0560951535_00_121813_Columbus 3 Advanced Operation Manual_ENG

Article Number: 0560951535Revision Date: December 18, 2013Revision Number: 00Language: ENG

COLUMBUS IIITM

ADVANCED OPERATION MANUAL

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Preface

The purpose of this operation manual is to provide more in-depth information for the Columbus III™ nesting software. It is strongly suggested that new users first review the Columbus III™ Quick Start Reference Manual before attempting to use this manual. Article numbers for both manuals will vary depending on the language required. Please use the contact information on page 7 if you require additional languages for your site.

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Table of Contents

Hotline and Support

Thicknesses

Introduction .................................................................................................................................................................................13

Creating New Thicknesses ......................................................................................................................................................13

Practical Application - New Thicknesses .....................................................................................................................14

Managing Thicknesses .............................................................................................................................................................15

Thickness Tab Icons .............................................................................................................................................................16

Materials

Introduction .................................................................................................................................................................................19

Creating New Materials ............................................................................................................................................................19

Practical Application - New Materials ...........................................................................................................................20

Managing Materials ...................................................................................................................................................................22

Materials Tab Icons ..............................................................................................................................................................23

Materials Tab Columns .......................................................................................................................................................27

Material Groups

Introduction .................................................................................................................................................................................29

Managing Material Groups .....................................................................................................................................................29

Edit Material Group Icons ..................................................................................................................................................30

Edit Material Group Sections ...........................................................................................................................................31

Practical Application - Using Material Groups ...........................................................................................................31

Sheets

Introduction .................................................................................................................................................................................35

Creating New Sheets .................................................................................................................................................................35

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Text and Drop-List Fields ..................................................................................................................................................36

Icons .........................................................................................................................................................................................38

Practical Application - New Sheets ................................................................................................................................41

Managing Sheets ...................................................................................................................................................................... 44

Sheet Icons .............................................................................................................................................................................45

Sheet Column Headings ....................................................................................................................................................50

Parts

New Part Basics ...........................................................................................................................................................................55

New Part Fields ...........................................................................................................................................................................56

New Part Icons.............................................................................................................................................................................56

Creating New Parts ....................................................................................................................................................................59

Using the Internal CAD System .............................................................................................................................................59

Drafting Board Elements ...................................................................................................................................................60

Command Line and Console ..........................................................................................................................................61

Magnifier Window ..............................................................................................................................................................62

Property-Editor Window ..................................................................................................................................................63

Drafting Tool Groups ..........................................................................................................................................................64

Practical Application - Using the Internal CAD System .................................................................................................68

Using Imported Drawing Files ...............................................................................................................................................76

Import Window ....................................................................................................................................................................76

Managing Profiles ................................................................................................................................................................77

Editing Profiles ......................................................................................................................................................................83

Show Preview ........................................................................................................................................................................90

Practical Application - Using Imported Drawing Files ..................................................................................................91

Practical Application - Troubleshooting Drawing Files ..........................................................................................93

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Managing Parts ...........................................................................................................................................................................99

Parts Tab Icons .......................................................................................................................................................................... 100

Parts Column Configuration .........................................................................................................................................101

Column Configuration Icons ..........................................................................................................................................102

Column Configuration Headings ................................................................................................................................ 103

Parts Tab Column Headings ................................................................................................................................................ 104

Parts Tab File Options ............................................................................................................................................................ 106

Layouts

New Layout Basics ................................................................................................................................................................... 111

Text and Drop-Down Fields..................................................................................................................................................112

Available Sheets Tab ...............................................................................................................................................................113

Available Sheets Icons ......................................................................................................................................................114

Column Configuration .....................................................................................................................................................114

Column Configuration Icons ..........................................................................................................................................115

Column Configuration Headings .................................................................................................................................117

Available Sheet Column Headings ..............................................................................................................................118

Practical Application - New Layout Basics .......................................................................................................................120

Working with the Layout Designer ....................................................................................................................................124

Layout Designer Icons ............................................................................................................................................................125

Adding Parts to the Layout ...................................................................................................................................................128

Practical Application - Using CAD within Layout ....................................................................................................128

Practical Application - Importing Parts Directly .....................................................................................................131

Practical Application - Drag and Drop Parts .............................................................................................................133

Arranging Nested Parts ......................................................................................................................................................... 134

Nested Part Components .............................................................................................................................................. 134

Travel Direction Icons .......................................................................................................................................................136

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Travel Direction Icons and Menus ................................................................................................................................139

Practical Application - Arranging Nested Parts .......................................................................................................147

Managing Layouts .................................................................................................................................................................. 169

Layouts Tab Icons ...............................................................................................................................................................170

Techno Settings

Introduction ...............................................................................................................................................................................177

Icons ..............................................................................................................................................................................................177

Parameter Groups ....................................................................................................................................................................177

Layout Settings ...................................................................................................................................................................178

Process Independent ....................................................................................................................................................... 186

Process Dependent ...........................................................................................................................................................193

Practical Application - Layout Settings ............................................................................................................................ 220

Practical Application - Spacing Settings ......................................................................................................................... 224

Practical Application - Approximate Element Measurement .................................................................................. 227

Practical Application - Working with Lead Elements .................................................................................................. 229

Bevel Profiles

Introduction .............................................................................................................................................................................. 243

Icons ............................................................................................................................................................................................. 243

Practical Application - Working with Bevel Elements .............................................................................................. 245

Machine Designer

Introduction .............................................................................................................................................................................. 265

CNC Parameters ....................................................................................................................................................................... 266

Machine Parameters .............................................................................................................................................................. 271

Carriage Parameters ............................................................................................................................................................... 272

Carriage Icons ........................................................................................................................................................................... 273

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Station Parameters ..................................................................................................................................................................274

Process Tool Parameters ....................................................................................................................................................... 275

Process Tool Icons ................................................................................................................................................................... 279

Placement Stopper Parameters .......................................................................................................................................... 280

Practical Application .............................................................................................................................................................. 281

Scenario #1 - Perfection Electric Company .............................................................................................................. 282

Scenario #2 - Gulwing Marine Corporation ............................................................................................................. 297

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Hotline and SupportWe are there for you.

Even with a reliable product, problems may occur. That is why we will be glad to receive your suggestions and questions.

Please use these details:Hotline (Europe): +49 (0)6039 - 40 - 335Hotline (USA): (843) 664 - 4404E-mail: [email protected]

You can reach us at these times:Monday - Thursday: 8 a.m. to 3 p.m. (CET)Friday: 8 a.m. to 12 noon (CET)

Under our general guarantee for software, you can use our telephone support free of charge for the first six months. If you have agreed to a contract for the software modules purchased, any subsequent support you receive is also free.

Note:

We will be glad to receive your questions and current problems as well as enquiries about coaching, training, and workshops via our hotline.

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Thicknesses Introduction

This database provides the user with different sheet/plate thicknesses, based on material type and quantity available.

The Create New Thickness window will be displayed:

Creating New Thicknesses

To create a new plate thickness, click the browser tree’s Explorer tab, right-click Thicknesses and select New.

Thickness: enter decimal equivalent for the plate thickness required. Imperial (inch) and metric (millimeters) thickness can be created.

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Thicknesses Tab (with entries)

Depending on application settings, measurements will be displayed in imperial (inch / ") or metric (millimeters / mm) units. Use the conversions below to switch between units:

• 1.00" = 25.4mm

• 1mm = 0.0394"

PLATE THICKNESS DECIMAL

1/8" 0.125"

1/4" 0.250"

3/8" 0.375"

1/2" 0.500"

5mm 0.197"

10mm 0.394"

15mm 0.591"

Practical Application - New Thicknesses

Create the thicknesses seen in the table below:

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Managing Thicknesses

To open the Thicknesses database, click the browser tree’s Explorer tab, right-click Thicknesses, and select Open.

The Thicknesses tab will be displayed:

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Thickness Tab Icons

The following icons are used in conjunction with the Thicknesses tab:

• Move First: moves selection to first available thickness.

• Move Previous: moves selection to previous thickness.

• Move Next: moves selection to next available thickness.

• Move Last: moves selection to last available thickness.

• Add New Item: opens the Create New Thickness window for a new entry.

• Delete Selected Item(s): deletes all selected thicknesses.

• Export: translates the data, as seen on the Thicknesses tab, to a .txt file for use with other applications.

• Reload: refreshes the Thicknesses tab and checks for any recently added entries.

• Column Configuration: determines which column headings will be displayed.

• Filter Selected Items: when enabled, displays only the selected thickness from the database.

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Materials Introduction

The Materials databases stores raw material density and composition for determining weight and process used respectively.

The Create New Material window will be displayed:

Creating New Materials

To create a new material, click the browser tree’s Explorer tab, right-click Materials and select New.

• Name: specific title that will allow the user to quickly identify/search for the material in a list.

• Material Group: material thicknesses and types are grouped together so that process parameter development becomes streamlined.

• Create New Material Group icon: prompts user for a specific name based on material referenced.

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• Specific Gravity: density of the material for estimating object weight in pound/inch³ [grams/cm³].

• Note: stores user-defined details for material used.

Practical Application - New Materials

The procedure below will guide new users through the process of creating and organizing new materials:

1. Click the browser tree’s Explorer tab, right-click Materials and select New.

2. The Create New Material window is displayed - in the Name field, type Carbon Steel.

3. Click the Create New Material Group icon and type CS for the material group name. Click OK.

4. Select CS from the Material Group drop list.

5. In the Specific Gravity field, type in 0.284 for imperial units [lb./in³] or 7.861 for metric units [g/cm³].

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6. Click OK to add this material to the Materials database.

7. Repeat steps #1-6 above for the metals below, if applicable to your product offering:

• Stainless = 0.285 lb./in³ [8.03 g/cm³]

• Aluminum = 0.098 lb./in³ [7.75 g/cm³]

• Titanium = 0.159 lb./in³ [4.40 g/cm³]

• Brass = 0.306 lb./in³ [8.47 g/cm³]

• Copper = 0.323 lb./in³ [8.94 g/cm³]

Materials Tab (with entries)

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Managing Materials

To open the Materials database, click the browser tree’s Explorer tab, right-click Materials, and select Open.

The Materials tab will be displayed:

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Materials Tab Icons

The following icons are used in conjunction with the Materials tab:

• Move First: moves selection to first available material.

• Move Previous: moves selection to previous material.

• Move Next: moves selection to next material.

• Move Last: moves selection to last available material.

• Add New Item: opens the Create New Material window for a new entry.

• Delete Selected Item(s): deletes all selected materials.

• Export: translate the data, as seen on the Materials tab, to a .txt file for use with other applications.

• Reload: refreshes the Materials tab and checks for any recently added entries.


• Filter Selected Items: when enabled, displays only the selected material from the database.

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• Move First: moves selection to first available column headings.

• Move Previous: moves selection to previous column headings.

• Move Next: moves selection to next column headings.

Column Configuration

Information displayed in the Materials tab columns can be fully customized by clicking the Column Configuration icon:

Icons

The Column Configuration window for Materials will be displayed:

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• Move Last: moves selection to last available column headings.

• Show All Columns: displays additional columns available to user.

• Move Up: moves selected column ahead in display order.

• Move Down: moves selected column back in display order.

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• Frozen: checkbox to hold the column in its current position in the Materials tab.

• Name: lists all materials available by name.

• Width: sets column width in millimeters (mm).

• System Name: title used/designated by the Columbus III™ software.

In the screenshot above, notice the first checkbox background is gray in color. This indicates that the Name column must be displayed and can not be unchecked.

Column Headings

• Visible: Checkbox to include or hide selected columns from displaying in the Materials tab.

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Materials Tab Columns


• Material Group: material thicknesses and types are grouped together so that process parameter development becomes streamlined. The material group can be changed using the drop list icon.

• Specific Gravity: density of material for estimating object weight in pound/inch³ [grams/cm³].

• Note: stores important user-defined details of material.

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Material Groups Introduction

This database combines material type and thickness ranges to reduce the amount of time and effort required when creating sheets and layouts.

The Edit Material Groups window will be displayed:

Managing Material Groups

To modify material groups, click the browser tree’s Explorer tab, right-click Material Groups and select Edit.

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Edit Material Group Icons

The following icons are used in conjunction with the Edit Material Groups window:

• Details: displays thickness ranges for the selected material group.

• Split Vertical: displays the thickness ranges in column or row format.

• Move First: moves selection to first available thickness.

• Move Previous: moves selection to previous thickness.

• Move Next: moves selection to next thickness.

• Move Last: moves selection to last available thickness.

• Add New Item: creates an additional material group entry.

• Delete Selected Item(s): deletes all selected material groups.


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Edit Material Group Sections

The Edit Material Groups window is divided into three sections - Material Groups , Thickness Ranges , and Assigned Material and Thicknesses .

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Practical Application - Using Material Groups

The procedure below will guide new users through the process of using and editing material groups:

1. Select Brass in the Material Groups section.

2. Rename the Brass material group by clicking the selection again - change the group name to BR.

3. Click the Details icon - the Thickness Ranges section will be displayed.

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4. Click the Add New icon in the Thickness Ranges section.

5. A new range entry will appear with the Min Thickness column selected for editing. Change this value to 0.5000".

6. Change the Max Thickness value to 0.5000".Delete the 0.0000" - 0.3937" entry from the database.

7. Repeat steps #4 through #7 for any additional thicknesses applicable for your company’s product offering.

Creating thickness ranges, where the values are set equal to one another, will save time when modifying Techno Settings.

Techno Settings will be fully discussed later in this manual.

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Sheets Introduction

The Sheets database allows users to organize and maintain sheet/plate metal inventories, using parameters such as material type and thickness, dimensioning, and quantity on site. The database can also track serial numbers, suppliers, and delivery dates.

The Create New Sheet window will be displayed:

Creating New Sheets

To create a new sheet, click the browser tree’s Explorer tab, right-click Sheets and select New.

The words "Sheet" and/or "Plate" are used interchangeably when referring to the metallic work surface.

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Text and Drop-List Fields

• Name: specific title used to quickly search and identify desired plate for use.

• Material: metallic composition of plate metal selected.

• Thickness: designated plate metal thickness used with sheet.

• Total: number of sheets available for use on site.

• Warning Quantity: if total sheets fall below this minimum value, a warning will be displayed in the Sheets tab.

• Is Remnant Sheet: enable this checkbox to designate previously used sheet.

• Mirrorable: enable this checkbox if sheet can be used with mirrored parts.

• Rotatable: enable this checkbox if sheet can be rotated.

• Rotatable 180° Only: enable this checkbox if sheet can only be rotated by 180°.

• Delivered: date when sheets arrived on site.

• Supplier: text field used to designate vendors across sheets.

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• Category: user-defined drop list associated with the sheet (e.g., stock locations, material grade, lot size, lead times, etc).

• Note: stores important, user-defined information regarding the sheet (e.g., manufacturer information, charge account numbers, certificate numbers, drawing revision level, etc).

The remaining non-white fields, as seen in the screenshot above, cannot be modified at this time.

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Icons

• New Basic Geometry: window used to generate rectangular (length and width) or circular (diameter) sheet metal shapes.

• Import Geometry: popup browse window used to import custom drawing files.

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• History: popup window that displays sheet origination and modification information.

• Details: opens an additional window section to track sheet serial numbers, suppliers, and delivery dates.

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• Open Designer: opens sheet geometry in the Digicad™ application.

• File Arrows: navigates between sheets without closing the Edit Sheet window.

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Practical Application - New Sheets

The procedure below will guide new users through the process of creating and defining new sheets:

1. Click the browser tree’s Explorer tab, right-click Sheets and select New.

2. The Create New Sheet window is displayed - make the following changes in the white fields:

• Name: 6’ x 6’ chamfer

• Material: Stainless Steel

• Thickness: 0.2500"

• Total: 6

• Warning Quantity: 2

3. Click the New Rectangular Geometry icon and enter 72" in both Dimension fields.

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4. Ensure Mirrorable, Rotatable, and Open Designer checkboxes are enabled and click OK.

5. The Digicad™ application will launch - click the Chamfer icon.

6. Enter a value of 12 for the first and second distances in the command line.

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8. Move cross hairs within the boundaries of the sheet - the upper right-hand corner of sheet will display the chamfer as a light gray line.

9. Close this tab and click Yes to save the changes.

7. Select the right side and top edge of sheet - the edges are light blue in color.

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Cross hairs (focal point = red + )

Top edge of sheet

Preview of chamfered edge

Right side edge of sheet

Command line

Sheet geometry previews

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Managing Sheets

To open the Sheets database, click the browser tree’s Explorer tab, right-click Sheets, and select Open.

The Sheets tab will be displayed:

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Sheet Icons

The following icons are used in conjunction with the Sheets tab:

• Move First: moves selection to first available sheet.

• Move Previous: moves selection to previous sheet.

• Move Next: moves selection to next sheet.

• Move Last: moves selection to last available sheet.

• Add New Item: opens the Create New Sheet window for a new entry.

• Delete Selected Item(s): deletes all selected sheets.

• Export: translates the data, as seen on the Sheets tab, to a .txt file for use with other applications.

• Add New Item Using Designer: opens the Digicad™ application to define the sheet geometry.

• Print: lists all selected sheets, along with basic sheet parameters (e.g., material used, quantity, thickness, etc).

• Import: sheet geometry is defined using a .dwg, .dxf, or .cnc file.

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• Reload: refreshes the Sheets tab and checks for any recently added entries.


• Filter Selected Items: when enabled, displays only the selected sheet from the database.


Information displayed in the Sheets tab columns can be fully customized by clicking the Column Configuration icon:

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Icons


The Column Configuration window for Sheets will be displayed:

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Column Headings

• Visible: checkbox to include or hide selected columns from displaying in the Sheets tab.


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Sheet Column Headings


• Width: dimensional measurement of sheet along the X-axis.

• Height: dimensional measurement of sheet along the Y-axis.

• Material: metallic composition of sheet metal selected.

• Thickness: designated material thickness used with sheet.

• Area: sheet width multiplied by sheet height, displayed in square feet (ft2) or meters (m2).

• Weight: sheet volume (width x height x thickness) x material density, displayed in pounds (lbs.) or kilograms (kg).

Weight calculations can assist users in determining shipping and handling costs requirements.

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• Available: total number of sheets that have not been assigned to a specific layout.

• Total: number of sheets available for use on customer site.


• Rectangular: denotes only rectangular or square sheet geometries

• Is Remnant Sheet: designates previously used sheet.

• Mirrorable: sheet can be used with mirrored parts.

• Rotatable: sheet can be rotated.

• Rotatable 180° Only: sheet can only be rotated in 180° increments.


The Warning Quantity column can assist your company’s inventory control system in maintaining required stock levels.

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• Note: stores important, user-defined information regarding sheet metal (e.g., manufacturer information, charge account numbers, certificate numbers, drawing revision level, etc).

• Category: user-defined drop list associated with sheet metal (e.g., stock locations, material grade, lot size, lead times, etc).

• Parent Sheet: provides serial number of the next highest sheet or remnant this sheet was created from - Is Remnant Sheet checkbox must be enabled.

• Original Sheet: provides serial number of the master sheet this sheet was created from - Is Remnant Sheet checkbox must be enabled.

• Created On: date recorded when sheet was created.

• Created By: user that created sheet in question.

• Modified On: date recorded when sheet was altered, if applicable.

• Modified By: user that altered sheet in question, if modified.

• Sheet Object Exists: indicates the sheet has a geometry assigned to it.

• Sheet Object Timestamp: time when a geometry was assigned to the sheet.

The Sheet columns described here are not displayed in the screenshot above.

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Parts

New Part Basics

Click the browser tree’s Explorer tab, right-click Parts, and select New.

The Create New Part window will be displayed:

The Parts database is a collection of shape geometries to be created; they can be linked and maintained using higher assemblies and customer-specific orders. Parts can be easily organized using a vast array of parameters (e.g., material, quantity, plate thickness, etc).

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New Part Fields

• Name: specific title used to quickly search and identify desired part geometry.

• Default Material: suggested metallic composition of plate used with part.

• Default Thickness: suggested plate metal thickness used with part.

• Width: horizontal measurement of rectangular geometries.

• Height: vertical measurement of rectangular geometries.

• Area: extent of two-dimensional geometry surface; shape of geometry determines the formula used.

• Weight: mass of part; material dependant.

• Category: user-defined drop list associated with the part (e.g., stock location, lot size, process status, etc).

• Note: stores important, user-defined information regarding the part (e.g., drawing revision level, similar to, department number, etc).

New Part Icons

• Generate Name From Dimensions: names the part based on the current geometry’s width, height, or diameter.

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• New Basic Geometry: used to generate a basic rectangular (length and width) or circular (diameter) part shape.

• Import Geometry: window used to locate and import custom drawing files. File types recognized include .dwg, .dxf, .cnc, .eia, .esi, .mpg, .csv, or .txt file extensions.

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• History: popup window that displays part origination and modification information.

• Open Designer: opens internal CAD system to create part geometries.

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Creating New Parts

Using the Internal CAD System

With the Parts tab displayed, click the Add New Item Using Designer icon; the internal CAD system will launch and a new tab, entitled Part, will be displayed.

Two options for creating new part geometries are available for the user - geometries can be developed using Columbus’s internal CAD system or previously created CAD files can be imported into the Columbus environment. The following pages will describe each of these options in detail.

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Drafting board

Geometry elements

Source point +

Termination point +

Rubberband

Sheet boundaries

Drafting tool bars

Horizontal crosshair

Vertical crosshair

Relative position window

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Drafting Board Elements

Geometry elements are created, modified, and displayed on the drafting board . The drafting board’s grid (denoted with + symbol) is enabled in the screenshot above.

The intersecting pair of gray lines, called crosshairs , are used to select points or objects on the drafting board. The termination point is identified using + symbol. The source point is identified using + symbol. The line between these two points is called the rubberband .

Drafting tool bars provide users with a much easier method of selecting and performing drafting commands within the internal CAD system.

The relative position window indicates crosshair position relative to origin (coordinate), relative to set reference point (vector), and drafting board zoom level (scale).

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Command Line and Console

Below the drafting board is a thin, horizontal window called the command line - it’s primary functions include prompting users for input and status reporting on previously executed commands. The command line can also be used to initiate commands by using key words in the console .

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B

To see a list of keyword commands , press the Tab key in the console . C

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The Magnifier window is used primarily to enlarge areas of small detail and operates in one of two modes:

Magnifier Window

• Magnify: magnifier displays objects sampled at the drafting board crosshairs.

• Overview: drafting board displays objects sampled at the magnifier crosshairs.

While in Overview mode, the crosshair view window can be re-sized using the mouse wheel.

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The Property-Editor window allows users adjust drawing element parameters for the object(s) selected.

Selected objects on the drafting board are expressed using dashed, red lines.

Parameters will vary depending on the type of object selected. Circular objects are defined by radius and center point values, where as lines are defined by start/end points along X and Y axes.

Property-Editor Window

Parameters can be sorted in one of two ways:

• Categorized: parameters are grouped with other related attributes.

• Alphabetical: parameters are listed according to attribute name.

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Drafting Tool Groups

The internal CAD system uses six icon tool groups to design new part geometries - these groups are entitled Standard, Draw, Object Snap, Modify, Layer, and Dimension. Tool bars can be arranged horizontally in rows or vertically in columns .

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B

The internal CAD tool icons with gray triangles in the upper left corner signifies multi-purpose tools.

Right-clicking these icons will display additional options.

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Draw Tools

These icons are used to create new objects such as lines, circles, and arcs. They are fundamental elements for any shape geometry.

Standard Tools

These icons perform basic software functions, such as saving progress, selecting, zooming, and undoing previous commands.

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Apply (Save)

Apply Selection

New

Zoom All

Redraw

Settings

Undo

Redo

Properties

Highlight

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Select All

Measure

Snap Grid

Snap Orthogonal

Set Reference Point

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Point

Line

Polyline

Circle

Arc

Ellipse

Text

Cross (Series)

Rectangle

Polygon

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Slot

Flange

Ring Segment

Symmetry Lines

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Object Snap Tools

Object snap indicators are paramount for drawing precise and accurate shape geometries. They allow the selecting of specific object points by “snapping” to the exact point location.

Autosnap

Point

Midpoint

Endpoint

Perpendicular

Intersection

Center

Quadrant

Tangent

Near Object

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Modify Tools

Modify commands give the user full control when transforming previously created shape elements. Common alteration methods include moving, copying, rotating, and scaling of drawing components.

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Move

Copy

Rotate

Scale

Mirror

Offset

Stretch

Copy (Multiple)

Break

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Trim

Extend

Chamfer

Fillet

Knife

Heal

Erase

Block

Insert

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Layer Tools

Layer tools help the user control and manage the viewable aspects of a drawing. Layers properties determine element visibility, type, weight, color, and access.

Dimension Tools

Dimensioning tools are used to clearly measure and visually represent part attributes. Dimension commands used in the internal CAD system are classified in one of three categories: linear, radial, or angular in nature.

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• Layer Management: allows the user to alter drawing element settings on a global level.

• Layer Selection (drop-list): selects layer to utilize when creating new drawing components.

Dynamic Dimscale

Dimension Horizontal

Dimension Vertical

Dimension Aligned

Dimension Diameter

Dimension Radius

Dimension Arc

Dimension Angle between Two Parts

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Practical Application - Using the Internal CAD System

The procedure below will guide new users through the process of creating and defining new parts using Columbus III™ Internal CAD system.

1. Click the browser tree’s Explorer tab, right-click Parts, and select New.

2. The Create New Part window is displayed:

3. Make the following changes in the white fields seen above:

• Name: Part AAA

• Default Material: Stainless Steel

• Default Thickness: 0.2500"

4. Click the New Basic Geometry icon and enter 12" in both Dimension X and Y fields.

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5. Ensure the Open Designer checkbox is checked...

6. The Columbus III™ internal CAD system will launch - click the Offset icon.

8. A prompt to Select Object or Contour will appear at the command line. Using the blue crosshairs, select right side of part.

7. A prompt to Enter Distance will appear in the command line. Enter a value of 1.25" and right-click to confirm choice.

...and click OK.

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9. Move crosshairs towards the interior of part. A gray preview line will appear next to the selected side . Repeat process for three remaining sides of part. With all offset lines in place, right-click to confirm selections.

10. Create center lines by repeating steps #5 through #8 using a distance of 6.00". Your results should look similar to the screenshot at left.

11. On the Snap To toolbar, enable Autosnap , Midpoint , Endpoint , Perpendicular , Intersection , and Center icons.1 2 3 4 5 6

12. Click the Properties icon.

13. Select all six, newly created offset lines and right-click to confirm choices. When performed properly, selected lines will turn into dashed lines.

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14. Click the browser tree’s Property-Editor tab .

15. Expand the Common tree and select the Layer field .

16. Click the drop-list icon and select Marking layer.

17. Click Apply icon and right-click twice in the Part Design window . Your results should look similar to the screenshot below.

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18. Change current layer to 0 using the drop-list icon.

19. Click the Circle: Radius icon.

20. Move crosshairs to the bottom left intersection until the green snap symbol is displayed. Left-click to confirm this point.

21. A prompt to Enter a Radius in the command line will appear - type 0.5" and right-click to confirm choice.

22. Click the Copy (Grid) icon - select the cut hole and right-click to confirm choice.

23. A prompt to Enter Horizontal Distance will appear - type 4.75" and press Enter.

24. A prompt to Enter Number of Columns (Horizontal) will appear - type 3 and press Enter.

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26. A prompt to Enter Number of Rows (Vertical)will appear - type 3 and press Enter. A 0.5" hole will be placed at each offset line intersection. Your results should look similar to the screenshot at left.

27. Click the Properties icon and select the center hole.

28. On the browser tree’s Property-Editor tab, expand Geometry tree and select the Radius field. Change radius from 0.5" to 3.0" and press Enter.

25. A prompt to Enter Vertical Distance will appear - type 4.75" and press Enter.

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30. Right-click in the Part Design window - results should look similar to the screenshot at left.

31. Click the Erase icon.

32. Select all green offset lines and the four small center holes . Right-click to confirm choices.

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29. Click the Apply icon.

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34. On the browser tree’s Property-Editor tab, change layer to Cutting.

35. Click Apply icon and right-click twice in the Part Design window.

33. Click the Properties icon and select all remaining holes.

36. Click the Apply (Save) icon - the part will be saved and internal CAD system will close.

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Using Imported Drawing Files

With the Parts tab displayed, click the Import icon. The Import window will be displayed:

Import Window

The Import window is much like any other file browser screen: it contains standard navigation tools , common folder locations , and file selection drop-lists .

However, this window does provide some additional functionality for users:

The preview window allows users to examine geometries before importing and provides basic sizing information. This sizing information is useful when comparing sheet and part nesting/spacing requirements.

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Profiles are custom, user-preference setting files that determine how Columbus III™ will interpret imported drawing files. The profile used is selected using the profile drop-list.

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Navigation tool

Common folder locations

File selection drop-lists

Preview window

Import profiles

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Managing Profiles

Specialized user settings can be developed, saved, and applied to imported files. The Manage icon opens the Add-Ins window - from here, user profiles can be created and/or modified.

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Add-In Window Icons

The following icons are used in conjunction with the Add-Ins window:

• Move First: moves selection to the first add-in category.

• Move Previous: moves selection to the previous add-in category.

• Move Next: moves selection to the next add-in category.

• Move Last: moves selection to the last add-in category.

• Details: displays the profiles available for the add-in selected.

• Split Vertical: displays the profile window vertically when enabled.

• Restore Defaults: returns the profile selected back to default settings.


Profiles enclosed with left and right carats symbols < > signify default system profiles; these profiles cannot be modified or overwritten.

Instruction on developing custom profiles will be covered in the upcoming pages.

< Default profile >

User profile

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Add-In Column Configuration

Information displayed in the Add-Ins columns can be fully customized by clicking the Column Configuration icon:

The Column Configuration window for Add-Ins will be displayed:

• Move First: moves selection to the first column heading.

• Move Previous: moves selection to the previous column heading.

• Move Next: moves selection to the next column heading.

Add-In Column Configuration Icons

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• Move Last: moves selection to the last available column heading.

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columns from displaying.

• Frozen: checkbox to hold the column in its current position.

• Name: lists all add-ins columns available by name.



Add-Ins Column Configuration

Headings• Visible: checkbox to include or hide selected

In the screenshot above, notice the first three checkbox’s background is gray in color. This indicates that the blank, Type, and Enabled columns must be displayed and can not be unchecked.

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Add-Ins Column Headings

• Type: denotes the add-in category selected.

• Enabled: indicates the add-in category is available for use.

• Released: indicates the add-in category is released by dongle option.

• Default Extension: default filename extension used with file upon saving (e.g., US-EIA uses .cnc versus ESSI, which uses .mpg)

• Extensions: file name extensions that can be used along with default extension.

• Name: specific title used to identify system name and version used.

• Folder: full file path to add-in assembly.

• Provider Type: .net class type name of the add-in.

Both Default Extension and Extension parameters above can be modified by the user.

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Editing Profiles

To modify user-created profiles, click the Edit icon in the Import window.

The window displayed depends on the file extension selected (e.g., .dwg, .dxf, .cnc, etc).

AutoCAD DWG Formats• Convert Splines: scans drawing for splines and

converts any found to polylines.

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• Convert Ellipse: scans drawing for ellipses and converts all to polylines.

• Convert Polylines: scans drawing for polylines and converts all to line elements.

• Tolerance: tolerance in mm for splitting elements.

• Explode Proxy: proxy elements are exploded to basic elements.

• Create AutoCAD R12 format: all ellipses and objects will be split into basic elements.

• Warning Level: suppresses all warning messages below this level when importing .dwg files.

• Sample: loads a reference .dwg file in lieu of using settings above.

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AutoCAD DXF Formats

Editing DXF profiles requires a clear understanding of settings used with the DXF Format tab. The Drawing Preview window provides a visual overview of the drawing file before importation.

Additional layer, linetype, and color information can be revealed by hovering over drawing elements with your mouse pointer .

Drawing Preview window

Drawing element (deselected)

Drawing element (selected)

Part dimensions

Cutting layer (selected)

Element hint text

User’s mouse pointer

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As Columbus III™ examines the prospective drawing file, it will find all layer, linetype, and color selections within the file - these results are displayed in the Current File Information tab .

When a drawing element is selected here , the drawing preview window will place emphasis on that attribute. In the example above, selecting CUTTING, CONTINUOUS, or 1 (red) drawing elements in will highlight cutting attributes seen in .

Conversely, selecting MARKING, CENTER2, or 3 (green) drawing elements in will place emphasis on marking attributes seen in .

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DXF Import Configuration settings are used to adjust scaling, sampling, and viewing parameters:

• Scaling: scaling factor used when importing geometries; one inch is default factor of 1:1.

• Warning Level: suppresses all warning messages below this level when importing files.

• Area: drawing area sampled when importing file.

• View: determines part position when displaying file - used with three dimensional geometries.

• Show Hidden: displays any hidden drawing elements.

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The Process Assignment tab is used to link machine tool stations to drawing-specific elements found during file sampling. Process tools can be assigned using drawing layers, linetypes, or colors.

The element count column returns the total number of drawing elements found in the file. In the example above, the CUTTING layer hold a total of six elements: two inner contour circles, two arcs, and two vertical lines connecting the arcs. The MARKING layer has one element - the green, center circle.

An asterisk * symbol used in a Process Assignment cell indicates the default state of element.

• Sample: loads a reference .dwg file in lieu of using settings above.

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The following icons are used in conjunction with the Process Assignments tab of the Edit Profile window:

• Move First: moves selection to the first assignment element.

• Move Previous: moves selection to the previous assignment element.

• Move Next: moves selection to the next assignment element.

• Move Last: moves selection to the last assignment element.

• Add New: creates a new assignment element.

• Delete Selected Items: deletes all selected assignments.

• Move Up: moves selection up one assignment element.

• Move Down: moves selection down one assignment element.

• Layer Assignment Filter: displays all assignment elements sharing a common layer.

• Linetype Assignment Filter: displays all assignment elements sharing a common linetype.

• Color Assignment Filter: displays all assignment elements sharing a common color.

• Show Original DXF Color: displays assignment element in color designated in original CAD drawing.

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With the drawing file to be imported selected, click the Open icon. The newly imported part will be displayed on the Parts tab.

Show Preview

When enabled, the Show Preview icon displayss a preview of the geometry to be imported.

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Practical Application - Using Imported Drawing Files

The procedure below will guide new users through the process of importing previously created drawing files for use in Columbus III™.

1. Click the browser tree’s Explorer tab, right-click Parts, and select New.

2. The Create New Part window is displayed:

3. Make the following changes in the white fields seen above:

• Name: Part BBB



4. Click the Import Geometry icon.

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5. The Import browser window will be displayed - navigate to the location containing the sample drawing files and select Part BBB.

6. Click the Open icon.

8. Ensure the Open Designer checkbox is not checked...

...and click OK.

7. The user will be returned to the Create New Part window - notice that the Width, Length, Area, and Weight fields are now populated.

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Practical Application - Troubleshooting Drawing Files

Often times when a non-native drawing file is imported into Columbus III™, drafting defects in the file are loaded as well. The most common defects experienced are open contours and component duplication. The procedure below is included to assist users in identifying and correcting these defects.

Defect Identification

The Columbus III™ nesting software provides multiple methods in which to identify problematic drawing components:

1. Import Previewing: as the user attempts to import an external file, a preview of part can be checked before actual uploading begins.

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To enable Part Preview window , click the Show Preview icon . Most drawing defects can easily be seen before loading the file.

Part files can also be imported using the Import icon on the Parts tab.

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2. Import Messages: any issues encountered during the importation process will be summarized in the Import Messages window. Messages seen here will be repeated in the Message Center but will not include GUI- supported error positioning.

Message navigation icons

Zoom selection

Part Preview window

Indicator - Total Criticals

Toggle indicator - Total Errors

Toggle indicator - Total Warnings

Toggle indicator - Total Messages

Clear selected message

Message details / description

Message time stamp

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Messages, Errors, and Warning alerts can be toggled off/on using their dedicated indicator.

Critical alerts cannot be toggled off; these alerts will be displayed, as they are encountered, in all message centers.

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Click OK to import part in its current state or...

Click Cancel to correct drawing errors in the native drawing application.

Use the Zoom Selection icon if the defects are small, as compared to the part size.

Selecting any individual message detail will display that defect in the Part Preview window . In screenshot bellow, the red circles define the error location; bold red lines define the contour effected. This tool becomes particularly useful when several defects are found in any one part.

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3. Message Center: after file importation, the Message Center performs almost identically to the Import Message window. However, flawed components (seen in Part Preview window above) will not be displayed.

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Open Contour Defects

Paths with interruptions and/or overlapping elements are referred to as open contours. All line paths within the drawing file must be completely closed and terminate on point. Open contours exist as one of two types and are classified by their location on the part geometry:

Outer or “Hull” Open Contours

The open path is located on the part’s outside edge. These defects can cause several errors, which include problems with kerf, travel direction, and contour recognition.

These defects use the Import Messages window to alert the user and are classified as Errors.

Outer contour is interrupted.

Outer contour is overlapped.

Defect-free part

In all cases above, the green background represents the program’s attempt to distinguish inner from outer contours and vice-versa.

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Inner Open Contours

The open path is located on the part’s inside edge. If the sample shapes (at left) were used without correction, results would produce the cut part as seen, with the exception of the large, center hole.

These defects use the Message Center to alert users and are classified as Warnings.

Duplication Defects

Drawing files often times contain objects that are drawn on top of one another, which are referred to as duplication defects. These defects can be very difficult to locate and correct, especially if the objects share the same color, size, or similar layer properties.

Inner contour is overlapped.

Inner contour is interrupted.

As Columbus III™ attempts to import the drawing file, the program will automatically scan all geometry contours for duplicated elements. If a duplication is found, a Message will be displayed in the Message Center.

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Managing Parts

To open the Parts database, click the browser tree’s Explorer tab, right-click Parts, and select Open.

The Parts tab will be displayed on the desktop:

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Parts tab

Browser tree (Explorer tab displayed)

Message center

Part preview window

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Parts Tab Icons

The following icons are used in conjunction with the Parts tab:

• Move First: moves to first available part.

• Move Previous: moves to previous part.

• Move Next: moves selection to next part.

• Move Last: moves to last available part.

• Add New Item: opens the Create New Part window for a new entry.

• Delete Selected Item(s): deletes all selected parts.

• Export: translates the data, as seen in the Parts tab, to a .txt file for use with other applications.

• Add New Item Using Designer: opens internal CAD system to design part.

• Print: lists all selected parts, along with basic part parameters (e.g., material used, quantity, thickness, etc).

• Import: part geometry is defined using a .dwg, .dxf, or .cnc file.

• Reload: refreshes the Parts tab and checks for any recently added entries.


• Filter Selected Items: when enabled, displays only the selected part from the database.

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Parts Column Configuration

Information displayed in the Parts tab columns can be fully customized by clicking the Column Configuration icon:

The Column Configuration window for Parts will be displayed:

• Search Text: searches all Part files for user-specified text.

• Search in Current or All Columns: search mode isolated to current column (disabled) or all columns (enabled).

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Column Configuration Icons


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Column Configuration Headings

• Visible: checkbox to include or hide selected columns from displaying in the Parts tab.


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Parts Tab Column Headings


• Width: dimensional measurement of part along the X-axis.

• Height: dimensional measurement of part along the Y-axis.

• Default Material: metallic composition of part metal selected.

• Default Thickness: designated material thickness used with part.

• Area: part width multiplied by part height, displayed in square feet (ft2) or meters (m2).

• Weight: part volume (width x height x thickness) x material density, displayed in pounds (lbs.) or kilograms (kg).

Weight calculations can assist users in determining shipping and handling costs requirements.

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• Note: stores important, user-defined information regarding part metal (e.g., manufacturer information, charge account numbers, certificate numbers, drawing revision level, etc).

• Category: user-defined drop list associated with part metal (e.g., stock locations, material grade, lot size, lead times, etc).

• Created On: date recorded when part was created.

• Created By: user that created part in question.

• Modified On: date recorded when part was altered, if applicable.

• Modified By: user that altered part in question, if modified.

• Part Object Timestamp: time when geometry was assigned to the part.

• Part Object Exists: indicates the part has a geometry assigned to it.

The Part columns described here are not displayed in the screenshot above.

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Parts Tab File Options

To view additional commands for a specific part geometry, open the Parts tab and right-click the part in question.

• Delete: deletes all selected parts from the Parts tab.

• Edit: opens the Edit Part window; material, thickness, and geometry parameters can be modified in this window.

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• Print: opens the Preview tab, arranges the selected parts in a printable format, and provides basic part information (e.g., material, dimensions, thickness, etc).

• Show Reference: provides details on part usage, creation, and assignment.

• Part Designer: opens the internal CAD application to define the part geometry.

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• Nested on Layouts: displays all layouts using the selected part; results are displayed in the Layouts tab or Message Center.

• Used in Orders: displays all orders using the selected part; results are displayed in the Orders tab or Message Center.

• Export: opens the Export window; translates the part’s geometric elements and creates a drawing file.

• Import: opens the Import window; the part’s geometric elements are redefined using a drawing file (e.g., .dwg, .dxf, .cnc, etc).

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Layouts

The Create New Layout window will be displayed.

The Layout Designer’s primary function is to place (or nest) parts on the material work surface for part creation. These production parts are strategically placed in order to minimize waste and maximize quality and efficiency.

New Layout Basics

To create a new layout, click the browser tree’s Explorer tab, right-click Layouts and select New.

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Text and Drop-Down Fields

• Name: specific layout title that allows the user to quickly identify/search for the layout in a list.

• Machine: assigned machine configuration to be used with the new layout - used when multiple cutting machines are present at the customer site.

• Default Material: designated raw material type used with layout.

• Default Thickness: designated raw material thickness used with layout.

• Note: Use this text field to store important aspects of layout.

The remaining non-white fields, as seen in the screenshot above, cannot be modified at this time.

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The screenshot above has the “Parts to Produce” option enabled. Your layout screen may or may not have this option installed.

Available Sheets Tab

In the Sheets section of this manual, the user learned how to create and manage sheet geometries using multiple parameters. These parameters include material type, weight, thickness, and available quantities. The user will now use these parameters to determine which sheet will work best when used with a new layout.

The words "Sheet" and/or "Plate" are used interchangeably when referring to the raw material work surface.

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Available Sheets Icons

The following icons are used in conjunction with the Available Sheets tab:

• Column Configuration: designates which column headings will be displayed.

• Filter: displays sheets using the default material and thickness of the selected layout.


Information displayed in the Available Sheets tab columns can be fully customized by clicking the Column Configuration icon:

• Move First: moves selection to first available sheet.

• Move Previous: moves selection to previous sheet.

• Move Next: moves selection to next sheet.

• Move Last: moves selection to last available sheet.

• Reload: refreshes the Sheets tab and checks for any recently added entries.

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The Column Configuration window for Available Sheets will be displayed:

• Move First: moves selection to first available column heading.

• Move Previous: moves selection to previous column heading.

• Move Next: moves selection to next column heading.

Column Configuration Icons

• Move Last: moves selection to last available column heading.

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Column Configuration Headings

• Visible: checkbox to include or hide selected columns from displaying in the Available Sheets tab.

In the screenshot above, notice the first two column backgrounds are gray in color. This indicates that Quantity and Name columns must be displayed and can not be unchecked.

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Available Sheet Column Headings

The Sheet columns described below and on the following page are not displayed in the screenshots above.

• Quantity: determines number of sheets assigned to the layout.


• Width: dimensional measurement of sheet along the X-axis.

• Height: dimensional measurement of sheet along the Y-axis.

• Material: raw material composition of sheet selected.

• Thickness: designated material thickness used with sheet.

• Area: sheet width multiplied by sheet height, displayed in square feet (ft2) or meters (m2).

• Available: total number of sheets that have not been assigned to a specific layout.

• Total: number of sheets available for use on customer site.


• Rectangular: denotes only rectangular or square sheet geometries.

• Is Remnant Sheet: designates previously used sheet.

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• Mirrorable: sheet can be used with mirrored parts.

• Rotatable: sheet can be rotated in any manner.

• Rotatable 180° Only: sheet can only be rotated in 180° increments.



• Note: stores important, user-defined information regarding raw material used (e.g., manufacturer information, charge account numbers, certificate numbers, drawing revision level, etc).

• Category: user-defined drop list associated with raw material selected (e.g., stock locations, material grade, lot size, lead times, etc).

• Parent Sheet: provides serial number of the next highest sheet or remnant this sheet was created from - Is Remnant Sheet checkbox must be enabled.

• Original Sheet: provides serial number of the master sheet this sheet was created from - Is Remnant Sheet checkbox must be enabled.

• Created On: date recorded when sheet was created.

• Created By: user that created sheet in question.

• Modified On: date recorded when sheet was altered, if applicable.

• Modified By: user that altered sheet in question, if modified.

• Sheet Object Exists: indicates the sheet has a geometry assigned to it.

• Sheet Object Timestamp: time when a geometry was assigned to the sheet.

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Practical Application - New Layout Basics

1. Click the browser tree’s Explorer tab and double-click Layouts.

2. The Layout tab is displayed - click the Add New Item icon.

3. The Create New Layout window will be displayed - make the following changes in the white fields:

• Name: Layout Training

• Machine: QUICK START



The procedure below will guide new users through the process of creating, defining, and modifying new layouts:

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4. Click the Sheets tab.

5. On the Available Sheets tab, click the Column Configuration icon.

6. Using the screenshot below, make changes to Visible and Frozen fields. Use Move Up/Down icons (green arrows) to adjust the order.

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7. The resulting Available Sheets tab should look similar to the screenshot seen below:

8. On the Available Sheets tab, select the entry entitled 6’ x 6’ chamfer.

9. Click inside the Quantity field and change the value to one (1).

10. Click the Edit Row icon to confirm quantity.

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11. Click the Add Sheet icon.

12. The user will notice that one 6’ x 6’ chamfer sheet was added to the Sheet tab.

13. Ensure the Open Designer checkbox is checked,

and click OK.

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Working with the Layout Designer

The Layout Designer can be described simply as the graphical interface used to nest and sequence parts on the sheet work surface.

A dedicated Layout Designer tab, entitled Layout Training, will be displayed:

Layout browser

Layout designer desktop

Layout icon bar

Nested part (deselected / not sequenced)

Nested part (deselected / sequenced)

Nested part (selected / not sequenced)

Sheet border

Object preview window

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Layout Designer Icons

The following icons are used in conjunction with the Layout Designer tab:

• Print: displays basic layout parameters (e.g., material type and thickness, quantity, and tool used), along with advanced, process-related statistics (e.g., % scrap, process changes, and tool on time) in a printer-friendly format.

• Save: records current changes to the open layout.

• Load Last Saved: restores layout to default saved state and excludes any recent changes.

• Import: sheet geometry is defined using a .dwg, .dxf, or .cnc file.

• New Part: users design part geometry using internal CAD application.

• Export: translates layout parameters, as seen on the Layouts tab, into a .txt file for use with other applications.

Icons having an inverted, black triangle represent multifunction tools. Clicking these icons will display menus with several options for the user.

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• Edit Layout Information: used to change the default material, thickness, and machine configuration.

• Set Completed State: used to prevent changes to layout after program file has been approved.

• Normal Mode: primary operational mode to select, position, sequence, and apply leads to parts.

• Sequence: used to apply process ordered steps to part components.

• Bridge To: used to provide a physical link between cut part components.

• Tab: used to provide small, uncut sections on part components.

• Common Cut: used to establish a common cut line between part components.

• Remnant Cut: used to establish a designated cut line between two remnant sheets.

• Preview NC-Code: performs identically to the Generate to NC-Code Folder icon above but allows the user to view the code before it is compiled.

• Generate NC-Code: performs identically to the Generate to NC-Code Folder icon above but file name and location are determined by the user in each instance.

• NC-Code Generation: combines several data sources within project (e.g., part programming, tool parameters, nest/sequence/lead settings) into a single program file used at the CNC.

• Generate to NC-Code Folder: resulting program file is saved to a predetermined file storage location. Folder location is specified in CNC properties of the Machine Designer.

• Direct Modes: specialized functions that allow users to more closely control aspects of part production. Modes include:

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• Book Unused: moves all unused sheets and parts to a new, dedicated layout.

• Work Off All: requires user to use all sheets and parts assigned to layout.

• Nest Automatically: automatically positions all unnested parts on the sheet.

• Nest and Sequence Automatically: automatically positions all unnested parts on sheet and assigns process order.

• Delete Selected Parts: removes selected parts from layout.

• Select Unsequenced Contours: highlights all part contours not sequenced.

• Undo: discards changes to layout and returns to previous state.

• Redo: reinstates the user’s last command after using Undo command.

• Show Tool Area: removes selected parts from the layout and browser.

• Show Rapid Move Optimizer Stripes: displays vertical lines on sheet to assist users in determining sequence.

• Refresh View: regenerates desktop and browser windows after changes are made.

• Zoom Main Placement: zooms to objects confined within the sheet outline.

• Zoom All: zooms to include all objects placed on layout desktop.

• Column Configuration: designates which column headings will be displayed.

• Show Browser: toggles part or sheet information from being displayed.

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• Part Browser: displays basic part information, including thickness, material, width, etc.

• Sheet Browser: determines type of sheet information presented.

• Sheets View: displays basic sheet information, which includes thickness, material, width, etc.

• Sheets Detailed View: displays basic and additional, detailed sheet information. Additional information includes supplier, delivery date, and sheet serial numbers.

Adding Parts to the Layout

Part geometries can be added to layouts using several methods. Parts can be designed within layout using the Internal CAD application, imported directly as drawing files, or drag and dropped in from the Parts tab.

Practical Application - Using CAD within Layout

1. To design parts within the Layout Designer, click the New Part icon.

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The internal CAD application tab will be displayed:

3. After completing the flange, click Apply (Save) icon.

For specific directions on creating part geometries with the internal CAD application, see the Parts section of this manual.

2. Using the flange command, create a part with the following attributes:

• Outer diameter: 20" [508mm]

• Inner diameter: 7" [178mm]

• Hole center line: 14" [356mm]

• Number of Holes: 6

• Hole diameter: 2" [51mm]

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The internal CAD application will close - users will be returned to Layout Designer:

Columbus will assign a temporary system name to part and nest a quantity of one to the sheet .

4. Open the Parts tab and double-click in the Name column - rename this part Flange 1A.

5. Return to Layout Designer and click the Part Browser icon.

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Layout browser

Layout designer desktop

Part Browser icon

Nested part (deselected / not sequenced)

Outline of sheet

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6. Right-click part in the layout browser and select Reload to update the part’s name.

Practical Application - Importing Parts Directly

1. Click the Import Geometry icon; the Import window will be displayed:

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2. Select Part CCC and click the Open icon - the Edit Import Part popup window will be displayed:

3. In the Ordered column, change the quantity to 2 pcs and click OK.

4. Users will notice that a quantity of two was added to the part browser, while only one part was nested to the sheet. Highlight Part CCC in part browser and drag the remaining part within the sheet borders.

The Parts browser uses green/red indicator lines to denote Ordered versus Nested quantities:

Green - # of currently nested partsRed - # of remaining unnested parts

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Practical Application - Drag and Drop Parts

1. On the Parts tab, right-click and select Float from the menu that appears.

3. Right-click the Part window and click Dock.

2. From the Part window, drag and drop one each of Part AAA and Part BBB - the resulting window should look similar to the screenshot below:

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Arranging Nested Parts

Optimizing placement of cut parts on the sheet surface can reduce cycle time and scrap generated. The content below describes the tools available to place geometries in the most effective and efficient manner possible.

Nested Part Components

Upon part selection, several icons will appear on the layout designer desktop. The point at which the selected part rotates about is defined using the Point of Rotation icon.

The Rotate Part icon is used to initiate the actual rotation of the part.

The Move Diagonally icon repositions the selected part along a linear, diagonal path.

Point of Rotation icon

Rotate Part icon

Move Diagonal icon

Travel Direction icon

Part Center indicator

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Using the mouse pointer, hover over any of the icons until it's color changes from black to red - this indicates an activated status and the command can be utilized. Use a left-click & hold mouse combination to execute the command.

The entire icon group can be moved manually by hovering over the Point of Rotation icon and dragging it to any point on the desktop.

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The Travel Direction icon graphically represents the machine tool's path when cutting the selected contour.

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Point of Rotation icon

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Travel Direction icon

Part Center indicator

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Additionally, the travel direction icon color indicates which contours are affected when subsequent commands are made - the four colors used are:• Black: applied to all part contours; selected

using a single, left-hand mouse click.

• White: applied to a specific section of contour; selected using a double, left-hand mouse click directly on the section.

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• Light Gray: applied to entire contour. For outside contours, double click anywhere on the part's surface . For inner contours, double click white, enclosed spaces .

• Yellow: commands used are applied to all part contours; selected using a single, left-hand mouse click on each element while holding the keyboard's CTRL key.

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Each travel direction icon uses a customized command menu, accessed by right-clicking the nested part in question:

In order to pick multiple part elements, press and hold the keyboard's CTRL key.

Black travel icon

• Copy: places one identical part to the right side of original.

• Copy Pair: places one identical, mirrored part to the right side of original.

• Mirror at Y-Axis: flips selected part right or left at part's Point of Rotation marker.

• Mirror at X-Axis: flips selected part up or down at part's Point of Rotation marker.

Travel Direction Icons and Menus

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• Copy (Grid): places multiple copies of original part on the sheet surface. Quantity, direction, and position of newly-added parts can be customized, using the Grid Copy window.

• Move (Precise): relocates selected part using absolute (sheet origin at 0,0) or relative (from part's current position) increments.

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• Rotate (Precise): rotates selected part using absolute (sheet origin at 0,0) or relative (from part's current position) increments; rotation angle must lie between ±180°.

• Clamping Functions: used when multiple tooling stations are used simultaneously; clamping modes include none, like, or mirror:

• Clamping: opens the Clamping Dialog window; aids in setting distances between process tools and clamping method.

• Apply Current Layout Clamping: assigns current clamping parameters to selected part.

• Save as Current Layout Clamping: takes current part clamping settings and applies them to layout.

• Minimize Clamping between Copies: moves part copies as close together as possible.

• Edit with CAD: opens the selected part for editing in Columbus III's™ internal CAD system.

• Zoom: enlarges selected part on the layout designer desktop.

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• View in 3D window: opens the selected part in the 3D View window.

• Append to Sequence: designates rapid movements and cut order for selected contours.

• Remove from Sequence: removes all rapid moves, leads, and cut orders for selected contour.

• Set Leads: assigns lead in/lead outs for selected contours. Lead parameters are modified using Techno Setting tab for tool selected.

• Delete Leads: removes lead in/lead out elements from selected contours.

• Set Loops: defines and positions corner loops.

• Delete Loops: removes all references to corner loops on selected contours.

• Reverse Direction: changes direction of tool travel when inside and outside cutting contours.

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Gray travel icon







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• Set Tabs: assists user when placing tabs on the selected part; tabs are used to prevent cut parts from dropping into cut table.

• Reverse Direction: changes direction of tool travel when inside and outside cutting contours.

White travel icon

• Rotate (Precise): rotates selected part using absolute (sheet origin at 0,0) or relative (from part's current position) increments; rotation angle must lie between ±180°.

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• Move Leads: relocates all lead elements to a different contour element.


• Split: takes a single contour element and breaks it into two smaller elements.

Yellow travel icon

• Rotate to Parallel: rotates part so that selected contour or sheet edge elements are parallel.

• Rotate to Parallel and Align: rotates part so that selected contour or sheet edge elements are parallel and face one another.

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• Combine: takes two contiguous contour elements and joins them into a single element.

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Practical Application - Arranging Nested Parts

1. Return to the Layout Training example and click the Part Browser icon.

2. Double-click Part BBB in the layout browser. Zoom in using the keypad's + key or mouse wheel.

3. Move Point of Rotation icon to the upper left corner of part.

4. Rotate part to any arbitrary angle using the Rotate Part icon.

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New part position

Rotate Part icon

Angle indicator

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5. At this point, the part is no longer parallel with respect to the sheet borders . To realign the part, double-click on a part straight edge - the white travel direction icon will be displayed and selected edge will be outlined in blue.

6. Press and hold keyboard's CTRL key and double-click the sheet's vertical border - the white travel direction icon will turn yellow and the sheet's vertical border will now also be outlined in blue.

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7. Right-click anywhere on the layout desktop - in the menu that appears, click the first icon entitled Rotate to Parallel icon.

Sheet border - top side

Sheet border - left side

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8. Right-click Part AAA in the layout browser; in the menu that appears, click the Edit icon.

9. The Edit Order Part window will be displayed:

Adding Additional Parts

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10. Click the Add Multiple Items icon.

11. In the window that appears, type the number 3 - this will add three additional part requirements for Part AAA to layout browser.

12. Right-click Part AAA and select Copy (Grid). Make the changes seen in the Grid Copy window at left.

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13. Your results should look similar to the layout screenshot below:

14. On the layout desktop, select part Flange 1A, press and hold the keyboard's SHIFT key, and drag part to the sheet's upper left corner.

Holding the SHIFT key while moving nested parts will constrain movement to straight paths (orthogonal-based movement only).

Assigning Sequence

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Part BBB

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15. Right-click the flange and click Append to Sequence from the menu that appears.

16. Deselect the flange; users will recognize the command sequenced and created lead elements for all flange contours:

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17. Reposition Part BBB to the right side of Flange 1A - repositioning of multiple parts may be required.

To select multiple parts at once, hold the keyboard's SHIFT key and drag selection box from right to left.

18. Right-click Part BBB and click Set Leads icon.

19. Compare contour elements between Flange1A and Part BBB:

Notice that sequenced contours and lead elements are magenta in color. Each sequenced lead element is connected using a blue-dashed, rapid move path.

Conversely, unsequenced part elements are red in color and share no common rapid move paths.

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20. Click the Select Unsequenced Contours icon; all nested parts with unsequenced contours will be outlined in blue.

21. On the layout browser tool bar, click the drop-list for Direct Modes and select Sequence.

Keyboard Shortcut Sequence Direct Mode

CTRL + L

Users will notice the mouse pointer has changed to reflect the sequence direct mode.

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22. Click the bottom hole on Part BBB; users will notice that is possible for nested parts to have both sequenced and unsequenced elements for part in question.

23. Right-click Part BBB and select Remove from Sequence.

24. Double-click the upper left Part AAA - the outer contour will be outlined in blue and a gray-colored travel icon will be displayed.

25. Right-click and click Append to Sequence; rapid move paths and lead elements will be applied to the lower, right corner.

26. Double-click the part's top edge; a white travel direction icon will be displayed.

27. Right-click and select Move Leads - lead elements and travel direction icon will be relocated to this edge.

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28. Right-click the part and select Remove from Sequence.

29. At some point, users may need to split a contour element to accommodate new lead locations:

To split an element, double-click the individual contour element, right-click, and click Split. The Split window will appear and users can make adjustments.

Single contour element

Two contour elements

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30. Users may also need to combine contour elements to simplify a given part's paths: Element #1

Element #2

To combine elements, press and hold the CTRL key, double-click both elements to be joined, right-click on part, and select Combine in the menu that appears.

The elements to be combined must be contiguous (i.e, share a common point).

New single element

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31. In most cases, inner contours are cut counter-clockwise and outer contours are cut clockwise.

If you need to change directions, right-click (all contours) or double-click (entire contour) the part and select Reverse Direction icon from the menu that appears.

Reversed cut path

Travel Direction

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32. Instances arise where physical links between cut parts are required; on the layout browser tool bar, click the drop-list for Direct Modes and select Bridge To.

Keyboard Shortcut Bridge To Direct Mode

CTRL + B

Users will notice the mouse pointer has changed to reflect the bridge direct mode.

To create the bridge, click and drag the selection line between two nested parts.

The new outside contour created from the bridge is outlined in blue above.

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Keyboard Shortcut Common Cut Direct Mode

CTRL + C

Users will notice the mouse pointer has changed to reflect common cut direct mode.

Users will select the first part edge to common cut, using a single mouse-click . Select the second part edge using a single mouse-click . Notice the first part selected turns darker in color - this signifies the part now shares a common cut side.

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33. Users have the option of cutting one side of two parts at once; on the layout browser tool bar, click the drop-list for Direct Modes and select Common Cut.

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34. Tabs can be used for many applications, which include holding cut parts in place, torch cooling, or bent back for free-standing cut parts. The Tab command can be initiated in one of two ways:

a. Right-clicking a contour and selecting the tab icon from the menu that appears; this method uses a prompt window to determine number and placement of individual tabs,

b. Clicking the drop-list for Direct Modes and select Tab; use this method to manually place tabs on the nested part.

Keyboard Shortcut Tab Direct Mode

CTRL + T

Users will notice the mouse pointer has changed to reflect the tab direct mode.

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To remove all tabs, right-click the nested part in question and select Delete Tabs.

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35. Rearrange the nested parts within the sheet borders to maximize cut area - the goal here is to leave as much free sheet space towards the bottom as possible.

Your results should look similar to the screenshot below:

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36. Manually sequence all part contours on the sheet - enter manual sequence mode by pressing CTRL + L.

Your results should look similar to the screenshot below:

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Keyboard Shortcut Remnant Cut Direct Mode

CTRL + R

Users will notice the mouse pointer has changed to reflect the remnant cut direct mode.

37. With a large, uncut portion of the sheet surface preserved in the previous step, additional cut parts can be created. On the layout browser tool bar, click the drop-list for Direct Modes and select Remnant Cut.

Remnant sheets are created using negatives or by cut separation:

• Negatives are defined as sheets containing both previously cut part holes and uncut areas. To use this method, ensure all nested parts are sequenced, right-click the layout desktop, and select Prepare Remnant Sheet from Negative icon.

A red, dashed line will encompass the layout desktop.

Right-click and select the Create Prepared Remnant Sheet icon.

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The Enter Value window will be displayed; rename the new remnant sheet and click OK.

Click the sheet - the user will notice that the preview window displays the newly created remnant sheet.

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• Cut Separations are used to "trim off" previously cut sheet sections from the uncut portion. Click and drag a line across the entire sheet, and release.

This line will form the final cut line, isolating the skeleton from the remaining, uncut material.

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Right-click and select the Create Prepared Remnant Sheet icon.

The Enter Value window will be displayed; rename the new remnant sheet and click OK.

Either method will create a new entry on the Sheets tab.

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Managing Layouts

To view all layouts available, click the browser tree’s Explorer tab, right-click Layouts, and select Open.

The Layouts tab will be displayed:

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Layouts Tab Icons

The following icons are used in conjunction with the Layouts tab:

• Move First: moves selection to first available layout.

• Move Previous: moves selection to previous layout.

• Move Next: moves selection to next layout.

• Move Last: moves selection to last available layout.

• Add New Item: clicking this icon will open the Create New Layout window for developing new layouts.

• Delete Selected Item(s): clicking this icon will delete all selected layouts.

• Print: clicking this icon will list all selected layouts, along with basic layout parameters (e.g., material used, quantity, thickness, etc).

• Export: this icon will translate the data, as seen on the Layout tab, to a .txt file for use with other applications.

• Reload: refreshes the Layout tab and check for any recently added layouts.

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Information displayed in the Layout tab can be fully customized by clicking the Column Configuration icon:

The Column Configuration window for the Layouts tab will be displayed:

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• Name: specific title that will allow the user to quickly identify/search for the layout in a list.

• Quantity: number of sheets assigned to the layout.

• Dimension X: specific title that will allow the user to quickly identify/search for the layout in a list.

• Dimension Y: number of sheets assigned to the layout.

• Default Material: designated raw material type used with layout.

• Default Thickness: designated raw material thickness used with layout.

• Machine: assigned machine configuration used with layout - used when multiple cutting machines are present at one customer site.

• State: status indicator of the layout’s current progress. Status categories include:

• None: used when the layout has not been initially saved.

• Editing: used after layout has been saved and contains unnested parts.

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• All Nested: all parts included in layout have been nested.

• All Sequenced: all ordered parts included in layout have been nested and sequenced.

• Code Generated: used when the numerical programming has been created.

• Completed: used when orders for the layout have finished.

• Created By: identifies user who created the selected layout.

• Created On: lists date the selected layout was created.

• Modified By: identifies user who last changed the layout.

• Modified On: lists date the selected layout was changed.

• State Changed By: identifies user who last changed the layout’s status level.

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• State Changed On: lists date the selected layout’s status was modified.

• Code Generated By: identifies user who last generated the NC programming code.

• Code Generated On: lists date the selected layout’s NC programming file was compiled.

• Printed By: identifies user who last printed the layout parameters.

• Printed On: lists date the selected layout was last printed.

• Original Layout: identifies parent layout after parts are assigned to a remnant sheet.

• Layout Object Exists: layout has a sheet object assigned.

• Locked By: identifies user who currently has the layout open on another terminal.

• Program Name: identifies program used with layout.

• Note: text field used to store important aspects of layout.

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Techno Settings Introduction

The Techno Settings browser tree assists the user in selecting and modifying process parameters such as leads, object spacing, the handling of small holes, and layout settings.

• Save: Saves user settings made to the current technology file.

• Reload Techno Settings: moves selection to previous sheet.

• Show All: moves selection to next sheet.

Icons

Parameter Groups

Technology settings are divided into three specific groups, which include Layout Settings, Process Independent, and Process Dependent parameters. In the screenshot below, each of the three groups are highlighted.

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Process specific parameter groups will vary (in number and content), depending on the tool stations present. This group will use the torch type to identify itself (e.g. oxyfuel torch, plasma marker, laser pointer, etc).

Layout Settings

The Layout Settings group contains six subgroups:

Automatic Nesting

These settings determine how parts are placed automatically onto the sheet, and whether or not circle optimization, hole filling, and rotation angles are used.

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• Circle Optimization: Places circles diagonally using grid nesting. Default setting is No.

• Mirror Forbidden: Prevents parts from being mirrored when nested on sheet. Default setting is No.

• Nest Over Marking: Allows placing of parts over sheet markings. Default setting is No.

Non-Default (i.e., user-modified) settings are denoted using bold text. In the screenshot below, notice the Placements and True Sheet settings have been modified by the user.

• Nesting Algorithm: Set of rules used to position parts on sheet. Default setting is Standard Advanced.

• Part In Part Mode: Determines if smaller parts can be nested into holes of larger, nested parts. Default setting is Enabled.

• Part Selection: Criteria to select part order for nesting, based on area or perimeter. Default setting is Sorted by Area.

• Placements: Number of placements to use; a default setting of 0pcs will automatically detect placements required.

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Contour Start Position

These settings determine outer and inner contour start positions, marking points, and if elements can be split.

• Rotation Angle: Rotation angle that parts can be rotated during nesting. Default setting is 90°.

• Torch Reduction: Determines if reduction of torches used during part processing is allowed. Default setting is Yes.

• Torch Spacing: Determines if torch spacing can be changed. Default setting is Yes.

• True Sheet: This setting determines if the program is to consider the kerf of remnant sheets when nesting parts. Default setting is Yes.

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• Enabled: Enables or disables use of contour starting positions. Default setting is Yes.

• Inner Contour: Designates default position for inner contours. Users can select from ten different positions - default setting is Left Middle.

• Marking Contour: Designates default position for marking contours. Users can select from ten different positions - default setting is Any.

• Move Automatically Set: Allows or prevents moving start position after leads have been set automatically. Default setting is No.

• Move Manually Set: Allows or prevents moving start position after leads have been set manually. Default setting is No.

• Outer Contour: Designates default position for marking contours. Users can select from ten different positions - default setting is Bottom Right.

• Split Elements: Determines if element splitting can set the starting position. Default setting is No.

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General

These settings determine multipass, corner loop, and sequencing options in order to create closed contours.

Close Last Multipass Cut: Use last multipass cut to construct a closed contour. Default setting is Yes.

Sequence Enclosed Parts: Setting to automatically sequence all parts inside the contour in question. Default setting is Yes.

Set Corner Loops: Automatically set corner loops during sequencing. Default setting is Yes.

Use All Multipass Cuts: Use all multipass cuts on single cut selections. Default setting is Yes.

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Leads

These settings determine lead in/out behavior with distance conflicts, when leads are created, and if leads can be automatically set when part is sequenced.

• Apply To: Determines when leads are set. Settings include None, Existing, Not Existing, and the default setting of All.

• Auto Move: Determines if leads are automatically repositioned when distance conflicts arise. Default setting is Yes.

• Auto Set During Link: Determines if leads are automatically set when part is sequenced. Default setting is Yes.

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• Auto Shorten: Enables/disables automatic lead length reduction on inner contours. Default setting is No.

• Auto Window: Setting to set bevel windows when placing leads. Default setting is Yes.

• Check Distances: Setting to enable/disable distance conflict monitoring when leads are set. Default setting is Yes.

• Cut Rapid Movement: Setting to enable/disable the cutting of rapid moves in between lead out to lead in. Default setting is No.

• Stop Sequencing On Error: Stop the sequencing function from continuing when an error occurs.

Mirror Text

These settings determine identification of text marking and use of extensions.

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Sequence Optimization

Settings that determine if optimizations can be used, orientation of nesting, and sorting methods.

• Append Extension: Adds a prefix or suffix to all text markings. If No is selected, a suffix will be used. The default setting is Yes, and a prefix will be used.

• Enabled: Setting to enable/disable all text settings. Default setting is No.

• Extension on Mirror: Defines the prefix or suffix used with mirrored text markings. Default setting is -M.

• Extension on Normal: Defines the prefix or suffix used with normal text markings. Default setting is [blank].

• Only for Part Name: Setting to enable/disable extension usage with part names only. Default setting is Yes.

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• Enabled: Setting used to enable/ disable all sequence optimizations. Default setting is Yes.

• Mark Ahead: Performs all part marking before cutting begins. Default setting is No.

• Nest Orientation: Determines preferred method of nesting part placement. Settings include Disabled, Horizontal, or default setting of Vertical.

• Stripes: This setting selects number of rapid move optimization stripes to be used. Default setting is 10pcs.

Process Independent

The Process Independent group contains three subgroups:

Layout

Expanding this browser tree reveals options for travel direction and tool preparation time.

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• Preparation Time: Additional time for machine tool adjustment. Default setting is 0.00 min.

• Set Direction: Setting used to enable/disable direction selection for cutting contours. Default setting is Yes/No.

• Inner CCW: Inside contours are cut in a counter-clockwise direction. Default setting is Yes.

• Outer CCW: Outside contours are cut in a counter-clockwise direction. Default setting is No.

• Set Direction: Setting used to enable/disable direction selection for cutting contours. Default setting is Active.

Default files are denoted with a white check mark inside a black circle .

To create user-defined files, right-click the subgroup folder and select New.

User-defined files can be set as default, edited, copied, hidden, and deleted with a right-click.

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A graphical representation for cut direction can be activated by clicking the Property Page icon.

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Representation of cut part

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Travel direction - outer contour

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Spacings

Expanding this browser tree will reveal all default/user spacing selections. Spacing files contain the following options.

• Lead - Part: Minimum distance between lead and next part. Default setting is 1.0mm.

• Lead - Sheet: Minimum distance between lead and sheet edge. Default setting is 1.0mm.

• Part - Part: Minimum distance between two parts. Default setting is 10.0mm.

• Part - Sheet: Minimum distance between part and sheet edge. Default setting is 7.0mm.

• Piercing Position - Part: Minimum distance between piercing point and part. Default setting is 1.0mm.

• Piercing Position - Sheet: Minimum distance between piercing point and sheet edge. Default setting is 1.0mm.

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A graphical representation for element spacing can be activated by clicking the Property Page icon.

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The user will notice that the Part - Part and Part - Sheet distances display the formula symbol.

Click the Options button to open the Formula Editor window.

In the window above, the distance between nested parts is determined by the formula (Layout Thickness x 2) + 0.25". With the sheet thickness at 0.5", the part-part distance equals 1.25". Formulas can be derived from functions, constants, variables, and operators. The State window displays the results of the formula used and converts the result to millimeters.

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Remnant

Expanding this browser tree will reveal all options associated with using remnant sheets.

• Hole Piercing Distance: Distance to piercing hole to edge of sheet.

• Leadout Overcut: Length of lead out over-cutting on contour.

• Length: Length of lead in before cutting contour.

• Height Control Off: Distance to turn height control off before edge of the sheet.

• Overcut: Over-cutting length past the edge of sheet.

• Height: Vertical size of text on remnant sheet.

• Label Mode: Label mode for new remnant sheets. Default setting is Always.

• Margin: Spacing margin around text.

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Process Dependent

This parameter group depends exclusively on which tooling stations are present on your cutting machine. The presentation of your specific cutting machine and tools included can be found browser tree’s Explorer tab under the Machines category. The following content will list the tool stations and define the parameters used with each.

The primary parameters modified by the user will be lead in / lead out elements on cutting tools.

However, secondary parameter sets can be viewed by clicking the Show All icon. The white folders seen below represent these secondary parameter sets.

Show All icon

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Leads Outer-Contour

Parameters that determine lead in/lead out cut paths in relation to the contour's outside edge.

• Lead In: Initial pierce and travel cut path that begins cutting of a nested part's outer contour.

• Lead Out: Cut path that travels off a nested part's outer contour.

• Multipass Piercing Distance: Distance between piercing positions used for multipass bevel cuts.

• Overcut: Length of lead out over-cutting on the outer contour; distance the cutting tool will continue to cut past the lead in point.

• Prepiercing: Cutting tool will travel to initial pierce point of nested part's outer contour, pierce the material, and travel to the next pierce point.

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A graphical representation for outer contour lead elements can be activated by clicking the Property Page icon.

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Lead in designator

Remaining cut part

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Cut path

Lead out - 1st element (arc)

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New users to Columbus can use the Techno Editor window to apply lead in /out changes and view results in real-time. Changes are made in the text fields (at right); results are displayed on contour (at left).

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The Lead In row n=1; l=0.394"; opt =Yes tells the user the number (“n”) of lead in elements, length (“l”) of the lead in path, and that Angle Optimization (“opt=”) is set to Yes.

Expanding the lead in element [1] displays the following:

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• Aperture Angle (α): Angle between the initial and final path of the lead in element. Default values are 90° and the angle is not calculated. Aperture angles are used only with arc lead elements.

• Joint Angle (β): Angle between final lead in point and first contour of the cut. Default value is 180°.

• Length (l): Overall length of lead arc or line. The default values are 0.394" and the length is not calculated.

• Radius (r): Length of the arc radius. By default, the arc radius is calculated based on aperture angle and arc length. Radii are used only with arc lead elements.

• Angle Optimization: When enabled, this setting optimizes the angle between leads and contour, depending on position.

Close the lead in elements and expand lead out elements. The user will notice that the lead out is comprised of two elements, one arc and one line:

The Lead Out row n=2; l=0.894"; opt =Yes tells the user the number ("n") of lead out elements, length ("l") of the lead out paths, and that Angle Optimization ("opt=") is set to Yes. Notice that the length of the lead out path is the sum of both the arc and line elements.

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Leads Inner-Contour

Parameters that determine lead in/lead out cut paths in relation to the contour's inside edge.

• Lead In: Initial pierce and travel cut path that begins cutting of a nested part's inner contour.

• Lead Out: Cut path that travels off a nested part's inner contour.


• Overcut: Length of lead out over-cutting on the inner contour.

• Prepiercing: Cutting tool will travel to initial pierce point of nested part's inner contour, pierce the material, and travel to the next pierce point. Default setting is No.

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A graphical representation for inner contour lead elements can be activated by clicking the Property Page icon.

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Lead in (small arc)

Lead in designator

Remaining cut part

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Cut path (inner countour)

Lead out (larger arc)

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The Techno Editor window for inner contours is displayed and manipulated in the same manner as the techno editor for outer contours. Changes are made in the text fields (at right); results are displayed on contour (at left). Notice that the lead in element is smaller than the larger lead out path - the modified component is the lead in arc length. The calculated arc radius is adjusted by the software accordingly.

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Tabs

Used to provide small, uncut sections on part components. Many times these tabs will be bend back and used to make the cut part stand.

• Cut Rapid Movement: When enabled, the rapid movements between parts will be cut. Default setting is No.

• Lead In: Cut path that forms the second (and final) side of the tab.

• Lead Out: Cut path that forms the initial side of the tab.

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• Width: Width of the tab.

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Lead out on a line-type tab.

Rapid move from lead out to lead in.

This section of the contour will not be cut.

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Lead in on a line-type tab.

Arc-type tab.

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Bridges

Bridges are used to provide a physical link between cut part components.

• Negative: When enabled, the negative bridge will cut itself upon return. Default setting is No.

• Width: Width of the bridge.

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Common Cut

These cuts are used to establish a single-pass cut line between part components.

• Kerf: Width of material (perpendicular to the torch) consumed during the cut; equivalent to the past nesting distance.

• Mode: Preferred mode of the common cut.

• Preheat Time: Duration (in seconds) of preheating after crossing the common kerf.

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Pre Piercing

These settings are used to set the behavior and edge starting options with pre-piercing.

• Distance: Distance to edge start. Positive values enlarge the lead in.

• Process: Process used to pierce the material (oxyfuel, plasma, drilling, etc). Default setting is None.

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• Edge Start: Determines if edge starting is to be used on restart cutting. Default setting is Yes.

• Mode: Piercing type and the geometry to apply. Default setting is Circle; Restart at Edge.

• Overcut: Percentage of over-cutting the circle.

• Radius: Radius of the circular geometry.

• Split Distance: Distance where the lead is split before reaching contour.

Small Holes (Plasma Only): These parameters assist the user in cutting small hole in a proper manner. These pre-configured parameter settings are know as ESAB's Precision Hole Technology or simply known as PHT. Cutting small holes have several factors that influence their shape such as leads, flying ends, height control, and cutting speeds.

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• Apply Container: Maximum size of a container to handle it as a small hole.

• Height: Maximum height of a container to handle it as a small hole.

• Width: Maximum width of a container to handle it as a small hole.

• Apply Diameter: Maximum diameter of a hole to treat it as a small hole.

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• Apply Mode: Criteria method used to define a small hole or shot. The default setting is Hole/Slot.

• Mode Container: Parameter settings used when the apply mode is set to Container.

• Feedrate Reduction: Activates/deactivates travel speed reduction of machine when cutting small holes; uses a percentage or set value.

• Flying End: Parameters that define angle, distance, and location of an activated flying end.

• Height Control Off: Lead in position and distance in which to turn height control off for containers.

• Macro Name: Users will import and designate a .sdp file (files define thickness, amperage, pressure, flow, material information) for use with the small hole in question.

• Overwrite Existing Macros: Enable/disable the ability to replace the current .sdp settings with user modifications.

• Mode Hole/Slot: Parameter settings used when the apply mode is set to Hole/Slot.

• Height Control Off: Lead in position and distance in which to turn height control off for hole or slots.

• Overwrite Existing Macros: Enable/disable the ability to replace the current .sdp settings with user modifications.

• Ratio 1:1 - Used with hole diameters less than or equal to the plate thickness.

• Flying End: Parameters that define angle, distance, and location of an activated flying end.

• Lead In Factor: Used to calculate the lead in arc radius (r = factor * hole radius).

• Lead In Type: Lead in will consist of either a single arc or a arc/line combination.

• Lead Out Factor: Used to calculate the overcut length (l = factor * hole radius).

• Macro Name: Program designated .sdp file used for 1:1 ratio small holes.

• Ratio 2:1 - Used with hole diameters that are greater than 1 but less than or equal to 2 * plate thickness.

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• Ratio 5:1 - Used with hole diameters less than or equal to 5 * plate thickness.

• Use Predefined Leads: When this parameter is set to No, Precision Hole Technology (PHT) settings will disabled.

A graphical representation for small hole elements can be activated by clicking the Property Page icon.

The yellow area in the screenshot below displays options associated with defining small holes. Small holes can be defined either by an approximated container, an actual round hole geometry, or a combination of both.

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4 Hole / Slot diameter

Application method - Hole / Slot

Container width / length

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Application method - Container

Container / Hole / Slot settings (text-based)5

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The yellow area in the screenshot below displays options associated with the reduction of machine/tool speed. These options are only available when using container mode. The feedrate can be modified using a percentage relative to the machine/tool speed or by an actual measurement of travel, which is inches/minute [or mm/minute for metric users].

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Application method - Hole / Slot

Container width / length

Application method - Container

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4 Feedrate reduction settings (text-based)

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The yellow area in the screenshot below displays options associated with hole/slot size ratios, height control behavior while cutting holes/slots, and flying ends. A flying end is the point where the plasma process starts to shut down but the machine/tool will continue to move on contour.

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Flying end toggle - angle or distance

Flying end location

Flying end value

4 Height control o� - before end distance

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Height control o� - at start toggle

Hole size ratio selection

Model hole/slot settings (text-based)

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NC Configuration

These settings are used to enable or disable end of contour settings, height control, and settings used to handle rotation.

• Activated: Enable or disable end of contour handling. Default setting is Yes.

• Feedrate: Percentage of reduced feedrate before end of contour.

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• Height Control Off: Turns height control off before end of contour. Default setting is Yes.

• Split Before End: Distance to end of contour where height control is turned off and feedrate is reduced.

• Center Torch Required: Use oxyfuel VBA ccenter torch for X/Y profiles. Default setting is No.

• Disable Touch Radius: Radius wherein multiple height settings are suppressed.

• Flying End: Enable or disable flying ends and specifying its location. Several setting options are available. Default setting is None.

• Height Control Off on Leadout: Turn height control off on lead out paths. Default setting is Yes.

• Minimal Element Length: Smallest length of an element to generate a warning on code generation. Default setting is Yes.

• Rotation Fixed on Leadout: Fix rotation on lead out if it was active. Default setting is Yes.

• Rotation on (straight): Turns rotational capability option on during straight cuts. Default setting is No.

• Rotation on (vertical pass): Turns rotational capability option on during vertical pass of multipass bevel cuts. Default setting is No.

• Rotation on contour wise: Turns rotational capability option for the entire contour if any element has a bevel. Default setting is Yes.

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NC-Macros

These settings associate cut part parameters with .sdp file constants, such as amperage, cut gas type, shield gas type, pressures, and gas flow.

• Note: The user can make notes in this field concerning parameter files.

• Vertical: Name of the parameter file for vertical cutting.

• Lower Bevel: Name of the parameter file used on lower bevels.

• Upper Bevel: Name of the parameter file used on upper bevels.

• Vertical Bevel: Name of the parameter file used on the vertical part ("land" or "nose") of bevel profiles.

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Corner Loops

These elements are used to keep the sides of cut part straight by cutting passed the part’s corners and reentering the part’s corresponding side at an 180 degree path.

• Distance Slow: Cut distance using reduced feedrate after loop.

• Feedrate: Percentage of reduced feedrate during corner loops. Default setting is 100%.

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• Height Control on After: Distance to enable height control after loop.

• Preheat Time: Duration of preheating after crossing the loop kerf.

• Apply Limit: Inside joint angle between elements up to which a loop is set.

• Set for Straight Cut: Set loops also on straight cuts. Default setting is No.

• Adjustment Limit: Bevel is adjusted on link element if smaller than this setting; if not, adjustment is made on the lead in element.

• Link Limit Length: Minimum length of the link elements on the loop.

• Tangential Limit Length: Minimum length of the tangential elements on the loop.

• Type: Shape type of the corner loop. Default setting is Triangular.

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Piercing Window

These parameters determine the spacing between torches, additional height offset, and dimensional components associated with piercing.

• Distance Minimum: Minimal distance between contour and preceding torch on last wait cycle. Default setting is 0.394” / 10mm.

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• Distance Slow: Cut distance using reduced feedrate. Default setting is 0.000” / 0mm.

• Feedrate: Percentage of reduced feedrate. Default setting is 60%.

• Preheat Time: Duration of preheating at edge start.

• Distance Ahead: Distance between forward and center torches. Default setting is 0.787” / 20mm.

• Distance Follow: Distance between back and center torches. Default setting is 0.787” / 20mm.

• Extra Height: Height added to the minimal window height. Default setting is 0.000” / 0mm.

• Suppress Tangential Control: Suppress tangential control during window cutting. Default setting is Yes.

• Width: Width of the window.

• Inside: Lead starts inside the window. Default setting is Yes.

• Length: Length of the lead in.

• Overcut: Length of lead out over-cutting on contour. Default setting is 0.394” / 10mm.

• Perpendicular: Align lead in perpendicular to part contour. Default setting is Yes.

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Production Data

Parameters used to estimate and control consumable life and wear.

• Character Time: Average time to mark a text character.

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• Dot Time: Average time to mark a dot.

• Cutting: Usage of nozzle while cutting.

• Ignition: Usage of nozzle while ignition.

• Piercing: Usage of nozzle while piercing.

• Ignition: Average time for a ignition.

• Piercing: Average time for a piercing.

• Pre-Heating: Average time for a pre-heating.

• Process Activation: Average time to activate the process.

• Smart Cycle Touching: Average time of height setting on Smart Cycle mode.

• Touching: Average time of height setting using touching cycle.

• Touching Off: Average time of height setting without using touching cycle.

• Kerf: Theoretical value of kerf.

• Acceleration: An increase in speed; the derivative of velocity with respect to time.

• Bevel: Speed reduction while cutting bevels.

• Deceleration: A decrease in speed; the derivative of velocity with respect to time.

• Feedrate: The rate at which the cutting tool moves relative to the work piece.

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Practical Application - Layout Settings

1. Open a previously created layout and delete and/or release all parts.

2. Nest a quantity of one Part BBB anywhere within the sheet borders.

3. On the Techno Settings browser tree, expand the Process Independent tree.

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4. Expand and right-click the Layout tree. In the menu that appears, click New Layout General.

5. Rename this layout Part BBB and click the radio button.

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6. Click the Property Page icon.

The Techno Editor: Part BBB screen will be displayed:

7. In most cutting instances, outer contours are cut in a clockwise direction. Conversely, inner contours are cut in a counter clockwise manner. Changes in travel direction can be altered in this menu.

8. The user can also verify contour processing direction using the nested part; select the nested part and notice the travel direction icon’s orientation.

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To view current travel direction for any contour, double-click the contour element.

9. Save changes to Part BBB layout by clicking the Techno Settings Save icon.

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Practical Application - Spacing Settings

1. Collapse the process independent Layout tree and expand the Spacings tree below it.

2. Expand and right-click the Spacings tree. In the menu that appears, click New Spacing.

3. Rename this file Spacing - Part BBB and click the radio button.

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4. Click the Property Page icon.

The Techno Editor: Spacing - Part BBB screen will be displayed:

5. Notice that as the mouse pointer hovers over text boxes on the left side of the screen, the text parameters are highlighted in blue on the right. In the screenshot above, notice that the yellow mouse pointer is hovering over the Part - Sheet text box. This corresponds to the blue-highlighted, text-based parameters on the right. Make the following changes within the spacings editor:

• Lead - Part: 0.25"

• Lead - Sheet: 0.25"

• Part - Part: 0.5"

• Part - Sheet: 0.5"

• Piercing Position - Part: 0.125"

• Piercing Position - Sheet: 0.125"

6. Once these values have been entered, click OK.

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7. Save changes to Spacings - Part BBB layout by clicking the Techno Settings Save icon.

8. Nested parts can be moved within the spacings constraints developed above. Select Part BBB, press and hold the SHIFT key, and press the Up and Left arrow keys. The nested part will position itself with a 0.5” gap on both sides of sheet (see yellow highlighted area in the screenshot at left).

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Practical Application - Approximate Element Measurement

1. Add 4 of part Flange 1A to the part browser. Nest a quantity of 1 to the right of Part BBB.

2. Add 3 of part Flange 2A to the part browser. Nest a quantity of 1 to the right of Flange 1A.

3. Zoom into the bottom hole on Part BBB; an approximate measurement of the hole’s diameter can be accomplished by:

• Using the mouse pointer, perform a left-click and hold,

• Drag the black selection line from the hole’s left side to right,

• Pressing the SHIFT key in order to pull a straight line,

• Finally, take note of the measurement displayed at the bottom of the screen.

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4. To calculate a hole ratio estimation, divide hole diameter by the plate thickness utilized. The bottom hole of Part BBB has a 1.00” diameter and the sheet has a thickness of 0.5” - the small hole ratio is 2:1. The rule set is as follows:

• Results less than or equal to 1 = 1:1 ratio

• Results greater than 1 and less than or equal to 2 = 2:1 ratio

• Results greater than 2 = 5:1 ratio

5. Repeat steps #1 - 3 for the remaining inner hole contours. Your results should be similar to the screenshot below:

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1.00” diameter / 0.5“ plate thickness = 2.00 ≤ 2:1 hole ratio

2.88” diameter / 0.5“ plate thickness = 5.76 > 5:1 hole ratio ***

2.36” diameter / 0.5“ plate thickness = 4.72 ≤ 5:1 hole ratio4

7.16” diameter / 0.5“ plate thickness = 14.32 > 5:1 hole ratio ***

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0.47” diameter / 0.5“ plate thickness = 0.94 ≤ 1:1 hole ratio5

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*** Holes greater than a 5:1 ratio will revert back to default Leads Inner-Contour.

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Practical Application - Working with Lead Elements

1. On the Techno Settings tab, expand the Plasma Torch menu.

2. Expand both the Leads Outer and Leads Inner Contour menus.

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3. Right-click Lead Inner Contour and click New Leads Inner-Contour.

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4. Rename this new file Circular 1". Right-click this file and select Edit.

5. The Property Page for the Circular 1" file will be displayed:

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6. Right-click Lead In and select Add Arc.

7. Expand the [1] element and change the length of the line to 0.500".

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8. Collapse the Lead In elements and expand the Lead Out element. Right-click Lead Out and select Set to Line-Arc.

9. Expand the Lead Out line element [2] and change the length of the line to 0.500".

10. Collapse the Lead Out elements and delete any value found in Multipass Piercing Distance.

11. In the Overcut field, enter a value of 0.25". Your results should look similar to the screenshot below:

12. Ensure Prepiercing is set to No and click OK.

13. Enter Sequence direct mode by menu selection or by pressing the CTRL key + L. The Sequence mode cursor will appear.

14. Zoom in to the large hole on Part BBB and left-click the inside contour. Your results should look similar to screenshot at left:

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15. We previously calculated that this hole had an approximated 2:1 small hole ratio. On the Techno Settings tab, expand the Small Holes menu.

16. Press the Show All icon. This will display all the pre-configured small hole files:

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17. Scroll down to the .50" Small Holes files. As a general rule of thumb, start with the lowest amperage file for the hole you are trying to cut. For this scenario, select the .50 Small Holes 100 Amp file.

18. Re-select the Small Holes folder and deactivate the Show All icon. Right-click this file and select Set as Default in the menu that appears.

The black icon that denotes default status will now appear on this file.

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19. Click the Property Page icon - the following Techno Editor screen will be displayed:

The user can derive several key points from the screen above (highlighted in yellow):

• The Apply Mode is set to Mode Hole/Slot.

• The Feedrate setting will be reduced by 50% while cutting the hole.

• The Height Control will be turned off 0.250" before the end of the cut.

• The Flying End will use distance and activate 0.500" before end of contour.

20. Without making any changes, click Cancel.

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21. While remaining Sequence direct mode, click Part BBB’s bottom and top hole . The software will automatically recognize these two holes as 2:1 ratio small holes and will size the lead elements accordingly. Your results should look similar to the screenshot at left.

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22. Right-click Lead Outer Contour and click New Leads Outer-Contour.

23. Rename this new file 90 Corner 1". Right-click this file and select Edit.

24. On the Lead In element, expand [1] and change the length of the line to 1.00".

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25. On the Lead Out element, right-click and select Add Line. Expand [1] and change the length of the line to 1.00". Delete any value found in Multipass Piercing Distance.

26. Enable the newly created 90 Corner 1” outer contour file.

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27. While remaining Sequence direct mode, zoom in and click Part BBB’s upper left corner. If done correctly, you will receive a lead distance error - this is due to the part-sheet distance set to 0.50” and lead elements set to 1.00”.

28. Correct this error by moving Part BBB and lead elements within the borders of the sheet.

29. Use the SHIFT and arrow keys to position Part BBB with the correct spacing in relation to the sheet. Put some space between Part BBB and the remaining nested parts. Adjustments to the spacing of all nested parts will be revisited before finishing the layout. Your results should look similar to the screenshot below:

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30. While remaining Sequence direct mode, select the large, interior hole on Flange 1A. The result will resemble the lead elements seen in Part BBB’s large, interior circle. Both holes revert back to the Leads Inner-Contour setting due to the ratios being greater than 5:1.

31. Select the upper right hole on Flange 1A. This hole has a ratio less than 5:1 and uses the PHT .50 Small Holes 100 Amp file.

32. Repeat step #31 for the five remaining interior holes on Flange 1A. In the Leads Outer-Contour settings, select an arced file and select the outer contour. Your results should look similar to the screenshot below:

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33. While remaining Sequence direct mode, select the upper right hole on Flange 2A. The software will automatically recognize this hole as a 1:1 small hole and will size the lead elements accordingly. Zoom in to view the lead elements. Repeat the sequencing for the remaining 1:1 ratio holes.

34. In the Leads Outer-Contour settings, select an arced file and select the outer contour. Your results should look similar to the screenshot below:

35. Use the SHIFT and arrow keys to position the nested parts with the correct spacing in relation to all spacing elements. Revisit step #4 above for spacing elements.

36. Save changes to the layout by clicking the Layout Save icon.

37. Save changes to techno settings by clicking the Techno Settings Save icon.

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Bevel Profiles Introduction

This window is used to graphically represent the bevelled elements of a cut part. Angle and length of the bevels and their types can be modified in this window.

Icons

The following icons are used in conjunction with the browser tree’s Bevel Profile tab:

• Straight Cut

• Top V Bevel

• Bottom V Bevel

• Top Y Bevel

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• Bottom Y Bevel

• X Bevel

• K Bevel

• Free Style

• Allow Variable Bevel

• Show Grid

• Set Current Profile to Selection

• Continuous Profile Adjustment

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Practical Application - Working with Bevel Elements

1. Nest a single Part AAA to the layout and open the Bevelprofile viewer.

2. In the Bevelprofile viewer, the user will identify nine elements on the nested part:

• four sides of the outer contour

• four small corner holes

• and one large center hole.

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3. Bevelled edges can be applied to one, multiple, or all of a nested part’s elements. The elements can be selected as seen in the Layout Designer module. Select the four outside edge elements and the large, center circle. Multiple elements can be selected using the CTRL key and left mouse clicks on the elements.

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4. Click the Select Bevel Style icon and select Top Y Bevel icon.

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5. The Bevelprofile window will display the change made to the five elements; a textbox appears in this window (highlighted in yellow below) so that the user can define the bevel angle desired. Change the bevel angle to 45° degrees.

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The user will notice that deselected beveled contours are displayed use red, bold line elements:

Blue with selected part elements, as seen below:

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The results of the bevel criteria chosen above can be seen in the screenshot below:

6. A second parameter can be configured to determine the vertical (‘land”) edge of the part. Change this parameter to 0.200”.

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7. Some part applications may require variable angles and lands. Click the Allow Variable Bevel icon; the user will notice that the parameters on the opposite end of the cut part can now be modified.

8. Deselect Part AAA’s outer contour.

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9. Change the secondary bevel angle to 30° degrees. The user will notice that the change in angle is visually reflected in the bottom portion of the Bevelprofile window.

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10. Return the secondary bevel angle back to 45° degrees. Change the secondary vertical (‘land”) edge to 0.100”. Notice the change reflected in the Bevelprofile window below:

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11. Change the secondary vertical (‘land”) edge from 0.100” to 0.400”. Notice the change reflected in the Bevelprofile window below:

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12. Reset all five bevel elements to 45° degree with a vertical (‘land”) edge of 0.250”. Disable the Allow Variable Bevel icon.

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13. Enter Sequence Direct mode by pressing the CTRL key + L and sequence the four, small corner holes on Part AAA.

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14. Select Part AAA, right-click and select Append to Sequence. Rapid moves, lead elements, and corner loops will be assigned to the nested part. Double-click the dashed, rapid movement line in between the upper right small circle and large inner circle.

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15. On the keyboard, press the right arrow key once. The white travel icon will move to the straight cut pierce point. Continue pressing the right arrow key to cycle through the straight cut elements. The user can identify which cut is being made by the red portion seen in the Bevelprofile window. For this example, the number 1 is used to identify the straight cut elements.

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16. Continue to press the right arrow key. The screen shot below displays the lead in for the large circle’s bevelled edge. Take note of the red portion of the Bevelprofile window - the number 2 is used to identify the 45° bevel cut elements.

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17. Continue to press the right arrow key until it reaches the outside contour. The torch will rotate back to 0° at the lead in point.

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18. After leading in, the program begins the straight cuts (highlighted in blue). Take note of the red portion of the Bevelprofile window.

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19. Continue to move through the contours by pressing the right arrow. The user will notice that the corner loops are cut at the 45° bevel.

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20. The program will continue to step through the cuts and end at the lead out.

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Introduction

In order to fully utilize the Columbus III™ nesting software, the application will require a detailed, knowledge base of cutting machine systems installed at your site.

Machine Designer tab

Carriage/station menu

Properties tab

Machine design model

Process tooling menu

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Machine Designer

Recall this topic was first introduced in the Columbus III™ Quick Start Reference Manual; a basic cutting machine called QUICK START was created. Using the Explorer tab, open this machine design page:

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The Machine Designer model contains six interdependent areas where parameters can be modified. These six areas include:

CNC

Placement stoppers

Machine

Carriage

Station

Process tool

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As each of these areas are selected, parameters will change in the browser tree’s Properties tab.

CNC Parameters

With the CNC selected, users can modify file type, storage location, and file formatting parameters.

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Properties tab (CNC selected)

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• File...

• Extension: Indicates the default file extension for the generated NC file. File extensions include EIA, ESSI, MPG, and CNC. The extension type will need to be manually typed in and should correspond to the Format selection below.

• Folder: Indicates the default folder location to store the generated NC file. Pressing the Options icon will prompt the user to browse for the desired storage folder.

• Format: Indicates export formatting when generating the NC file. Pressing the Options icon will display the Select Profile window:

Under Profile, pressing the drop list icon will display all currently available profiles. Changes cannot be made to profiles enclosed with < >, other than <current profile>. In most cases, the file extension and file format parameters should be in agreement (e.g. an .ESI file extension and <Essi Default> are to be used together).

To create or edit a format profile, press the Manage Profiles icon .

Options icon

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Drop List icon

Manage Profiles icon

Edit Profiles icon

Save As Profile icon

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For users that have little or no experience, it is recommended that one of the <default> profiles is copied and edited , as opposed to creating a new profile . To do this, select the <default profile> that best matches your requirements and click the Copy Selected Profile icon. Click in the new copy’s name field and rename the profile .

File Type menu

Profile menu

Set As Default icon

Currently selected profile (blue)

Add New Profile icon

Copy Selected Profile icon

Edit Selected Profile icon

Delete Profile icon

Newly created copy

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After renaming the new profile, right-click and select Edit... The Edit Profile window will be displayed:

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Not all parameters will be described below due to complexity of subject. Only modify parameters that are seen below.

• Configuration...

• Name: users can assign a custom name to the configuration set.

• Warning Level: parameter to set which warning types will be displayed in the message center. Notice that messages below this setting will be suppressed.

• NC-Code...

• Encoding: users can select the character encoding type for use with the NC code program.

• Units...

• Absolute: determines if coordinates are referenced from program’s zero point (Yes) or from the program’s previous point, referred to as Incremental mode (No).

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• Inches: parameter to set values using inches (Yes) or millimeters (No) for units of measure.

All selected parameters will display a brief description at the bottom of each window. Ensure you read and fully understand these before making changes!

Machine Parameters

Clicking the cutting table inside the machine design model will display machine parameters in the properties tab. Users can place CNC on either side of machine, designate machine type, single torch beveling capabilities, and text marking parameters.

Click here to access Machine Parameters.

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• Beveling...

• Y-Bevel mode: use Y-bevel for entire program.

• Y-Beveling: machine supports Y-bevelling on single torches.

• Machine...

• Additional Processes: this parameter is set by ESAB and cannot be edited.

• Controller: the CNC can be placed on the left or right side of the machine design model. The machine model will update after selection is made.

• Type: user can enter machine type in this text field.

• Technology...

• Text Marking: this parameters determines if machine supports marking text.

Carriage Parameters

Clicking any carriage on the machine design model will display that carriage’s parameters in the properties tab. Parameter sets will change based on carriage type selected. Users can select motorized, band-clamped, or attached carriages and place them on the machine model in any configuration.

Carriage #1 selected

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• Carriage...

• Can Park: this parameter sets the ability of carriage to be parked outside the working area.

• Carriage ID: number assigned to carriage for spacing and clamping purposes.

• Clamping Type: type of carriage clamping used on selected carriage.

• Park Position: side of machine where carriage will be parked.

• Spacing by Moving: carriage is spaced using Y-way versus spacing commands.

• Leader: carriage identifying number that is responsible for moving selected carriage; this parameter is used with non-motorized carriages.

Parameters will change based on carriage type selected.

Carriage Icons

Below are the available carriages that can be added to the machine model. Add carriages by clicking an icon or dragging to location; to remove carriages, right-click the carriage in the machine model and click Delete or drag to the recycle bin.

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Motor-Driven Carriage

Auto Clamping Carriage

Manual Clamping Carriage

Left Attached Carriage

Right Attached Carriage

Left Fixed Carriage

Right Fixed Carriage

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Station Parameters

Clicking any station on the machine design model will display station parameters in the properties tab. Stations are located on bottom of carriages in machine model. Parameter sets will change based on station selected. Stations are added/removed to machine design models in the same manner as carriages.

• Station...

• Selection ID: number assigned to select the station during programming.

• Virtual: all tools of this station are moved by NC offsets to a tool placed on another carriage.

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Station icon

Recycle bin

Station 1

Station 2 (selected)

Station 3

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Process Tool Parameters

Clicking any process tool icon on the machine design model will display process parameters in the properties tab. Process tools are located on bottom of stations in machine model. Parameters seen will change based on tool type selected.

Process tool on Station 1 (selected)

Process tool spacing distance

Process tool icons

Additional process tool icons

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Parameters displayed will vary based on process tool type and position. Definitions below may not be applicable for all process tool types and positions.

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• Technology...

• Alternate Sensor: Displays selections made in the parameters below:

• Alternate Sensor: Select Yes if the process tool has an alternate sensor.

• Sensor Distance: Distance to the sensor.

• Beveling: Select Yes if the process tool supports bevel cutting. If Yes is selected, additional parameters will be displayed above the Technology set.

• Rotation Unit: Select Yes if the process tool is mounted to a rotation unit. If Yes is selected, additional parameters will be displayed If Yes is selected, additional parameters will be displayed above the Technology set.

• Suppress Height Setting: Select Yes if the process tool supports suppression of height setting cycle inside defined areas.

• Tool...

• Distance: This is the minimum distance to the left tool. This parameter can also be modified directly on the machine design model.

• Name: This area can be used to give the tool a specific name. The default value will display torch type and station number.

• NC-Offset: Displays selections made in the parameters below:

• NC-Offset: Offset of NC to use when this tool is activated. Possible selections are None, Automatic, and Offset number.

• Offset Reference: Index of tool on this carriage where the NC offset will move to.

• Offset X: Offset to baseline; this value will be negative if the process tool is in front of the baseline.

• Processes: List of processes the tool will support.

• [1]: This parameter designates the first supported process of the tool:

• Corner Cooling: Process supports corner cooling after cutting.

• Corner Speed: Process supports

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corner speed reduction commands from CNC.

• Corner Stop: Process supports corner stop commands from CNC.

• Cutting Oxygen Off: Process supports turning off the cut oxygen.

• Edge Cutting: Process supports edge start cutting.

• Flying End: Process supports flying ends.

• Flying Start: Process supports flying starts.

• Kerf: Process requires a kerf measurement.

• Power Reduction: Process supports reducing power at end of cut.

• Preheating: Process supports the preheating of the plate surface for piercing.

• Text: Process has the ability to perform text marking.

• Reference: Select Yes if this tool determines the position of the carriage.

• Type: The type of process tool can be changed from this drop-list. Selections made here will be updated in the machine design model as well.

Bevel Unit and Rotation Unit parameter sets will appear above the Technology parameter set if Yes is selected in Bevelling and Rotation Unit respectively.

See content below for these parameters sets.

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• Bevel Unit...

• Automatic Adjustment: Tool can change bevelling angle automatically from CNC commands.

• Home Position Left: Default (home) position of left oxyfuel torch. This parameter is used only with triple torch tools.

• Home Position Left: Default (home) position of right oxyfuel torch. This parameter is used only with triple torch tools.

• Maximum Angle: Maximum positive angle of torch. When used with triple torch tools, this parameter is assigned to the left oxyfuel torch.

• Maximum Angle Right: Maximum positive angle of right oxyfuel torch. This parameter is used only with triple torch tools.

• Minimum Angle: Maximum negative angle of torch. When used with triple torch tools, this parameter is assigned to the left oxyfuel torch.

• Minimum Angle Right: Maximum negative angle of right oxyfuel torch. This parameter is used only with triple torch tools.

• Rotation Unit...

• Limited: This parameter determines if rotation unit is limited (Yes) or can rotate infinitely (No).

• Maximum Angle: Defines the maximum positive angle that limited rotation units can achieve. This parameter will only be used if the Limited parameter above is set to Yes.

• Minimum Angle: Defines the maximum negative angle that limited rotation units can achieve. This parameter will only be used if the Limited parameter above is set to Yes.

• Numeric: This parameter determines if rotation unit is controlled numerically.

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Process Tool Icons

Below are the available process tools that can be added to the machine design model. Process tools can be added by highlighting a station and clicking a tool icon or by dragging the tool icon to the station; to remove process tools, right-click the tool in the machine model and click Delete or drag the tool icon to the recycle bin.

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D E

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F

Oxyfuel torch

Oxyfuel Triple torch

Plasma torch

Laser torch

Waterjet torch

Punch marker

Powder marker

Plasma marker

Laser marker

Inkjet marker

Oxyfuel torch (secondary)

Oxyfuel Triple torch (secondary)

Plasma torch (secondary)

Plasma torch (tertiary)

Laser torch (secondary)

Waterjet (secondary)

Laser pointer

Drilling tool

Milling tool

Grinding tool

Plate alignment tool

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B

C

D

E

F

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Placement Stopper Parameters

Clicking any stopper on the machine design model will display that stopper’s parameters in the properties tab. Placement stoppers are added/removed to/from machine design models in the same manner as carriages and stations.

• Tool...

• Alignment: Determines side of the table the plate is aligned to. The stopper icon will change to reflect any changes.

• Area: Unique number given to area of stopper placement.

• Distance: Sets the distance between two placement stoppers, measured from the left stopper.

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Left aligned placement stopper

Right aligned placement stopper

Placement stopper #2 (selected)

Distance between stoppers #2 and #3

Placement stopper #3

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Practical Application

Now that basic components used in designing a cutting machine have been discussed, we will use some cutting machine scenarios below to fully illustrate the creation of machine design models. The following icons will be used to detail machine scenarios:

Manual band clamping

Automatic band clamping

CNC

Motor driven carriage

Band clamped carriage

Fixed / attached carriage

Rotation unit

Oxyfuel torch

Oxyfuel triple torch

Plasma torch

Plasma bevel torch

Marking torch

Waterjet torch

Laser torch

Material removal torch

Laser pointer

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Scenario #1 - Perfection Electric Company

You are a programming engineer for a large manufacturing facility that builds power generators. These generators are used with all types of turbines (steam, gas, and hydroelectric) and diesel engines. Perfection Electric has purchased a new ESAB Suprarex™ cutting machine to increase productivity at it’s North Carolina plant.

Your new task will be to take the cutting machine specifications provided and design the machine design model. The Columbus III™ software has been installed on your PC and the new machine is currently being installed on site.

The following information is presented to you in the form of engineering specifications, purchasing contracts, and sales documents:

• Machine is 18’ [5.5 meters] wide.

• Uses a 64’ [19.5m] rail system for longitudinal travel.

• Existing downdraft table is 12’ [3.7m] wide and 58’ [17.7m] long. The available cutting area on the table width is 10’ [3m].

• Using all the information provided, you determine that:

• CNC is located on the left.

• machine has four carriages; two motorized; two use automatic band-clamping.

• left to right, first motor-driven carriage has one station, containing one plasma torch and a laser pointer.

• the next two band-clamp carriages contain one oxyfuel torch station each.

Perfection Electric Suprarex™ 5500 - machine representation

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• second motor-driven carriage has one oxyfuel triple torch, with the following specifications:

• rotation is limited to ±540°.

• bevel torch minimum/maximum angles are 25°/55° respectively and auto adjusted using the CNC.

• all process tools use some type of automatic height control.

Creating the Machine Design Model

1. Double-click Machines in the Explorer browser tree to open the Machines tab.

2. Click on the Add New Item icon.

3. Rename this machine PERFECTION ELECTRIC press Enter to set the name.

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3

4. Right-click PERFECTION ELECTRIC and select Machine Designer.

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The following default machine design model will be displayed:

5. Click on the CNC icon in machine design model; CNC parameters will be displayed in the Properties browser tree .

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a. Since this facility is located in United States (North Carolina), change the File Extension from *.mpg to *.EIA.

b. Select Folder and click the Options icon . Choose a location where the machine’s CNC can access the generated NC output files.

c. Select Format and click the Options icon . In the Select Profile window , click the Profile drop-list icon , select <Eia US Default> and press OK.

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6. In the machine model, right-click the oxyfuel torch and delete it. You will now have motor-driven carriage #1 with an empty station.

7. Click the drop-list icon on the process tool menu and select Add Laser Pointer .

8. Reviewing the order, this station also contains a standard plasma torch - click Add Plasma Torch . At this time, ignore the dimension between the two process tools.

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The machine model should look identical to this illustration (at left):

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9. Click the cutting table to deselect all components on the model. From carraige/station menu, click the Add an Automatic Clamped Carriage icon; the new carriage #2 should be on the right side of carriage #1.

10. Select carriage #2 and click Add Oxyfuel Torch icon. Station #2 and an oxyfuel torch will be added to carriage #2. Ignore the distance dimension between tools.

11. Repeat steps 9 and 10 above for the second oxyfuel station. The machine model should look identical to the illustration below:

12. Click the cutting table to deselect all components on the model. Click the Add a Motorized Carriage icon; carriage #4 will appear to the right of carriage #3.

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13. Select carriage #4 and click Add Oxyfuel Triple Torch icon. Station #4 and torch will be added to carriage #4. Ignore the distance dimension between tools.

The machine model should look identical to the illustration below:

At this point, all assemblies have been added to the machine. However, parameters for these assemblies currently hold default values. We will now verify these against the machine information available and modify them, if needed. Complex process tools will require some parameter adjustment. Continue with the steps below to review these parameters:

Hotline and Support.

Fine tuning of assembly parameters can be complex!

If you have trouble with these or any Columbus III™ issue, please allow us to assist you. Use the Hotline and Support information found on the last page of this manual.

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Verifying/Modifying Parameters

Each model assembly is defined by specialized parameters. These are accessed by selecting assemblies within the machine design model. All parameters can be found in the Properties browser tree. We will now verify all parameters for each design model assembly for the Perfection Electric project. The assembly parameter groups include:

• CNC

• Machine

• Carriage

• Station

• Process tools

• Placement stoppers

CNC parameters for Perfection Electric were verified previously when the machine design model was created (see step #5 above); this procedure will continue with the remaining parameters:

1. Click on the cutting table in the machine design model; default machine parameters are displayed in the Properties browser tree:

Cutting table

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• Y-Bevelling should be set to No; this machine’s single torches do not support Y bevelling.

• Y-Bevel mode will automatically be set to No due to the Y-Bevelling parameter selection above.

• Additional Processes should not be modified; additional processes are not applicable for this project.

• Controller should remain at the default Left setting based on provided information.

• Type should be set to Suprarex.

• Text Marking should be set to Yes; this machine is equipped with a PT-36 plasma torch, which has the ability to both cut and mark. In marking mode, text marking can be generated.

2. With machine parameters verified, select carriage #1 in the machine design model; default carriage parameters are displayed in the Properties browser tree:

• Can Park parameter should remain at the default setting of Yes; all carriages have this ability unless otherwise stated.

• Carriage Id parameter should remain at the default setting of 1; it is the closest carriage to machine CNC.

• Clamping Type parameter should not be modified; the carriage clamping was determined at model creation.

• Park Position parameter should not be modified.

• Spacing by Moving parameter should remain at the default setting of No unless otherwise specified in machine documentation.

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3. Repeat parameter verification (step 2 above) for carriages #2 and #3. Note that Park Position and Spacing by Moving parameters will be replaced with the Leader parameter; leave this parameter at its default state of 1.

4. Repeat the parameter verification (step 2 above) for carriage #4. Carriage Id should remain at the default setting of 4.

5. Select each station in the machine design model:

• Station Id parameters should remain at their default settings.

• Virtual should remain at the default setting of No.

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6. Select the oxyfuel triple torch located on carriage/station #4. Before looking at parameters, review the technical information we received for this tool:

• rotation is limited to ±540°.

• bevel torch minimum/maximum angles are 25°/55° respectively and auto adjusted using the CNC.

• all process tools use some type of automatic height control (AHC).

7. Extended, default parameters for the oxyfuel triple torch are displayed in the Properties browser tree. We will analyze parameters we have information on, starting with the Bevel Unit category:

Parameter Modification

It is highly recommended that you do not modify any parameters without

a firm understanding of the resulting effect. Please contact us first under these circumstances and allow us to

assist you.

• Automatic Adjustment should be set to Yes; the bevelling torches are controlled by the CNC.

• Homeposition parameters should not be modified.

• Maximum Angle should be modified to 55°; this parameter corresponds to left torch on triple torch units.

• Maximum Angle Right should be modified to 55°; this parameter corresponds to right torch on triple torch units.

• Minimum Angle should be modified to 25°.

• Minimum Angle Right should be modified to 25°.

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Parameters for the Bevel Unit category are now verified - continue with Rotation Unit:

• Limited should be changed to Yes.

• Maximum Angle should be changed to 540°.

• Minimum Angle should be changed to 540°.

• Numeric should not be modified.

Rotation Unit parameters are now verified - continue with Technology:

• Alternate Sensor should not be modified.

• Sensor Distance should not be modified.

• Bevelling parameter is set to Yes by selecting an oxyfuel triple torch (default setting).

• Rotation Unit parameter is set to Yes (default setting) by selecting an oxyfuel triple torch.

• Suppress Height Setting should be changed to Yes; this tool uses capacitive AHC.

Technology parameters are now verified - continue with Tool:

• Distance parameters will be discussed later in this procedure and should not be modified at this point.

• Name parameter can be changed based on user’s preference. For training purposes, the default value will be used.

• NC-Offset parameters should not be modified.

• Processes parameters are based on the oxyfuel cutting process.

• Parameters with a value of No are not applicable/available (i.e. corner cooling, flying points, power reduction, etc) for oxyfuel cutting.

• Parameters with a value of Yes are applicable (i.e. cutting oxygen off, edge cutting, preheating, etc) and used with oxyfuel cutting.

• Reference parameter is set to Yes (default), being the only tool on this station.

• Type parameter determines the process tool type and it should not be modified.

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8. Select the oxyfuel torch located on carriage/station #3.

9. Repeat parameter verification procedure (seen in step 15 above) for this tool. Parameters for a standard oxyfuel torch will be identical to the oxyfuel triple torch, with these exceptions:

• Standard oxyfuel stations do not have alternate sensors - keep the default setting of No.

• Standard oxyfuel stations do not rotate or bevel - keep the default setting of No for both parameters.

• All process tools on this machine use some type of AHC. Suppress Height Setting should be changed to Yes.

• Station #3 distance parameters will be discussed later in this procedure and should not be modified at this point.

10. Select the oxyfuel torch located on carriage/station #2.

11. Repeat step 17 above for station #2; this station is identical to station #3.

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12. Select the plasma torch located on carriage/station #1.

13. Repeat parameter verification procedure (seen in step 15 above) for this tool. Begin with the Technology parameters:

• Standard plasma stations do not have alternate sensors - keep the default setting of No.

• For this machine, the plasma station does not rotate or bevel - keep the default setting of No for both parameters.

• All process tools on this machine use some type of AHC. Suppress Height Setting should be remain at the default setting of Yes.

Technology parameters are now verified - continue with Tool parameters:

• Station #1 distance parameters will be discussed later in this procedure and should not be modified at this point.

• Name parameter can be changed based on user’s preference. For training purposes, the default value will be used.

• NC-Offset parameters should not be modified.

• Processes parameters are based on the plasma cutting process. This plasma torch has the ability to cut [1] and mark [2] so it will contain parameters for both processes.

• Parameters with a value of No are not applicable/available (i.e. corner cooling, cutting oxygen off, edge cutting, etc) or possibly not required (corner speed, power reduction, etc) for plasma cutting/marking.

• Parameters with a value of Yes are applicable (i.e. flying points, kerf measurements) and can be used for plasma cutting/marking.

• Reference parameter needs to be changed to Yes so that the plasma torch holds the position of the carriage and not the laser pointer.

• Type parameter determines the process tool type and it should not be modified.

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14. Select the laser pointer located on carriage/station #1. No parameters for this tool will need modification.

15. After reviewing engineering prints, lateral spacing between tools can be modified, moving left to right:

• Distance between laser pointer and plasma torch = 4.0” [102mm].

• Distance between plasma torch and station #2 oxyfuel = 10.0” [254mm].

• Distance between #2 and #3 oxyfuel stations = 8.0” [203mm].

• Distance between #3 oxyfuel and triple torch stations = 12.0” [305mm].

Click each dimension value to set distances. The machine model should look identical to the illustration below:

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16. Define available cutting area using placement stoppers. Reviewing the specifications, we find the cutting area is 10’ or 120”.

• From carraige/station menu, click the Add stopper - Right aligned icon. Stopper #2 will be added to right side of the table model.

• Click on the dimension between both stoppers and set value = 120”.

17. Save your work by clicking the Save icon.

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Scenario #2 - Gulwing Marine Corporation

You are a manufacturing technician for a large company that produces offshore drilling assemblies. Gulwing Marine has purchased a new ESAB Numorex™ cutting machine to lower costs at its plant in Oslo, Sweden.

Your new task will be to take cutting machine specifications provided and design the machine design model. The Columbus III™ software has been installed on your PC and the new machine is currently being installed on site.

The following information is presented to you in the form of engineering specifications, purchasing contracts, and sales documents:

• The machine is 5m [16.4’] wide.

• Uses a 20m [66’] rail system for longitudinal travel.

• Existing downdraft table is 4m [13.1’] wide and 18m [59’] in length. The available cutting area on the table width is 3.5m [11.5’].

• Using all the information provided, you determine that:

• CNC is located on the right.

• machine has four carriages; one motorized; three use manual band-clamping.

• from left to right, the motor-driven carriage has two stations: the first contains one plasma torch with a laser pointer. The second station has a punch marker.

• the first manual band-clamping carriage contain two stations: the first contains one plasma torch and second contains a punch marker.

Gulwing Marine Numorex™ 5000 - machine representation

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• the next two manual band clamp carriages contain one station each and both use standard oxyfuel torches.

• As for spacing, 150mm [5.9”] separates each station and 300mm [11.8”] between all carriages, measured from the stations.

• all process tools use some type of automatic height control (AHC).

• This facility uses ESSI machine code programming.

Using these specifications, create this machine design model, verify parameters, and compare it to the screenshots below:

Machine Design Model Gulwing Marine

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Motorized carriage - two stations - three process tools

Manually clamped carriage - two stations - two process tools

150mm station spacing

3500mm available cutting area

300mm carriage spacing (measured from tools)

CNC located on right side of machine.

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Properties Browser Tree CNC Parameters

Properties Browser Tree Machine Parameters

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Properties Browser Tree Carriage #1 Parameters

Properties Browser Tree Carriage #2 Parameters

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Properties Browser Tree Process Tool #1-1 Parameters

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Properties Browser Tree Process Tool #1-2 Parameters

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Properties Browser Tree Process Tool #2 Parameters

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ESAB CUTTING SYSTEMS GmbH

Robert-Bosch-Str. 20 61184 Karben GermanyTel.: +49 (0) 6039 / 40-0 Fax: +49 (0) 6039 / 40-301E-mail: [email protected] Internet: www.esab-cutting.de

2010 ESAB CUTTING SYSTEMS, Karben, GermanyAll rights reserved. Reproduction or copying in whole or part only with the publisher's written permission.

0560951535_00_121813_Columbus 3 Advanced Operation Manual_ENG

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