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, manufacturingand 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 work 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 legendary. 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 honoredwith various awards by many machine tool manufacturers.Success is a mirror of reliability and quality. A total ofover 1.4 million FANUC and GE Fanuc CNC controlshave 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 centers. 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 and softwaresolutions, all from one company. All of its CNC productsare designed from the outset as a system and matched as a CNC package, so that the optimum performance isattained. The user also gets customer service and warranty services from 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 miniaturizationand 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 fiber connection provides failure-proof data interchange at distances of up to 100 m.

A similar optical fiber connection can also beutilized between the control and the drives.Digital technology throughout ensures thatany data transfer can be performed quicklyand loss-free.

Applications:

• Metalworking

• 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 configuration

• Easy workshop programming

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 precisionservo-system with nanometer resolution. Thisinterpolation, without rounding the Nano valueto the smallest command increment, enablesthe digital system to track the tool path veryaccurately and smoothly thereby 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) allows machining with Nano interpolation at an optimalfeedrate to fully exploit 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 in smooth acceleration and deceleration resulting in a significantly reduced path error. Further, the feedrateadapts itself automatically to the programmed contour,although the motion always remains within theacceleration ranges permitted for each axis.

Jerk control is another function that ensures smoothmotion and therefore high surface quality. Contours with sudden changes in direction, force sudden changein acceleration, causing mechanical shock. Jerk controlreduces such awkward transitions by smoothing theacceleration profile, thus reducing the shock.

The smooth motion, especially at the region of blocktransitions, results in an improved 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 exchange information via a high-speed interface through which custom functions can also be 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 Center Point control (TCP) (Toollength compensation for simultaneous 5-axis machining): If the direction of thetool axis changes, the movement at the toolcenter point is controlled in such a way that the tool center 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 a 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 inclinedsurface with the tool being vertical to thatsurface. This allows the user to retract thetool in the tool direction, manually via Jog mode or handwheel. The tool can berotated manually around its tool center 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 makes it possible to exploit theirmathematical properties such as continuoustransition among blocks. This reduces the jerk– mechanical shock – and ensures smooth,uniform surfaces. As a side effect this also can increase 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 axessimultaneously 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 high-performancecapability and at the same time must be easyto operate. Even the standard products of thei Series CNC provide an operator interfacethat is simply structured and self-explanatory.Anybody who has a command of one FANUCor GE Fanuc CNC is also able to work with

any other model. Continuity in furtherdevelopment ensures this.

In all modernization 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 by which the user can calibrate the measuring sensor andthen measure the position, surfaces, angle,etc., on the part.

Programming

The user has several ways of producing an 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 memory card.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 can display the remaining service life of the machinecomponents that have to be regularly replaced.

• The user can file and call up information on themaintenance information screen.

• If any faults occur, a well arranged alarm and processdata archive allows system diagnosis and convenienttroubleshooting.

• Alarms can be polled in a dialogue on the errordiagnosis screen. This 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.

• The user can take advantage of remote monitoring,provided that the control has an Internet connection.

• At our service center, experts will analyze the problemand can frequently help from afar. If a service call isnecessary, the service engineer receives importantinformation so that he can select the right parts and optimally prepare his visit.

GE Fanuc offers special software for workshopprogramming. The highlight is the Manual Guide i. In version i, the developers have united thefunctionalities of the two predecessor versions, T (turning) and M (milling). With Manual Guide i,the user can now configure software for a turning,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.

• The user can also edit the NC programs with a word processing program and cut or paste randomprogram segments.

• In addition, comments are displayed on the bottomarea of the screen relating to the G and M codesmarked 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

Customized adaptation

Screen display and operator control: Via C-EXECUTER the machine-tool manufacturercan create special screens, which can be usedinstead of the standard CNC screens. Theprogramming 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 exchange 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 modeled onstructured sequences of ladder logic.

Open CNC

The i Series Open CNC is what its name states. It is the optimum combination of a CNC and a computervia a serial high-speed interface, enabling the transferof large 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 exchange of large data volumes via networks, tool file management via a database and more.

The i Series Open CNC is available with two types of operating 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 opticalfiber 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 fiber 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

For a detailed list of functions, refer to the i-Series-MODEL B specifications GFTE-525 or the manual GFZ-63522EN

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 Communication

Analog Input Board Analog Input BoardEthernet 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

Analog 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 AutomationGE Fanuc Automation Information Centers

USA and the Americas 1-800-GE FANUC or (434) 978-5100Europe and Middle East (352) 727979-1Asia Pacific 86-21-3222-4555

©2003 GE Fanuc Automation Americas, Inc. All RightsReserved. Windows is a registered trademark of MicrosoftCorporation. All other trademarks and registered trademarksare the property of their respective owners.

GFA-5521K 10/03

Additional ResourcesFor detailed technical specifications and product ordering information, please visit the GE Fanuc website at:

www.gefanuc.com