5 Steps to ActiveEdge

5 steps to installing your Zenith Loop with

ActiveEdge tools

Why do I want a Zenith solution?

● Reduce labour costs

● Eliminate scrap

● Fully automated, 24 hour production through lights-out manufacturing

● Micron accurate adjustments & compensations

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5 Steps to ActiveEdge

Step 1 — Machine Control Wiring

ActiveEdge supports Siemens, Fanuc and Mazak machine controls, which covers most CNCs.

We need to have exclusive access to a block of 100 user variables and access to one input and one

output on your CNC, connected to the ActiveEdge Interface using AEI-CABLE01, which is shown in the

below image.

See information and images below for examples of the wiring required for each of the typical

machine types:

Siemens

TYPICAL SIEMENS X132 PANEL WIRING FOR RIGIBORE AEI

BLACK [X124] 0V

RED [X124] +24V

PINK [X124] +24V (This can be doubled with red)

ORANGE [X132] DI 0 Input

WHITE [X132] DI/DO 11

M + M1 MUST BE LINKED

Using this wiring configuration, your inputs and

outputs are as follows:

$A_OUT[1] =1

$A_OUT[1] =0

$A_IN[1] =1

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5 Steps to ActiveEdge

Fanuc

TYPICAL FANUC XT4 I/O PANEL WIRING FOR RIGIBORE AEI

ActiveEdge connections for wire harness AEI-CABLE01

BLACK [33] 0VRED [03] +24E (Red & Pink can be doubled up)PINK [03] +24EORANGE [01] X04.0WHITE [35] Y02.6

Using this wiring configuration on a Fanuc I/O, your inputs and outputs are as follows:

CNC input = #1015

CNC output = ON: M105

CNC output = OFF: M115

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5 Steps to ActiveEdge

Mazak

TYPICAL MAZAK MAZATROL PANEL WIRING FOR RIGIBORE AEI

BLACK [XT155] – 1M = 0V

RED [X155]— 2L+ = +24V

PINK [X155]— 2L+ = +24V (This can be doubled with red)

ORANGE [X155]— = 3155 (Input)

WHITE [X155]— = 12485 (Output)

Using this wiring configuration for the Mazak I/O, your inputs and outputs are as follows:

CNC input = #1030

CNC output = ON: M418

CNC output = OFF: M419

If your machine has these connections available (or similar), and you have taken note of the 100 user

variables and inputs and outputs you can assign to ActiveEdge processes, then move onto the next

step (there is a checklist in step 3 where you can fill out this information)! Please note your

compensations will only be as accurate as your measuring probe, please contact Rigibore if you need

suggestions for suitable measuring probes in your Zenith loop.

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5 Steps to ActiveEdge

Step 2 — Networking & Software Setup

Now your tools are designed and we know your machine is compatible, this is a good time to

consider how you would like to connect your AEI to the network. While it is highly recommended

that you connect your Zenith loop to your factory network, it is possible to install it on a separate

(ad-hoc) network if required.

The free software “ActiveNet” allows you to monitor every step, check tool statuses, battery levels,

and keep your ActiveEdge firmware and cartridge library up to date. ActiveNet is available as a free

download for Windows PCs from the Rigibore website.

ActiveEdge can support tools with up to 7 cartridges. In the screenshot you can see multiple tabs,

each one represents an ActiveEdge Interface which may correspond to each manufacturing line. Each

ActiveEdge Interface can support an unlimited number of ActiveEdge tools.

The AEI or “ActiveEdge Interface” can connect to your network in one of two ways:

● DHCP - This setting is very easy to connect to ActiveNet, just plug your AEI into the network

with an ethernet cable, open ActiveNet > AEI Management > Add Interface and enter the

AEI’s specific number and press “Get IP”, for example “AEI02159”. ActiveNet will fetch the IP

automatically (using DNS) and open a new tab in the software, the light will go green when it

is connected.

● Static IP - This method is a little more complicated but is often the preferred option if you

want to give your AEI a permanent address in your network that no other device can take.

This option makes a permanent address for the AEI and will connect regardless if you turn it

off and on again.

You will need to ask IT for a specific IP address that can be allocated to your AEI, the AEI will

then be set up prior to delivery to look for the IP address that has been provided by your IT

department.

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5 Steps to ActiveEdge

Step 3 — Checklist

In this section we provide a checklist to ensure that all aspects required for a smooth installation

have been completed.

1. Has Rigibore been provided with 100 user variables and I /O configuration ?

You can choose any block of user variables as long as it is available exclusively for Rigibore

use, this is essential for the system to make micron accurate compensations.

Please fill in the table below:

Control system (Siemens, Mazak or Fanuc)

Block of 100 user variables (eg Siemens RAE,R,GD, GUD) exam RAE 100 -> RAE 200

Inputs & Outputs exam $A_IN[1] input,$A_OUT[1]=1 output on $A_OUT[1]=0 outputoff

2. Has the tool design been finalised and the drawing signed off?

You’ve now designed your tools in RADS, or had your tools designed in house. The design has

been finalised at Rigibore, there is a mutual agreement on the complete design.

3. Has Rigibore been provided with your network preferences?

DCHP or Static IP, please ask your IT department which network settings would be preferable.

Please tick the relevant tables below and provide relevant information, if applicable:

DCHP (easy to connect, simply connect viaethernet cable and search for AEI on ActiveNet,it will grab a IP automatically)

Static IP (this requires pre-configuration atRigibore, we will tell your AEI to look for a IPaddress that your IT department has specified)

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5 Steps to ActiveEdge

Step 4 — Connection Testing

With the checklist complete and following a completed purchase order, we can now start

manufacturing your custom tools. This can usually take up to 8 weeks so to make good use of the

time, we will send you a few things straight away to get started;

Your customised programs and subprograms also known as macros which can be included in your

main production program. These must be placed in the appropriate folders.

AE-Cable-01

This connects your Machine’s I/O & power to the ActiveEdge AEI

AE-TESTBOX

This is sent on loan to be returned, along with a test script for your machine to test if the cable has

been fitted correctly before your tools arrive.

Plug the AE-CABLE-01 into your machine as

described in Step 1 and as you have recorded in

Step 4.

Plug the AE-TESTBOX into AE-CABLE-01 and run

Program 8536. If the AE-TESTBOX LED lights

up, everything is connected correctly.

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5 Steps to ActiveEdge

Step 5 — Calibration

1) Set your antenna within a reasonable distance from your ActiveEdge tool.

2) Connect the antenna into the jack on the right of the AEI and the network cable into the jack

on the left.

Then connecting AE-CABLE-01 into the AEI completes all your connection requirements.

One final step to take before you're ready to go. The AEI needs to create a timing profile for the

messages sent between the AEI and the machine control.

This process takes around 7 minutes in total to complete. Now you have your programs and

subprograms sitting in the correct folders, look for the program “8500” and execute this program, it

will take around 5 minutes to complete.

Once complete it will drop a new file “8510” into your AEI, you can access this file by opening

ActiveNet, connecting to your AEI and looking in the AEI system folder, found in the AEI management

drop down menu. Do not delete or edit any of the files in the AEI system folder!

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5 Steps to ActiveEdge

Put the 8510 file onto a memory stick and copy the file onto your machine control in the relevant

folder.

And now your Zenith loop is up and running! You can now use our macros in your main production

program for micron accurate compensations!

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