CNC programs are developed outside the control, so there
is a program file for each sheet of material in the job
and yet another program file for each flip operation. These
files are normally processed into individual CNC programs.
A single job may require a hundred files or more that must
be sent individually to the machine. Some really limited
controls may only allow one, or maybe a couple of programs
to be loaded at a time. An operator then needs to
sort through, identify, handle and load hundreds of files
each day. This takes time and reduces productivity of a
major investment, the CNC router. Also, this approach is
more prone to error.
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React
to problems at the machine - For
example, if you have a damaged sheet or a partial sheet
of material, it is easy to tell the control what you
have and it will nest on it. If the partial sheet is
from a previous job, it is not even necessary to provide
a description to the control. The control prints a bar
code label for any material left from a job and all you
need to do is scan that label. Theoretically this is
possible with a first generation approach but from a
practical standpoint, most times you don’t know
exactly what you have until you are ready to run the
job. Changes are easy at the control with little delay
to the job but that’s usually not a good time to
stop everything, go back to the office to re-program.
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 Create
modeling program to produce almost any profile
without custom tooling - When
you have a design with a profile edge, there are two
ways to cut the profile.The most common way is to have
a cutting tool made with the desired profile. A second,
less known method is to model the profile. Modeling
is a technique commonly used to make prototypes or
patterns from CAD designs. It uses a series of standard
tools. The process begins by moving a ball nose tool
back and forth over the surface, incrementing a small
distance each pass. This creates the base surface of
the part. Then a second and perhaps third tool are
used which machines away those areas that the first
tool could not reach. With the higher speeds of today’s
CNC routers, modeling is practical for short run production
parts but does require a modeling program. Most CAD
systems can create modeling programs but seldom are
used for this purpose. Thermwood’s Gen 2 SuperControl
has the ability to create these modeling programs,
automatically right in the control. If you send a part
with a profile edge to a Gen 2 control, it asks if
you have a tool for the profile. If you say no, it
automatically creates a modeling program to machine
the edge. This simple feature can be incredibly useful.
It can be used to machine custom profiles on parts
or machine moldings, even large complex or curved moldings
without special tooling.
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Design
files can be exchanged between machines without post
processing – Just
like fingerprints, no two CNC machines are the same.
Sometimes differences are major, like different table
sizes. Sometimes differences are subtle, like different
head spacing. Regardless, no two machines are exactly
the same so the CNC program needs to be tailored to
the particular machine it will be run on. If you want
to run the exact same part on different machines using
a first generation control, you need to create a different
program tailored to EACH machine. With first generation
controls, you cannot freely exchange programs between
machines. Next generation controls, however, accept
design files and automatically tailor the program to
produce the correct part. You can freely exchange these
files between machines with next generation controls
regardless of the physical differences in the machine.
This is the basis for an entire Production Sharing
program under which Thermwood machine owners make parts
for other shops.
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 Run
panel saw programs - Thermwood’s
control accepts either Excel or CPOUT files commonly
used to send size information to a panel saw optimizer.
It then nests the panels and cuts them. Since panels
do not need to be lined up along common cut lines, as
they do in a panel saw, they can be true shape nested,
often resulting in better yield. If you just want rectangular
panels, you can also just type a list of sizes at the
control and it will nest and cut them.
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 Produce
cabinet and furniture doors - The
Gen2 SuperControl has the ability to take door definition
files from eCabinet Systems and create machine programs
to make either MDF or traditional solid wood raised panel
doors.
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Reconfigure
control operation for special applications - Thermwood’s
Gen2 SuperControl includes the ability to read imbedded
Advanced Function Language commands in the CNC program
and reconfigure control operation based on those commands.
The Advanced Function Language is a programming language,
similar to Microsoft Basic that can be included in a CNC
program to make it into an intelligent computer program,
capable of reacting to its environment or operator input.
This feature, which is intended for sophisticated users,
will allow the control to address complex or sophisticated
applications for which the control was not originally intended.
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Machine
communication to the operator
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 Tool
Management - The
Gen2 SuperControl has a tool management system used to
define and manage tools. With the advent of automatic
tool changers and random use of tools, this makes management
of tooling easier and tracks tool use, informing the
operator when tool life has expired for a particular
tool. It can even automatically switch to a back-up tool
when life expires.
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 Maintenance
Tracking - The
Gen2 SuperControl tracks routine maintenance, alerting
the operator when maintenance such as lubrication or
filter cleaning is required.
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 Error
Reporting - When
an error occurs, the control displays a diagram of the
machine pointing out possible causes for the error and
suggesting solutions.
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 Electronic
searchable operator’s manual - The
Gen2 SuperControl includes a complete operator’s
manual that can be displayed on the screen including
the ability to search for words or phrases.
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 Maintenance
Videos - The Gen2 SuperControl
will display videos that detail common maintenance
adjustment or repair procedures, allowing users to
perform many of these functions without outside technical
assistance.
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 Dynamic
exploded assembly drawings
- The
Gen2 SuperControl can display three-dimensional images
of all machine assemblies which can be rotated and
exploded on the screen. This shows customer maintenance
people the assembly sequence for all components and,
by placing the cursor over any part it displays the
part number making it easy to order replacement parts.
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Job
Guide - When a job containing
a large number of parts is sent to the Gen2 SuperControl,
it nests the parts, tells the operator the number of
sheets of each material needed for the job and guides
him through the job step by step.
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Operator
communication to technical help and resources
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 Direct
audio/visual/data link to Thermwood technical assistance - The
Gen2 SuperControl can quickly connect to Thermwood technical
service through a Virtual Service communication link.
This audio visual link allows the machine operator to
see and hear the Thermwood technician and allows the
Thermwood technician to see and hear the machine operator.
The link also provides in-depth data sharing allowing
the following:
Complex
data and diagnostics – Using
the Virtual Service communications link allows a Thermwood
technician to access all the data, error logs and configuration
files that he could access if he were actually at the
machine.
Remote
machine configuration and tuning – Using
the Virtual Service communication link the Thermwood
technician can evaluate machine performance, then
adjust and reconfigure the machine as required, all
remotely.
Program
debugging assistance – Most
machine problems are caused by programming errors.
The Virtual Service communication link allows a
Thermwood technician to review, and if necessary
modify programs working directly with the customer.
Purchase
tooling or spare parts – Using
the Virtual service communication link a customer
can purchase spare or replacement part right through
the Gen2 SuperControl.
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 Hand
Held Programmer - Thermwood offers a hand held
programming device that is used to move the machine around.
It is used to quickly, easily and intuitively create
programs without having to deal with cryptic CNC code.
This is a great tool for those not familiar with CNC
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Depth
oscillation increases tool life - Certain
materials such as high pressure laminates and certain
types of plywood with abrasive adhesive between layers
will quickly dull tooling at the point or points where
the tool contacts the abrasive layer or layers. The
Gen2 SuperControl has a feature which oscillates the
tool up and down as it cuts to move this abrasive contact
point over a larger area of the tool increasing tool
life dramatically.
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 Full
color display - A full size, full color flat
panel display makes information easier to read and
understand, allows display of more information, including
graphics and pictures and generally makes the control
simpler and easier to use.
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 Huge
program storage – The Gen2 SuperControl
has, as standard, a 120 Gigabyte hard disk drive allowing
storage at the control of tens or hundreds of thousands
of part programs and allows the storage of very large
programs such as those used for carving. The control
can easily, efficiently and without pausing, process
programs that are many gigabytes in size, and can process
blocks of data at unequaled speeds, resulting in faster
execution of these types of programs.
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 Sealed
air-conditioned cabinet - Thermwood
encloses its controls, including power supplies and servo
drives, in a sealed, air conditioned cabinet keeping
them cool, free from contamination which substantially
improves reliability.
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Proper
wire and component labeling - Thermwood uses
professional wiring practices in its control, labels
and color codes all wires, labels major components
inside the control cabinet to make finding them easy
for service (changing a fuse for example), and supplies
complete blueprints of wiring inside the control.
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 Easy
update and upgrade – Advanced Support Program -
Since Thermwood designs its own control, it can tailor
new features so that they can be easily added to existing
controls. This keeps you competitive as control technology
advances. Thermwood offers an Advanced Support Program
which provides automatic software updates each year,
continuing Virtual Service and discounts on hardware
upgrades and other service products.
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Single
source responsibility - Thermwood builds both
the machine and the control. Should you have a problem
it is Thermwood and no one else responsible for fixing
it.
Upgrade
Existing Controls to Next Generation
Most existing Thermwood CNC controls can be upgraded
to the new Gen2 SuperControl. This allows existing Thermwood
CNC routers to benefit from advancing next generation
technology at a relatively low cost without requiring
that the entire control be replaced. 91000 SuperControls
and early Gen2 SuperControls can generally be updated
rather quickly and easily. Older controls, even those
using DC servo drives can also be updated to a full Gen2
SuperControl with the addition of certain electronic
hardware. This upgrade does not generally require that
the servo motors be replaced resulting in much lower
upgrade cost.
Please check with Thermwood’s Technical Service for more information on upgrading your existing Thermwood
machine.
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