Precise, Fast and Reliable CNCs

i Series CNC

CNC Controls from the Market Leader: CNC Controls from the Market Leader:

GE Fanuc Automation

was formed in 1986 as a joint venture by GeneralElectric Co. (GE), USA, andFANUC Ltd, Japan. FANUC has had experiencein production automation formore than 50 years and is the worldwide marketleader in CNC technology.With its broad range of technology, manufacture,and services and roughly300,000 employees, GE is one of the largest companies in the world.

FANUC and GE Fanuc develop and manu-facture state-of-the-art automation productsand solutions. The product range includesboth entry-level and high-performance

CNC products with high-speed functions,digitally controlled servomotors and spindlemotors, and user-friendly operator interfaces.

Continuity in the interest of the userDespite all the innovation with the latesthardware and software, FANUC has alwaysmaintained continuity in its productdevelopment. The installation dimensionshave been maintained wherever possible tomake the changeover to new controlgenerations as easy as possible for machinemanufacturers. Above all, FANUC has alwayskept end users in mind. Anybody who haslearned to handle a FANUC or a GE FanucCNC is able to cope with subsequent modelswithin an extremely short period of time –thus saving on training costs.

High degree of reliability

The high degree of quality and reliability of FANUC orGE Fanuc controls is already almost proverbial. Statisticshave shown that their MTBF (mean time betweenfailures) is 14 years: So when the machine tool isoperating normally, a control-caused failure will occurstatistically only once every 14 years. Users haveconfirmed this reliability in many surveys, and even theautomotive industry – known for its extremely highrequirements – uses FANUC or GE Fanuc controls allover the world. This failure statistic has been honouredwith various awards by many machine tool manu-facturers. Success is a mirror of reliability and quality. Atotal of over 1.4 million FANUC and GE Fanuc CNCcontrols have been distributed to date all over the world.

So many satisfied users cannot be mistaken

In the field of CNC controls, FANUC and GE Fanuc CNCsare the yardsticks against which all others are measured. The standard versions of FANUC or GE Fanuc CNCscover all production applications, from the simplemilling or turning machine to complex systems andmachining centres. They control single or double turretlathes, grinding machines, laser machines, stampingmachines and electro-erosion machines. Adaptation tothe relevant machine is achieved using the extensiverange of hardware and the individual software andoperator control solutions.

Automation from one source

GE Fanuc offers not only controls but also amplifiers,motors, I/O modules, control panels, cables andsoftware solutions, all from one and the same company.All of its CNC products are designed from the outset as asystem and matched as a CNC package, so that theoptimum performance is attained. The user also gets customer service and warranty servicesfrom one source – worldwide.

Precise, Fast, Reliable and Easy to Use Precise, Fast, Reliable and Easy to Use

FANUC has been the forerunner in this technology since the very beginning of CNC development:

• In 1956 FANUC developed the first NC in the non-military sector.

• In 1969 FANUC introduced the first fully modular CNC to the market.

• In 1985 FANUC presented the CNC 0 Series – to date this is the most commonly used CNC in the world

with sales of over 400,000 controls.

• In 1997, the start of the i Series – the latest generation of high-precision, high-speed CNCs.

• In 1999 FANUC launched the is series onto the market, the first CNC with Windows® CE.

• In 2001 the i Series MODEL B was introduced, the first CNC with an Ethernet interface as standard.

Both machine tool manufacturers and endusers profit from the leading-edge technologyof the i Series CNC. Thanks to the integratedLCD, the modular controls are ultra-compactand ultra-flat. The CNCs are equipped withan Ethernet interface as standard and haveoptional PC functionalities.

Highly integrated circuitry developed in-house contributes towards miniaturisationand a low component count. This contributesconsiderably to our renowned reliability anddependability.

Thanks to the limited number of components,the design of the control enclosure is simplifiedand requires a minimum of wiring.

If the control and the monitor are separated,an optical fibre connection provides failure-proof data interchange at distances of up to100 m. A similar optical fibre connection can also beutilised between the control and the drives.Digital technology throughout ensures thatany data transfer can be performed quicklyand loss-free.

Applications:

• Metal Working

• Wood, Marble andGlass Working

• Manufacturing Cells

• Laser, Water jet, Plasmaand Glass Cutting

• EDM

• Handling

• etc.

Technology for Our CustomerTechnology for Our Customer

Speed and precision

• Nano CNC system

• High-speed precisionmachining

• High-speed PMC

• 5-axis machining

• NURBS

Operator friendliness

• Continuity in productdevelopment

• Ergonomic menu configu-ration

• Easy workshop program-ming

Openness and modularity

• Individual configuration

• Ethernet as standard

• Openness for componentsfrom other manufacturers

Nano CNC system

Nano interpolation is a highlight of the Series16i/18i/18i-MB5 CNCs. This calculates thepositioning commands for the digital preci-sion servo-system with nanometre resolution.This interpolation, without rounding theNano value to the smallest command incre-ment, enables the digital system to track the tool path very accurately and smoothlythereby achieving a very high surface quality.

The High Response Vector control (HRV)servo-control, together with Nanointerpolation, generate smooth motionresulting in high surface quality. These twofeatures ensure a smooth servo-feed by

exploiting servo-motor structure, exactcurrent measurement, high-resolution pulseencoder (16,000,000/rev) and fast responseservo-control. The HRV filter suppressesmechanical resonance and ensures a stableservo-system with high amplification.

Several resonance frequencies can be blocked.Fast Digital Signal Processor (DSPs) andadvanced algorithms for automatic currentcontrol provide a fast response characteristicand stable current control circuit.

Shorter control loop sampling and a high-resolution detector contribute to theresponsive and precise control system.

High speed and precision are two terms thatare fundamentally contradictory. The higherthe speed, the more the precision decreases –and vice versa. Although GE Fanuc’sdevelopers cannot change this basic physical

law, they have managed to jointly enhancespeed and precision to a very high level. The functionalities of the i Series CNC makea contribution towards this.

Speed and PrecisionSpeed and Precision

High-speed precision machining

In conjunction with a fast RISC processor, the AI NanoHigh-Precision Contour Control (AI Nano HPCC) allowsmachining with Nano interpolation at an optimal fee-drate thus to fully exploiting the machine capabilities.

With AI Nano HPCC, the acceleration values for theindividual axes can be set separately, thus consideringthe differing inertia of the different axes. This results insmooth acceleration and deceleration resulting in asignificantly reduced path error. Further the feedrateadapts itself automatically to the programmed contour.Although the motion always remains within theacceleration ranges permitted for each axis.

The jerk control is another function that ensures smoothmotion and therefore high surface quality. Contours withsudden changes in direction, force sudden change inacceleration, causing mechanical shock. Jerk Controlsmoothens such awkward transitions by smoothing theacceleration profile, thus reducing the shock.

The smooth motion especially at the region of blocktransitions results in smooth motion and therefore animproved surface quality.

High-speed PMC

The Programmable Machine Control (PMC) is veryimportant in relation to high speed. A specific PMCprocessor is used in the i series CNC, processing evenextensive control sequences at lightning speed. Theexecution time for PMC basic commands is 0.033µs perinstruction step.

The CNC and PMC interchange information via a high-speed interface through which custom functions can alsobe integrated. The CNC now has, as standard, ladderdiagram monitoring and editing functions for easierinterplay with the PMC.

In addition, the improved signal tracking function allowsproblem-free maintenance on site.

The Series 16i-MB/18i-MB5 CNCs support5-axis machining in aninclined plane. Further,with the aid of a fastRISC processor they alsosupport simultaneous5-axis machining.

All standard machineconfigurations aresupported. The machinetool can rotate the toolhead, the rotary table ora combination of the two.

Easy Handling of 5-Axis MachiningEasy Handling of 5-Axis Machining

5-Axis Machining Highlights

• The rotational axes can be controlled andcommanded easily to position the toolvertically to the inclined machining plane.

• Tool Centre Point control (TCP) (Toollength Compensation for simultaneous 5-axis machining): If the direction of thetool axis changes, the movement at the toolcentre point is controlled in such a way that the tool centre point follows the programmed curve.

• The user can set a tool at a specific angle tothe surface (Draft Angle) to avoid the zerospeed zone of a spherical cutter.

• Three-dimensional cutter radiuscompensation enables the control system to

compensate the milling cutter radius in aplane that runs vertically to the inclinedtool direction. For Head Type machineconfigurations, it also compensates theleading edge of an inclined tool motion.

• An arc or an helix can be specified in theinclined plane, and for 5-axis simultaneousmachining.

• The user can manually traverse the toolwithout difficulty by advancing it via ahandwheel or in Jog mode along an inclin-ed surface with the tool being vertically tothat surface. This allows to retract the toolin tool direction, manually via jog mode orhandwheel. The tool can be rotatedmanually around its tool centre point.

NURBS

The Series 16i/18i/18i-MB5 CNCs provide thefacility to use NURBS curves. NURBS presentthe original shape very accurately, since mostCAD systems often store their geometrical datain a NURBS format.

Using NURBS allows to exploit their mathe-matical properties such as continuous transi-tion among blocks. This reduces the jerk –mechanical shock – and ensure smooth,uniform surfaces. As a side effect this also canincrease tool and machine life.

In comparison to an NC part programconsisting of consecutive small programblocks, a NURBS part program is distinctlysmaller. A higher transfer rate from hostcomputer to CNC is not required.

NURBS interpolation supports up to five axissimultaneously and enables extremely complexmachining operations.

Tool center point control for 5-axis machining

Tool radius compensation for 5-axis machining

A modern CNC must have a high-performance capability and at the same timemust be easy to operate. Even the standardproducts of the i Series CNC provide anoperator interface that is simply structuredand self-explanatory. Anybody who has acommand of one FANUC or GE Fanuc CNC

is also able to cope with any other model.Continuity in further development ensuresthis. In all modernisation measures, such as touchscreens, embossed keys etc., the operatorcontrol concept has been retained so thatextensive training courses are unnecessary.

Operator Friendliness andEasy MaintenanceOperator Friendliness andEasy Maintenance

Easy machine preparation

Easy handling begins with preparation of themachine. A single screen enables convenientsetting of the parameters for machining,depending on the relevant machineconfiguration.

For workpiece setup, a selected screenprovides simple instructions, according towhich, the user can calibrate the measuringsensor and then measure the position,surfaces, angle, etc., on the part.

Programming

The user has several ways of producing a NC program. Simple programs can begenerated without difficulty via the standardscreens. These operator interfaces are alsosuitable for quickly and easily checking andamending existing programs.

If the machining becomes more complicated,the user frequently prefers the assistance of a CAD/CAM software system. The NCprogram, which is produced in an externalcomputer, can be transferred via a DNCconnection or data carrier to the control unit.

Particularly popular is the interface, availableon the display unit, for a PCMCIA memorycard. This can be used for data input and output.

Maintenance friendliness

Easy handling of the CNC includes practicalmaintenance and service tools. The maintenance-friendly i Series CNC puts extensive tools at thedisposal of the user:

• On the regular maintenance screen the user candisplay the remaining service life of the machinecomponents that have to be regularly replaced.

• He can file and call up information on themaintenance information screen.

• If any faults occur, a well arranged alarm andprocess data archive allows system diagnosis andconvenient troubleshooting.

• Alarms can be polled in a dialogue on the errordiagnosis screen. This is also applies to the servo-alarms and spindle alarms.

• A Help screen provides alarm-related detailedinformation and the relevant diagnostics. TheseHelp screens can be produced and adaptedmachine-specifically by the machine manufacturer.And if you are at your wits’ end, you can alwaysresort to the remote monitoring– provided that thecontrol has an Internet connection.

• At our service centre, experts will analyse the pro-blem and can frequently help out from afar. If a ser-vice call out is necessary, the service engineer recei-ves important information so that he can select theright parts and optimally prepare his visit.

Workshop programming also has many friends, forwhich GE Fanuc offers special software. The highlightis the Manual Guide i. In version i, the developershave united the functionalities of the two predecessorversions, T (turning) and M (milling). With ManualGuide i, the user can now configure software for aturning, milling or compound machine.

Manual Guide i is a cycle control with a simplifiedCNC operator interface used to program cycles.Various functionalities are available to makecommunication as easy as possible.

• All relevant information is on a single CNC screen,so the user does not have to switch constantlybetween several screens and get lost at some stage inall the pop-up windows.

• Intuitive working is ensured via icons so that even a skilled worker is in a position, without any specialCNC programming experience, to be able to write a program without any documentation whatsoever.

• The user can graphically and interactively constructon-screen the part to be machined, and simulate itin the volume model.

• He can also edit the NC programs with a wordprocessing program and cut or paste randomprogram segments.

• In addition, comments are displayed to him on thebottom area of the screen relating to the G and Mcodes marked by the cursor.

A CNC-controlled machine tool requires closecollaboration between the machine tool andcontrol manufacturer for optimumperformance. GE Fanuc therefore offers themachine tool manufacturer the possibility ofconfiguring the control’s operator interface

to suit his own needs and to introduce hisown functions. GE Fanuc has not only madethe controls open for this purpose, but alsooffers support on various levels. The result isthe increased user friendliness of the machinetool.

Openness and ModularityOpenness and Modularity

Customised adaptation

Screen display and operator control: Via C-EXECUTER the machine-tool manufacturercan create his own special screens, which canbe used instead of the standard CNC screens.The programming language is C.

The FANUC PICTURE program supports theuser in compiling his own screens byarranging components as graphical elements.

Ethernet as standard

GE Fanuc has performed pioneer work in the field of the network capability of CNCs.Since 2001 the i Series MODEL B has beenequipped with an Ethernet interface asstandard. Network connection is availableeither via the integrated Ethernet interface or via a PCMCIA card.

The interchange of large volumes of data viaFast Ethernet (up to 100Mb/s) is possiblesimultaneously between several computers.This is of particular importance for datacommunication between production plantsand the host computer of a manufacturingplant.

Large NC programs, used for the machiningof free-formed surfaces, are transferred withEthernet and are stored on a built-in ATAflash card or hard disk and are executed at ahigh processing speed.

CNC functions: Machine tool manufacturerscan generate custom library of macros thatuse M and G codes. In this way they canprovide their users with fixed cycles that canbe called off at the press of a button.

PMC programming: Machine toolmanufacturers can also influence themachine control. For example, they candevelop applications that are modelled onstructured sequences of ladder logic.

Open CNC

The i Series Open CNC is what its name states. It is theoptimum combination of a CNC and a computer via aserial high-speed interface, enabling the transfer oflarge volumes of data. With it, GE Fanuc supportsindividual applications on special machines that haveto be matched to special customer requirements bythe machine tool manufacturers.

The i Series Open CNC allows individual operatorcontrol of CNC machine tools via a graphic userinterface (GUI), the interchange of large data volumesvia networks, tool file management via a database, anda lot more.

The i Series Open CNC is available with two types ofoperating system, Windows® or Windows® CE.

The Series 160i/180i/210i CNC consist of a stand-alone CNC with a Windows® computer which isconnected to the CNC display via a high-speed opticalfibre interface (HSSB).

The Series 160is/180is/210is CNCs are open CNCswith Windows® CE. This compact operating systemmakes do without a hard disk and for this very reasonprovides extreme reliability in harsh deploymentconditions. These controls are available either as anintegrated CNC complete with a CNC display or as astand-alone version. Here again the Windows® CEcomputer is connected to the CNC via a high-speedoptical fibre interface (HSSB).

Open communication

The i Series CNC controls are open at field level.Many I/O components can be integrated viacommonly available bus systems (FL-net, PROFIBUS-DP,DeviceNet, I/O Link II).

Safety inside

Dual Check Safety is the safety function integratedinto the CNC in accordance with the European safetystandard. A special processor for the monitoring ofsafety-related parameters tracks the actual position andspeed of the servomotors, spindle motors and of theI/O interface, and by means of its redundancy ensures

system of its safety.

Technical DataTechnical Data

16i/160i/160is 18i/180i/180isModel Available MB/TB/LB/PB/LPB/WB MB/MB5/TB/LB/PB/WB

Max. Controlled Axes (Machine Axes x Paths + Loader)Machine Controlled Axes 8 8Simultaneous Controlled Axes 6 4 (5 for MB5)Controlled Path 3 2Loader Control Axes 4 4Max. Spindle Control 4 3Power Mate CNC Manager for additional Axes on I/O LINKPMC Systems SB7 or SD7 SB7 or SD7µs per Step 0,0033 0,0033Max. Steps 64 000 64 000Max. DI/DO Points 2,048/2,048 2,048/2,048Panel Mount I/O ModulesDecentralized Fieldbus I/O ModulesPart Program Storage Length 2,048 KB (5,120m) 1,024 KB (2,560m)Maximum Resolution 0.0001mm, 0.0001deg, 0.00001inchMaximum Resolution 0.00001mm, 0.00001deg, 0.000001inchNumber of Expansion Slots Available (LCD Mounted Version) 0, 2, 3 or 4 0, 2, 3 or 4Number of Expansion Slots Available (Standalone Version) 1 or 3 1 or 3Expansion Slot Option Boards Available 64 Bit RISC Processor 64 Bit RISC Processor

RISC Processor/Data Server RISC Processor/Data ServerSub-CPU Sub-CPU

PMC C Language PMC C LanguageLoader Control Loader Control

Data Server/ATA Interface Data Server/ATA InterfaceHSSB HSSB

PROFIBUS DP PROFIBUS DPDeviceNet DeviceNet

Fast Ethernet Fast EthernetI/O Link II I/O Link II

FL-Net FL-NetSerial Communication Serial CommunicationAnalogue Input Board Analogue Input Board

Ethernet on BoardOpen CNC System (160i/160is) (180i/180is)Communications RS232 RS232

DNC1, DNC2 DNC1, DNC2Ethernet Ethernet

PROFIBUS-DP PROFIBUS-DPDeviceNet DeviceNetI/O Link II I/O Link II

FL-Net FL-NetFront Access PCMCIA Slot Memory Card Memory Card

Ethernet Card Ethernet CardModem Card Modem Card

Standard DisplayMonochrome LCD Screen 7.2" or 9.5" 7.2" or 9.5"Color TFT LCD Screen 8.4" or 10.4" 8.4" or 10.4"Front Access PCMCIA

CNC Display with Windows® (160i/180i/210i only)Processor Intel® Celeron™ / Pentium® Intel® Celeron™ / Pentium®

Memory Up to 512MB Up to 512MBMin Hard Disk Size 40 GB 40 GBOperating System Windows® 2000/XP Windows® 2000/XPUSB PortsSerial PortsFront Access PCMCIAEthernet Port (100BASE-TX)Front Access PCMCIAColor TFT LCD Screen 10.4", 12.1" or 15.0" 10.4", 12.1" or 15.0"Screen Resolution Up to 1,024 X 768 Up to 1,024 X 768

20 20

21i/210i/210isMB/TB

54142

SB7 or SD70,003364 000

2,048/2,048

512 KB (1,280m)

0, 2, 3 or 41 or 3

PMC C LanguageLoader Control

Data Server/ATA InterfaceHSSB

PROFIBUS DPDeviceNet

Fast Ethernet I/O Link II

FL-NetSerial Communication Analogue Input Board

(210i/210is)RS232

DNC1, DNC2Ethernet

PROFIBUS-DPDeviceNetI/O Link II

FL-NetMemory CardEthernet CardModem Card

7.2" or 9.5"8.4" or 10.4"

Intel® Celeron™ / Pentium®

Up to 512MB40 GB

Windows® 2000/XP

10.4", 12.1" or 15.0"Up to 1,024 X 768

16i/160i/160is 18i/180i/180is 21i/210i/210isModel Available MB/TB/LB/PB/LPB/WB MB/MB5/TB/LB/PB/WB MB/TB

CNC Display with Windows® CE 3.0 (160is/180is/210is only)Processor HITACHI SH-4 HITACHI SH-4 HITACHI SH-4Memory 64MB 64MB 64MBFile Memory CompactFlash™ Card CompactFlash™ Card CompactFlash™ CardColor TFT LCD Screen 10.4" or 12.1" 10.4" or 12.1" 10.4" or 12.1"Screen Resolution Up to 800 X 600 Up to 800 X 600 Up to 800 X 600USB PortEthernet Port (100BASE-TX)Front Access PCMCIA

Touch Screen Optional Optional OptionalHandy Machine Operator Panel Optional Optional OptionalPMC C LanguageCNC Macro ExecutorCNC Custom MacroCNC C Language ExecutorConversational ProgrammingDisplay

Graphic DisplayStatus/Program/ParametersLadder Monitoring/EditingServo/Spindle SetupAlarm/Operation HistoryRemote DiagnosticMulti-Language SupportCustomization

Milling FunctionsTurning FunctionsCompound Machining FunctionElectronic Gear Box /Hobbing FunctionsGrinding FunctionsPunching Functions (PB) (PB)Laser Function (LB) (LB)EDM Functions (WB) (WB)Tool FunctionsMeasurement FunctionsGuidance for Machine Preparation FunctionsAccuracy Compensation FunctionsLinear/Circular InterpolationExponential InterpolationHelical InterpolationInvolute InterpolationCylindrical InterpolationPolar Coordinate InterpolationHypothetical InterpolationConical/Spiral InterpolationSmooth InterpolationNano InterpolationNURBS Interpolation5 Axis Machining Functions (MB5)3D Circular Interpolation (MB5)Nano SmoothingAdvanced Preview ControlAI Contour ControlAI Nano Contour ControlHigh Precision Contour ControlAI High Precision Contour ControlAI Nano High Precision Contour ControlJerk ControlRigid TappingSynchronous ControlTandem ControlAdvanced Tandem Control FunctionsTorque ControlAdvanced Acceleration/Deceleration Control Functions

9

CNC controls are noteverything. GE Fanuc offerswhat an automated machinetool needs – amplifiers,servomotors, spindle motors,I/O modules, stationary andmobile operator controlterminals and the relevantcables for them. All of itsCNC products are designedfrom the outset as a systemand are optimally matched asa CNC package.

To support our customers,we have created anextensive global support andservice network. We offer avariety of support servicesand programs to help you getyour GE Fanuc CNC up andrunning and keep it atmaximum productivity.

The CNC Package – Automation from One Stop Shop

GE Fanuc Automation

Europe:GE Fanuc Automation Europe S.A., Zone Industrielle, 6468 Echternach, LuxembourgTel.: (+352) 72 79 79 1, Fax: (+352) 72 79 79 214, www.gefanuc-europe.com

America:GE Fanuc Automation Americas Inc., P.O. Box 8106, Charlottesville, VA - 22906, USATel.: (+1) 434 978 5000, Fax: (+1) 434 978 5035, www.gefanuc.com

Asia/Pacific:FANUC Ltd., Oshino-mura, Yamanashi Prefecture, 410-0597, JapanTel.: (+81) 555-84-5555, Fax: (+81) 555-84-5512, www.fanuc.co.jp

Specifications are subject to changewithout notice. All rights reserved.

©2003 GE Fanuc Automation Europe S.A.

For the location of yournearest GE Fanuc sales representative or authorizeddistributor contact:

04/03 3C GFTE-560-EN