User manual

Rew. 17 of 10-05-2018
SUMMARY

1 DESCRIPTION OF THE SOFTWARE.................................................................................................... 12

1.1 INSTALLATION ................................................................................................................................... 12
1.1.1 PC minimum requirements ........................................................................................................ 12
2 OPERATOR INTERFACE ...................................................................................................................... 13
3 PROJECT ............................................................................................................................................... 14
3.1 PROJECT MANAGEMENT .................................................................................................................... 15
3.1.1 Project default ............................................................................................................................ 16
3.1.1.1 Default: "Project name” .................................................................................................................... 16
3.1.1.2 Default “Project folder” ..................................................................................................................... 16
3.1.1.3 Save the configuration parameters .................................................................................................. 17
3.1.1.4 Restore the configuration parameters .............................................................................................. 18
3.1.2 New project setting .................................................................................................................... 19
3.1.3 Open an existing project ............................................................................................................ 19
3.1.4 Import Pgm/Xxl .......................................................................................................................... 20
3.1.5 Import 3D template .................................................................................................................... 22
3.1.6 Import from STL ......................................................................................................................... 22
3.1.7 Import Image .............................................................................................................................. 23
3.1.8 End project ................................................................................................................................. 24
3.1.9 Save Project ............................................................................................................................... 25
3.1.10 Project Graphic display .......................................................................................................... 26
3.1.10.1 What you see of the project ............................................................................................................. 26
3.1.10.2 Where to see the project .................................................................................................................. 27
3.1.10.2.1 Zoom.......................................................................................................................................... 28
3.1.10.2.2 Pan ............................................................................................................................................ 28
3.1.10.2.3 Orbit ........................................................................................................................................... 28
3.1.10.3 How to see the project ..................................................................................................................... 29
3.2 W ORKPIECE ..................................................................................................................................... 31
3.2.1 Rough workpiece ....................................................................................................................... 31
3.2.2 Finalised workpiece ................................................................................................................... 31
3.2.2.1 Parallelepiped shaped workpiece .................................................................................................... 31
3.2.2.2 Extruded workpiece ......................................................................................................................... 32
3.2.2.2.1 New geometry creation for extruded ........................................................................................... 33
3.2.2.2.2 Geometry importing for extruded from another workpiece .......................................................... 33
3.2.2.2.3 Geometry importing for extruded from dxf ................................................................................... 33
3.2.3 Change workpiece dimensions .................................................................................................. 33
3.2.4 Import the workpiece .................................................................................................................. 34
3.2.5 workpiece Removal .................................................................................................................... 34
3.3 W ORKING PLANES............................................................................................................................. 35
3.3.1 Standard Faces .......................................................................................................................... 36
3.3.2 Parallel Plane ............................................................................................................................. 37
3.3.3 Inclined Plane ............................................................................................................................ 38
3.3.4 Plane from surface area ............................................................................................................. 39
3.3.5 Work plane tree .......................................................................................................................... 40
3.3.5.1 Work plane selection........................................................................................................................ 40
3.3.5.2 Properties and plane modification .................................................................................................... 41
3.3.5.3 Plane removal .................................................................................................................................. 41
3.3.5.4 Displaying working processes on planes ......................................................................................... 42
3.4 GEOMETRIES .................................................................................................................................... 43
3.4.1 Enter new 2D geometries .......................................................................................................... 43
3.4.1.1 Type a new point.............................................................................................................................. 44
3.4.1.2 Type an existing point by using the Osnap ...................................................................................... 45
3.4.1.3 Point................................................................................................................................................. 46
3.4.1.4 Line .................................................................................................................................................. 47
3.4.1.5 Arc ................................................................................................................................................... 48
3.4.1.6 Circle................................................................................................................................................ 50
3.4.1.7 Polyline ............................................................................................................................................ 52
3.4.1.8 Rectangle......................................................................................................................................... 53
3.4.1.9 Buttonhole........................................................................................................................................ 54

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 3.4.1.10 Loop line .......................................................................................................................................... 55
3.4.1.11 Smooth ............................................................................................................................................ 56
3.4.1.12 Offset ............................................................................................................................................... 57
3.4.1.13 Text .................................................................................................................................................. 58
3.4.2 Inserting blocking profile ............................................................................................................ 59
3.4.3 Enter new surfaces .................................................................................................................... 60
3.4.3.1 Flat surface ...................................................................................................................................... 61
3.4.3.2 Linear extrusion ............................................................................................................................... 62
3.4.3.3 Revolution ........................................................................................................................................ 62
3.4.3.4 Mesh lined ....................................................................................................................................... 63
3.4.3.5 Mesh corner ..................................................................................................................................... 63
3.4.3.6 Section surface ................................................................................................................................ 63
3.4.3.7 Sweeping ......................................................................................................................................... 64
3.4.4 Insertion of solids ....................................................................................................................... 65
3.4.4.1 Parallelepiped .................................................................................................................................. 65
3.4.4.2 Sphere ............................................................................................................................................. 66
3.4.4.3 Cylinder............................................................................................................................................ 66
3.4.4.4 Cone ................................................................................................................................................ 67
3.4.4.5 Pyramid............................................................................................................................................ 67
3.4.5 Enter new 3D curves .................................................................................................................. 68
3.4.5.1 3D arc .............................................................................................................................................. 68
3.4.5.2 3D composite line ............................................................................................................................ 69
3.4.5.3 Projection ......................................................................................................................................... 69
3.4.5.4 Normal surface projection ................................................................................................................ 70
3.4.5.5 Wrapping ......................................................................................................................................... 70
3.4.5.6 Extract surface edges ...................................................................................................................... 70
3.4.6 2D geometry imported from DXF ............................................................................................... 71
3.4.6.1 2D geometries advanced import from DXF ...................................................................................... 74
3.4.6.1.1 Import 2D geometries from DXF for machining ........................................................................... 76
3.4.6.1.2 Import 2D geometries from DXF for edge banding...................................................................... 83
3.4.7 Geometry selection .................................................................................................................... 87
3.4.8 Contextual Menu of graphic area ............................................................................................... 88
3.4.9 Geometry removal ..................................................................................................................... 89
3.4.10 Geometry properties .............................................................................................................. 89
3.4.11 Change existing geometries .................................................................................................. 90
3.4.11.1 Cut ................................................................................................................................................... 90
3.4.11.2 Extend.............................................................................................................................................. 90
3.4.11.3 Invert ................................................................................................................................................ 91
3.4.11.4 Initial point........................................................................................................................................ 91
3.4.11.5 Join .................................................................................................................................................. 91
3.4.11.6 Explode ............................................................................................................................................ 92
3.4.11.7 Change surfaces .............................................................................................................................. 93
3.4.11.7.1 Extend surfaces ......................................................................................................................... 93
3.4.11.7.2 Intersection between surfaces ................................................................................................... 93
3.4.11.7.3 Cut surface ................................................................................................................................ 94
3.4.12 Move and/or copy the existing geometries ............................................................................ 95
3.4.12.1 Move ................................................................................................................................................ 96
3.4.12.2 Rotate .............................................................................................................................................. 97
3.4.12.3 Mirror ............................................................................................................................................... 98
3.4.12.4 Oppose ............................................................................................................................................ 99
3.4.12.5 Cut ................................................................................................................................................. 100
3.4.12.6 Copy .............................................................................................................................................. 100
3.4.12.7 Paste.............................................................................................................................................. 100
3.5 W ORKING PROCESSES .................................................................................................................... 101
3.5.1 Boring ....................................................................................................................................... 102
3.5.1.1 Bore position .................................................................................................................................. 102
3.5.1.2 Bore structure ................................................................................................................................ 103
3.5.1.3 Boring mode .................................................................................................................................. 104
3.5.1.4 Boring technology .......................................................................................................................... 104
3.5.1.5 Drilling deduced from the surface .................................................................................................. 104
3.5.2 Inclined drilling ......................................................................................................................... 105
3.5.2.1 Position of the inclined hole ........................................................................................................... 105
3.5.2.2 Shape of the inclined hole.............................................................................................................. 105
3.5.2.3 Inclined drilling mode ..................................................................................................................... 106
3.5.2.4 Inclined drilling technology ............................................................................................................. 106
3.5.2.5 Drilling deduced from the surface .................................................................................................. 106
3.5.3 Automatic drilling deduced from the surfaces .......................................................................... 106

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3.5.4 Milling ....................................................................................................................................... 107
3.5.4.1 Miling position ................................................................................................................................ 107
3.5.4.2 Milling form .................................................................................................................................... 110
3.5.4.3 Milling modes ................................................................................................................................. 111
3.5.4.4 Milling technology .......................................................................................................................... 111
3.5.5 Slanted routing ......................................................................................................................... 112
3.5.5.1 Tilting routing position .................................................................................................................... 112
3.5.5.2 Tilting routing shape....................................................................................................................... 112
3.5.5.3 Tilting routing mode ....................................................................................................................... 113
3.5.5.4 Tilting routing technology ............................................................................................................... 113
3.5.6 Chamfering............................................................................................................................... 114
3.5.6.1 Chamfering position ....................................................................................................................... 114
3.5.6.2 Slotting shape ................................................................................................................................ 114
3.5.6.3 Chamfering mode .......................................................................................................................... 115
3.5.6.4 Chamfering technology .................................................................................................................. 115
3.5.7 3D routing................................................................................................................................. 116
3.5.7.1 3D routing position ......................................................................................................................... 116
3.5.7.2 3D routing shape............................................................................................................................ 116
3.5.7.3 3D routing mode ............................................................................................................................ 116
3.5.7.4 3D routing technology .................................................................................................................... 116
3.5.8 Channel .................................................................................................................................... 117
3.5.8.1 Channel position ............................................................................................................................ 117
3.5.8.2 Channel structure........................................................................................................................... 118
3.5.8.3 Channel execution mode ............................................................................................................... 118
3.5.8.4 Channel technology ....................................................................................................................... 118
3.5.8.5 Channel deduced from surface ...................................................................................................... 118
3.5.9 Blade cut .................................................................................................................................. 119
3.5.9.1 Cut position .................................................................................................................................... 120
3.5.9.2 Cut structure .................................................................................................................................. 121
3.5.9.3 Cut mode ....................................................................................................................................... 121
3.5.9.4 Cut technology ............................................................................................................................... 121
3.5.9.5 Cut deduced from the surface ........................................................................................................ 121
3.5.10 Contouring ........................................................................................................................... 122
3.5.10.1 Contouring position ........................................................................................................................ 122
3.5.10.2 Contouring structure ...................................................................................................................... 123
3.5.10.3 Contouring modes.......................................................................................................................... 123
3.5.10.4 Contouring technology ................................................................................................................... 123
3.5.11 Emptying .............................................................................................................................. 124
3.5.11.1 Emptying position........................................................................................................................... 124
3.5.11.2 Emptying structure ......................................................................................................................... 125
3.5.11.3 Emptying mode .............................................................................................................................. 125
3.5.11.4 Emptying technology...................................................................................................................... 125
3.5.12 Work on the lower face ........................................................................................................ 126
3.5.13 Technological data (shared by the machining operations) .................................................. 127
3.5.14 Approach/Retraction (shared by the machining operations) ............................................... 128
3.5.15 Advanced data (common to machinings) ............................................................................ 129
3.5.16 Machine data (shared by the machining operations) .......................................................... 131
3.5.16.1 Jerk ................................................................................................................................................ 131
3.5.16.2 Jerk3D ........................................................................................................................................... 132
3.5.16.3 Main hood ...................................................................................................................................... 132
3.5.16.4 Additional hood .............................................................................................................................. 132
3.5.16.5 Rotating axes brakes ..................................................................................................................... 133
3.5.16.6 5-axes head unrolling..................................................................................................................... 133
3.5.16.7 Electronic feeler ............................................................................................................................. 133
3.5.16.8 NC speed adjustment .................................................................................................................... 134
3.5.16.9 Tool blower .................................................................................................................................... 134
3.5.16.10 Mechanical hold-down .............................................................................................................. 134
3.5.17 Edge banding process ......................................................................................................... 135
3.5.17.1 Edge banding ................................................................................................................................. 135
3.5.17.1.1 Technological Data .................................................................................................................. 136
3.5.17.1.2 Approach/Retraction Data ........................................................................................................ 139
3.5.17.1.3 Edge banding advanced data .................................................................................................. 140
3.5.17.1.4 Machine Data ........................................................................................................................... 140
3.5.17.2 End trimming .................................................................................................................................. 141
3.5.17.3 Trimming ........................................................................................................................................ 143
3.5.17.4 Scraping......................................................................................................................................... 144
3.5.17.5 Shaving .......................................................................................................................................... 145

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 3.5.17.6 Edge Banding default settings ....................................................................................................... 146
3.5.17.6.1 Edge banding Default .............................................................................................................. 146
3.5.17.6.2 End trimming default ................................................................................................................ 149
3.5.17.6.3 Trimming default ...................................................................................................................... 149
3.5.17.6.4 Scraping default ....................................................................................................................... 150
3.5.17.6.5 Shaving default ........................................................................................................................ 150
3.5.18 Attributes .............................................................................................................................. 151
3.5.18.1 Depth ............................................................................................................................................. 151
3.5.18.2 Speed ............................................................................................................................................ 152
3.5.18.3 Microjoints ...................................................................................................................................... 155
3.5.18.4 Start work ....................................................................................................................................... 160
3.5.18.5 End work ........................................................................................................................................ 161
3.5.18.6 Edge banding attributes ................................................................................................................. 162
3.5.18.6.1 Head rotation ........................................................................................................................... 162
3.5.18.6.2 Rotation X ................................................................................................................................ 165
3.5.18.6.3 Ruller stop ................................................................................................................................ 167
3.5.18.6.4 Edge rollers opening ................................................................................................................ 168
3.5.18.6.5 Edge rollers closure ................................................................................................................. 168
3.5.18.6.6 Lamp on ................................................................................................................................... 168
3.5.18.6.7 Edge supply ............................................................................................................................. 170
3.5.18.7 Delete attributes ............................................................................................................................. 171
3.5.19 Working process tree ........................................................................................................... 172
3.5.19.1 Object selection ............................................................................................................................. 172
3.5.19.2 Working process ordering .............................................................................................................. 172
3.5.19.3 Working process display ................................................................................................................ 173
3.5.19.4 Contextual menu ............................................................................................................................ 174
3.5.20 Working process selection ................................................................................................... 175
3.5.21 Contextual menu for working processes ............................................................................. 175
3.5.22 Working process removal .................................................................................................... 175
3.5.23 Working process properties ................................................................................................. 175
3.5.24 Working process modification.............................................................................................. 176
3.5.25 Move and/or copy existing working processes .................................................................... 176
3.5.26 Machining technologies ....................................................................................................... 177
3.5.26.1 Create Technology......................................................................................................................... 177
3.5.26.2 Copy technology ............................................................................................................................ 179
3.5.26.3 Apply technology............................................................................................................................ 180
3.5.27 Display tool path .................................................................................................................. 181
3.6 3D MACHINING................................................................................................................................ 182
3.6.1 Roughing .................................................................................................................................. 183
3.6.2 Finishing ................................................................................................................................... 190
3.6.2.1 Finishing strategies ........................................................................................................................ 191
3.6.2.2 Tool strategies ............................................................................................................................... 193
3.6.3 Swarfing ................................................................................................................................... 194
3.6.4 Routing on surface ................................................................................................................... 197
3.6.5 3D pocketing ............................................................................................................................ 198
3.6.6 Tool path wrap ......................................................................................................................... 199
3.7 MACRO AND SUBPROGRAMS ........................................................................................................... 200
3.7.1 Creating machining-macros (.xsp) ........................................................................................... 200
3.7.1.1 Creazione della struttura base della macro ( wizard); .................................................................... 200
3.7.1.1.1 General parameters .................................................................................................................. 201
3.7.1.1.2 Image selection ......................................................................................................................... 203
3.7.1.1.3 Parameters ............................................................................................................................... 204
3.7.1.1.4 Groups ...................................................................................................................................... 205
3.7.1.1.5 Languages ................................................................................................................................ 206
3.7.1.1.6 Macro Management .................................................................................................................. 208
3.7.1.2 Implementation of the functions in the macro. ............................................................................... 209
3.7.2 Create Subprograms (.xsp)...................................................................................................... 209
3.7.2.1 Create project ................................................................................................................................ 209
3.7.2.2 Define the parameters ................................................................................................................... 210
3.7.2.3 Save the sub-program ................................................................................................................... 211
3.7.2.4 Open an existing sub-program ....................................................................................................... 213
3.7.3 Use of .XSP macros and subprograms ................................................................................... 214
3.7.4 Imort Script (.xcs) ..................................................................................................................... 215
3.8 NC FUNCTIONS............................................................................................................................... 216
3.8.1 Enter an ISO instruction ........................................................................................................... 217
3.8.2 Machine parking ....................................................................................................................... 218

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 3.8.3 Null operation ........................................................................................................................... 219
3.8.4 Workpiece probing ................................................................................................................... 220
3.8.4.1 Probing with side position correction.............................................................................................. 220
3.8.4.2 Probing with tool length correction ................................................................................................. 221
3.8.4.3 Probing with workpiece roto-translation ......................................................................................... 222
3.8.5 Display an operator message .................................................................................................. 223
3.8.6 Table cleaning .......................................................................................................................... 224
3.8.7 DY check .................................................................................................................................. 226
3.8.7.1 Automatic DY control ..................................................................................................................... 227
3.9 W ORKING STEPS ............................................................................................................................ 228
3.9.1 Working step tree ..................................................................................................................... 228
3.9.2 Inserting a working step ........................................................................................................... 229
3.9.3 Removal of a working step....................................................................................................... 229
3.9.4 Working step properties ........................................................................................................... 230
3.9.5 Modifying the workpiece position in one step .......................................................................... 230
3.9.6 Moving working processes from one step to another one ....................................................... 231
3.9.7 Add workpiece name to working process name ...................................................................... 232
3.9.8 Sub-programs Activation/Deactivation ..................................................................................... 233
3.10 W ORKPIECES LAYOUT IN MACHINE ................................................................................................... 234
3.10.1 Choice of work area, references and devices ..................................................................... 235
3.10.1.1 Work area selection ....................................................................................................................... 235
3.10.1.2 References Selection ..................................................................................................................... 236
3.10.1.3 Type of blocking selection.............................................................................................................. 236
3.10.2 Adding pieces on the machine plane................................................................................... 237
3.10.3 Workpieces positioning ........................................................................................................ 238
3.10.4 Elimination of pieces from the machine plane ..................................................................... 239
3.11 DEFINITION OF THE BLOCKING SYSTEM ............................................................................................. 240
3.11.1 Workpiece blocking with clamps .......................................................................................... 240
3.11.1.1 Type of clamp ................................................................................................................................ 240
3.11.1.1.1 Clamps with round plate .......................................................................................................... 241
3.11.1.1.2 Clamps with rectangular plate .................................................................................................. 241
3.11.1.1.3 Clamps with reference stops .................................................................................................... 241
3.11.1.1.4 Horizontal clamps .................................................................................................................... 242
3.11.1.2 Type of clamp selection ................................................................................................................. 243
3.11.1.3 Clamps positioning on the bars ...................................................................................................... 243
3.11.1.4 Saving plane layout........................................................................................................................ 244
3.11.1.5 Reusing the plane layout ............................................................................................................... 244
3.11.1.6 Blocking states of clamps .............................................................................................................. 245
3.11.1.6.1 Blocking state change .............................................................................................................. 245
3.11.1.6.2 Blocking state display .............................................................................................................. 246
3.11.1.7 Clamps positioning on workpiece................................................................................................... 247
3.11.1.7.1 Manual clamps positioning ....................................................................................................... 248
3.11.1.7.2 Manual clamps' positioning with blocking profile ...................................................................... 248
3.11.1.7.3 Automatic clamps' positioning with blocking profile.................................................................. 250
3.11.1.7.4 Positioning terminals outside the work area ............................................................................. 251
3.11.1.7.5 Enables the positioning of the clamps on the piece edge ........................................................ 252
3.11.1.8 Initial setup creation ....................................................................................................................... 253
3.11.1.9 Final setup creation........................................................................................................................ 253
3.11.1.10 Cycles generation for clamps exchange ................................................................................... 254
3.11.1.11 Cycles elimination for clamps exchange ................................................................................... 254
3.11.2 Workpiece blocking with suction devices ............................................................................ 255
3.11.3 Easier Load.......................................................................................................................... 256
3.11.3.1 Easier Load Insertion ..................................................................................................................... 256
3.11.3.1.1 Preset of easier load ................................................................................................................ 258
3.11.3.1.2 Preset of easier load creation/change...................................................................................... 258
3.11.3.1.3 Preset of easier load use ......................................................................................................... 259
3.11.3.2 Easier load elimination ................................................................................................................... 260
3.11.4 Work top automatic setup .................................................................................................... 261
3.11.5 Restoring the plan................................................................................................................ 262
3.12 DEFINITION OF WORKPIECES MACHINED CONTEMPORANEOUSLY ........................................................ 262
3.12.1 Number of workpieces machined contemporaneously........................................................ 262
3.13 PROJECT OPTIMIZATION .................................................................................................................. 263
3.13.1 Standard projects optimisation ............................................................................................ 264
3.13.1.1 Guided Optimization ...................................................................................................................... 264
3.13.1.2 Automatic optimization ................................................................................................................... 266

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 3.13.2 Nesting projects optimisation............................................................................................... 267
3.13.2.1 Nesting Guided Optimisation ......................................................................................................... 267
3.13.2.1.1 Basic Guided Optimisation ....................................................................................................... 268
3.13.2.1.2 Advanced Guided Optimisation................................................................................................ 271
3.13.2.2 Nesting Automatic Optimisation ..................................................................................................... 274
3.13.2.3 Edge banding optimization............................................................................................................. 275
3.13.2.3.1 Rotations optimization.............................................................................................................. 276
3.13.2.3.2 Lamps optimization .................................................................................................................. 276
3.13.2.3.3 Stop roller optimization ............................................................................................................ 277
3.13.2.3.4 Edge banding parameters optimization.................................................................................... 277
3.13.2.3.5 Autostart optimization .............................................................................................................. 278
3.13.2.3.6 Trimmer rotations optimization ................................................................................................. 278
3.14 AUTOMATIC PARTS ARRANGEMENT AND OPTIMIZATION ...................................................................... 279
3.14.1 Add Project .......................................................................................................................... 280
3.14.2 Pgmx editor.......................................................................................................................... 280
3.14.3 Saving and opening .wpx files ............................................................................................. 281
3.14.4 Optimisation criteria ............................................................................................................. 281
3.14.5 Optimisation ......................................................................................................................... 282
3.14.5.1 Generated .mixx file ....................................................................................................................... 282
3.14.5.2 Generated .pgmx files .................................................................................................................... 282
3.15 MATHEMATICAL FUNCTIONS............................................................................................................. 283
4 PROJECT MANAGEMENT FOR CYFLEX .......................................................................................... 284
4.1 LOADING PANELS ON CYFLEX. ......................................................................................................... 284
4.2 UNLOADING PANELS ON CYFLEX. ..................................................................................................... 284
4.2.1 Unload to the right (V70) .......................................................................................................... 285
4.2.2 Unload to the right complete (V72) .......................................................................................... 287
4.2.3 Unloading to the left (V71) ....................................................................................................... 288
4.2.4 Unload to the left complete (V73) ............................................................................................ 289
4.3 OPTIMISATION FOR CYFLEX PROGRAMS ........................................................................................... 290
4.3.1 Machining clustering ................................................................................................................ 290
4.3.2 Clamps-machining distances setting ....................................................................................... 291
4.3.3 Type of optimisation algorithm ................................................................................................. 292
4.3.4 Clamps options ........................................................................................................................ 292
4.3.5 Pressers options ...................................................................................................................... 293
4.3.6 Probing ..................................................................................................................................... 294
4.3.7 Panel anti-fall ........................................................................................................................... 294
4.3.8 Aligner ...................................................................................................................................... 296
4.3.9 Processing with optimiser ........................................................................................................ 296
4.4 LAYOUT FOR CYFLEX PROGRAMS .................................................................................................... 297
5 PROJECT MANAGEMENT FOR UNIFLEX ......................................................................................... 298
5.1 CREATE PROJECT ........................................................................................................................... 298
5.1.1 One piece mirror ...................................................................................................................... 298
5.1.2 Creating the Double Dual Project ............................................................................................ 300
5.1.3 Creating the Double Dual Project ............................................................................................ 301
5.1.4 Creating the Single Project ...................................................................................................... 302
5.1.5 Optimization of the project by Maestro .................................................................................... 303
5.2 TYPES OF DRAIN ............................................................................................................................. 304
5.3 TOEKICK ........................................................................................................................................ 305
5.4 TOOL PROGRAMMING RULES ........................................................................................................... 306
5.4.1 Flat bit ...................................................................................................................................... 306
5.4.2 Launch tip................................................................................................................................. 307
5.4.3 Smooth flat tip .......................................................................................................................... 307
5.4.4 Countersunk spear tip .............................................................................................................. 308
5.4.5 Blitz Tip .................................................................................................................................... 309
5.5 UNIFLEX OPTIONS .......................................................................................................................... 310
6 PROJECT MANAGEMENT FOR POWERFLEX ................................................................................. 313
6.1 MASTER SETTINGS ......................................................................................................................... 313
6.2 OPTIMIZATION CONSTRAINTS ........................................................................................................... 314
6.2.1 Generic Constraints ................................................................................................................. 315
6.2.2 Piece positioning restrictions ................................................................................................... 316

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 6.2.3 Heads rotation restrictions ....................................................................................................... 317
6.2.4 Tables position restrictions ...................................................................................................... 317
6.3 OPTIMIZING EXECUTION .................................................................................................................. 318
6.4 OPTIMIZATION RESULTS .................................................................................................................. 318
6.5 POWERSET TOOLING OPTIMIZER..................................................................................................... 319
6.5.1 Operating requirements ........................................................................................................... 319
6.5.2 Optimization Wizard ................................................................................................................. 320
6.5.2.1 Page1: Parameters ....................................................................................................................... 321
6.5.2.2 Page2: Execution .......................................................................................................................... 323
6.5.2.3 Page3: Results ............................................................................................................................. 324
7 NESTING PROJECT MANAGEMENT ................................................................................................. 328
7.1 DEFAULTS FOR “NESTING PROJECTS”.............................................................................................. 329
7.1.1 Default Folder for “Nesting Projects” ....................................................................................... 329
7.1.2 Default Nesting Parameters ..................................................................................................... 330
7.2 CREATING A NEW NESTING PROJECT ............................................................................................... 332
7.2.1 Nesting Parameters ................................................................................................................. 333
7.2.1.1 Type of Nesting .............................................................................................................................. 333
7.2.1.1.1 Rectangular Nesting.................................................................................................................. 334
7.2.1.1.2 Free Form Nesting .................................................................................................................... 334
7.2.1.1.3 Tubular Nesting ......................................................................................................................... 334
7.2.1.1.4 Manual Nesting ......................................................................................................................... 334
7.2.1.2 Part sequencing ............................................................................................................................. 335
7.2.1.2.1 Insertion in sequence by Area ................................................................................................... 335
7.2.1.2.2 Insertion in sequence by Perimeter ........................................................................................... 335
7.2.1.3 Minimum distance between two nested parts ................................................................................ 335
7.2.1.4 Spoil board thickness ..................................................................................................................... 335
7.2.1.5 Enable cutting outside the sheet .................................................................................................... 335
7.2.1.6 Enables the possibility of nesting the parts in the holes of other parts ........................................... 335
7.2.2 Nesting Sheets ......................................................................................................................... 336
7.2.2.1 Adding a sheet to the list................................................................................................................ 337
7.2.2.1.1 Meanings of sheet data ............................................................................................................. 337
7.2.2.2 Deleting a sheet from the list ......................................................................................................... 338
7.2.2.3 Copying sheet data ........................................................................................................................ 338
7.2.2.4 Pasting sheet data ......................................................................................................................... 338
7.2.2.5 Editing sheet data .......................................................................................................................... 338
7.2.2.6 Enable the use of materials magazine management ..................................................................... 338
7.2.3 Nesting parts ............................................................................................................................ 339
7.2.3.1 Enter workpiece in the list .............................................................................................................. 340
7.2.3.1.1 Meanings of workpiece data ..................................................................................................... 340
7.2.3.1.2 Inserting pieces from .CSV files ................................................................................................ 341
7.2.3.2 Deleting a workpiece from the list .................................................................................................. 342
7.2.3.3 Copying workpiece data................................................................................................................. 342
7.2.3.4 Pasting workpiece data .................................................................................................................. 342
7.2.3.5 Editing workpiece data ................................................................................................................... 342
7.2.4 Nesting Cut .............................................................................................................................. 343
7.2.4.1 Manual Cut .................................................................................................................................... 343
7.2.4.2 Automatic Cut ................................................................................................................................ 344
7.2.4.2.1 Tool for Nesting cut ................................................................................................................... 345
7.2.4.2.2 Cutting technology .................................................................................................................... 345
7.2.4.2.3 Scoring ...................................................................................................................................... 346
7.2.4.2.4 Approach ................................................................................................................................... 346
7.2.4.2.5 Retraction .................................................................................................................................. 346
7.2.4.2.6 Machine functions ..................................................................................................................... 346
7.2.5 Nesting optimisation ................................................................................................................. 347
7.2.6 Nesting remainders and scrap ................................................................................................. 348
7.2.7 Nesting labelling ....................................................................................................................... 350
7.2.7.1 Move labels .................................................................................................................................... 352
7.2.7.2 Delete labels .................................................................................................................................. 353
7.2.7.3 Enter labels .................................................................................................................................... 353
7.2.8 Loading, unloading and Nesting cleaning ................................................................................ 354
7.2.8.1 Load ............................................................................................................................................... 354
7.2.8.2 Unpacking and cleaning................................................................................................................. 355
7.2.9 Manual Nesting completion...................................................................................................... 356
7.2.9.1 Manual positioning of the parts on the sheet ................................................................................. 356
7.2.9.1.1 Create new part......................................................................................................................... 356

8
 7.2.9.1.2 Insert new part .......................................................................................................................... 356
7.2.9.1.3 Insert existing part ..................................................................................................................... 357
7.2.9.1.4 Part rotation .............................................................................................................................. 358
7.2.9.1.5 Part deletion .............................................................................................................................. 358
7.3 OPENING AN EXISTING NESTING PROJECT ....................................................................................... 359
7.4 CLOSING A NESTING PROJECT ........................................................................................................ 359
7.5 SAVING A NESTING PROJECT .......................................................................................................... 359
7.6 NESTING PROCESSING.................................................................................................................... 360
7.6.1 Conditions to be complied with in Nesting ............................................................................... 360
7.6.2 Recurring strategies in Nesting ................................................................................................ 361
7.6.2.1 Positioning small workpieces at the center .................................................................................... 361
7.6.2.2 Contouring outside the sheet ......................................................................................................... 362
7.7 OPTIMIZING NESTING MACHINING..................................................................................................... 362
7.8 LABELLING PIECES IN MACHINE ........................................................................................................ 363
7.8.1 Automatic labelling of pieces in machine ................................................................................. 363
7.8.2 Manual labelling of pieces in machine ..................................................................................... 363
7.8.2.1 Manual labelling of pieces with LabelPrinterManager .................................................................... 364
7.8.3 Nesting .nstrptx report file ........................................................................................................ 365
7.9 NESTING REPORT ........................................................................................................................... 366
7.9.1 General statistics ..................................................................................................................... 366
7.9.2 Materials ................................................................................................................................... 367
7.9.3 Pieces summary ...................................................................................................................... 367
7.9.4 Sheets and pieces matrices mapping ...................................................................................... 367
7.9.5 Cutting diagrams ...................................................................................................................... 368
8 MATERIALS MAGAZINE MANAGEMENT ......................................................................................... 370
8.1 ADD NEW SHEETS ........................................................................................................................... 371
8.1.1 Default dimensions for Nesting sheets .................................................................................... 371
8.2 DELETE EXISTING SHEETS ............................................................................................................... 372
8.3 CUT EXISTING SHEETS .................................................................................................................... 372
8.4 COPY EXISTING SHEETS .................................................................................................................. 372
8.5 PASTE CUT OR COPIED SHEETS ....................................................................................................... 373
8.5.1 Copy-Paste Cells ..................................................................................................................... 373
8.6 SHEET ROTATION ............................................................................................................................ 373
8.7 IMPORT MATERIALS MAGAZINE ......................................................................................................... 374
8.8 EXPORT MATERIALS MAGAZINE ........................................................................................................ 375
8.9 SAVE MATERIALS MAGAZINE ............................................................................................................ 375
8.10 UNLOAD MATERIALS ........................................................................................................................ 375
8.11 LOAD REMAINDERS ......................................................................................................................... 376
9 LABELS DATABASE MANAGEMENT WITH LABELEDITOR .......................................................... 377
9.1 CREATE LABEL ............................................................................................................................... 377
9.2 OPEN LABEL ................................................................................................................................... 379
9.3 CLOSE LABEL ................................................................................................................................. 380
9.4 SAVE LABEL.................................................................................................................................... 380
9.5 PRINT LABEL................................................................................................................................... 381
9.5.1 Print label on Zebra printer ...................................................................................................... 381
9.5.2 Print label on office printer ....................................................................................................... 381
9.6 TOOLS ........................................................................................................................................... 382
9.6.1 Zoom ........................................................................................................................................ 382
9.6.2 Pan ........................................................................................................................................... 382
9.7 DRAWING OBJECTS MANAGEMENT ................................................................................................... 382
9.7.1 Add object ................................................................................................................................ 382
9.7.2 Delete object ............................................................................................................................ 383
9.7.3 Copy object .............................................................................................................................. 383
9.7.4 Paste object ............................................................................................................................. 383
9.8 DRAWING OBJECTS ......................................................................................................................... 384
9.8.1 Horizontal line .......................................................................................................................... 384
9.8.2 Vertical line............................................................................................................................... 385
9.8.3 Rectangle ................................................................................................................................. 386
9.8.4 Image ....................................................................................................................................... 387
9.8.4.1 Fixed .............................................................................................................................................. 388

9
 9.8.4.2 Parametric ..................................................................................................................................... 388
9.8.5 Text .......................................................................................................................................... 389
9.8.5.1 Fixed .............................................................................................................................................. 391
9.8.5.2 Parametric ..................................................................................................................................... 391
9.8.5.3 Date ............................................................................................................................................... 392
9.8.5.4 Time ............................................................................................................................................... 393
9.8.6 Barcode .................................................................................................................................... 394
9.8.6.1 Unidimensional .............................................................................................................................. 394
9.8.6.1.1 Code 39 .................................................................................................................................... 394
9.8.6.1.2 Code 93 .................................................................................................................................... 396
9.8.6.1.3 Code 128 .................................................................................................................................. 398
9.8.6.2 Two-dimensional ............................................................................................................................ 400
9.8.6.2.1 Aztec ......................................................................................................................................... 400
9.8.6.2.2 Datamatrix ................................................................................................................................. 402
9.8.6.2.3 QR............................................................................................................................................. 404
9.8.6.2.4 PDF417 ..................................................................................................................................... 406
9.9 OPTIONS ........................................................................................................................................ 408
9.9.1 Files .......................................................................................................................................... 409
9.9.2 Parameters............................................................................................................................... 409
9.9.2.1 Geometries .................................................................................................................................... 409
9.9.2.2 Zebra ............................................................................................................................................. 409
9.9.2.3 Page layout .................................................................................................................................... 410
9.9.3 Language ................................................................................................................................. 411
9.10 ZEBRA PRINTER .............................................................................................................................. 412
9.10.1 Installation ............................................................................................................................ 412
9.10.2 Calibration ............................................................................................................................ 420
9.10.3 Download font ...................................................................................................................... 422
9.10.4 Memory ................................................................................................................................ 426
9.11 AT AUTOMATIC PRINTER.................................................................................................................. 430
9.11.1 Notes ................................................................................................................................... 430
10 TOOL DATA-BASE .............................................................................................................................. 431
10.1 DEFAULT FOR TOOL DATA-BASE ...................................................................................................... 432
10.1.1 Default "Name Tool Data-Base " ......................................................................................... 432
10.1.2 Default "Folder for tool Data-Base" ..................................................................................... 432
10.1.3 Default "Folder for Import/Export toll Data-Base" ................................................................ 432
10.2 TOOL DATA -BASE CREATION .......................................................................................................... 433
10.3 TOOL DATA-BASE OPENING.............................................................................................................. 433
10.4 CLOSING TOOL DATA-BASE .............................................................................................................. 434
10.5 SAVING TOOL DATA-BASE ................................................................................................................ 435
10.6 TOOL DATA-BASE IMPORT FROM XILOG ............................................................................................ 436
10.7 TOOL DATA-BASE EXPORT TO XILOG ................................................................................................ 437
10.8 ACTIVATE TOOL DATA-BASE ........................................................................................................... 438
10.9 TOOLS ........................................................................................................................................... 439
10.9.1 Tool introduction .................................................................................................................. 439
10.9.1.1 Bits ................................................................................................................................................. 442
10.9.1.1.1 Tools wear ............................................................................................................................... 444
10.9.1.2 Milling cutters ................................................................................................................................. 445
10.9.1.2.1 Sanders ................................................................................................................................... 445
10.9.1.2.2 Edge scraper............................................................................................................................ 446
10.9.1.2.3 Glue scraper ............................................................................................................................ 447
10.9.1.2.4 Trimmers .................................................................................................................................. 448
10.9.1.3 Blades ............................................................................................................................................ 449
10.9.1.4 Mortises ......................................................................................................................................... 450
10.9.1.5 Contact tools .................................................................................................................................. 451
10.9.1.5.1 Probes ..................................................................................................................................... 451
10.9.1.5.2 Pressure rollers ........................................................................................................................ 452
10.9.1.6 Special tools .................................................................................................................................. 453
10.9.1.6.1 Manipulators ............................................................................................................................ 453
10.9.1.6.2 Blowers .................................................................................................................................... 454
10.9.1.7 Heads ............................................................................................................................................ 455
10.9.1.7.1 Weldon ..................................................................................................................................... 458
10.9.1.7.2 General Head........................................................................................................................... 459
10.9.1.8 Aggregates tools ............................................................................................................................ 460
10.9.2 Modifying tolls ...................................................................................................................... 461

10
 10.9.3 Tool removal ........................................................................................................................ 461
11 TOOL EQUIPMENT .............................................................................................................................. 462
11.1 TOOL EQUIPMENT DEFAULT ............................................................................................................. 463
11.2 TOOL EQUIPMENT CREATION ........................................................................................................... 464
11.3 OPEN TOOL EQUIPMENT ................................................................................................................. 464
11.4 CLOSE TOOL EQUIPMENT................................................................................................................ 464
11.5 SAVE TOOL EQUIPMENT .................................................................................................................. 465
11.6 TOOL EQUIPMENT ACTIVATION......................................................................................................... 466
11.7 TOOL EQUIPMENT EDITOR ............................................................................................................... 467
11.7.1 Configuration selection ........................................................................................................ 467
11.7.2 Tools database selection ..................................................................................................... 467
11.7.3 Machine Selection ............................................................................................................... 468
11.7.4 Operator Group Selection .................................................................................................... 468
11.7.5 Association Tool-Spindle ..................................................................................................... 469
11.7.6 Tool removal from the spindle ............................................................................................. 469
11.7.7 Viewing Tool Information ..................................................................................................... 470
11.7.8 Spindle information display .................................................................................................. 470
11.7.9 Displaying Equipment .......................................................................................................... 471
11.8 PRINT FIXTURING DATA ................................................................................................................... 472
11.9 COMPARING TOOLING ..................................................................................................................... 474
11.10 TOOLS WEAR ............................................................................................................................. 478
11.10.1 Tool wear display ................................................................................................................. 478
11.10.2 Tool wear update ................................................................................................................. 479
11.10.3 Reset wear........................................................................................................................... 479
11.10.4 Wear report .......................................................................................................................... 479
12 EDGES DATABASE(EDGEMANAGER) ............................................................................................. 481
12.1 EDGES DATABASE DEFAULT............................................................................................................ 482
12.1.1 “Edges Database Name” Default......................................................................................... 482
12.1.2 “Edges Database Folder” Default ........................................................................................ 482
12.1.3 Automatic Export of the Edges Database in Ext. format .................................................... 483
12.2 EDGES DATABASE CREATION .......................................................................................................... 484
12.3 OPEN EDGES DATABASE................................................................................................................. 484
12.4 CLOSE EDGES DATABASE ............................................................................................................... 484
12.5 SAVE EDGES DATABASE ................................................................................................................. 485
12.6 ACTIVATE EDGES DATABASE ........................................................................................................... 486
12.7 EDGES ........................................................................................................................................... 487
12.7.1 Entering Edges .................................................................................................................... 487
12.7.1.1 Edge name .................................................................................................................................... 488
12.7.1.2 Edge data ...................................................................................................................................... 488
12.7.1.3 Machining Technological Data ....................................................................................................... 488
12.8 TECHNOLOGIES MANAGER .............................................................................................................. 489
12.8.1 Name ................................................................................................................................... 490
12.8.2 Speed .................................................................................................................................. 490
12.8.3 Edge heating lamps ............................................................................................................. 491
12.8.4 Edge dispensing .................................................................................................................. 491
12.8.5 Roller stop optimization ....................................................................................................... 492
12.8.6 Stoptime of the edge bander in infeed and outfeed to the profile ....................................... 492
12.8.7 Edge in closure compensation ............................................................................................ 493
12.8.8 Edge banding early-late ....................................................................................................... 493
13 POST-PROCESSOR ............................................................................................................................ 494
13.1 CREATE .XXL AND .PGM FILES .......................................................................................................... 494
13.1.1 Xilog installation ................................................................................................................... 494
13.1.2 Set output folder .................................................................................................................. 495
13.1.3 Execution Post-Processor ................................................................................................... 496
13.2 CREATE .EPL FILES ......................................................................................................................... 497
14 APPENDIX ............................................................................................................................................ 498
14.1 SIZES USED BY MAESTRO ............................................................................................................... 498

11
1 Description of the software

The software described in this manual allows the definition of workpieces and the related
machining operations so that they can be machined on numeric control machining centers.

The setting of all workpieces occurs in a three-dimensional CAD environment very useful
for the user in order to check immediately his schedule.

Working processes are divided in two different steps: firstly, by setting the geometries,
secondly by applying machine tools like in a CAM system.

After setting workpiece and working processes, all of the information will be passed to the
machine, which will carry out the machining.

1.1 Installation

1.1.1 PC minimum requirements

The software requires the following minimum requirements for installation:

- Operating system: Windows XP Professional (SP2), Windows Vista or Windows 7

- Processor: Intel compatible, minimum 2GHz;
recommended multicore processor
- Memory: minimum 1GB
recommended 2GB
- Space on disc: 5GB
- Graphical board: OpenGL compatible

The following minimum PC requirements are needed for the "Maestro3D" option for
machining surface or with a machine with "edge banding unit":

- Operating system: Windows XP Professional (SP2), Windows Vista or Windows 7

- Processor: Intel® I5 - 3.2 GHz
- Memory: 4GB (8GB recommended for 64bit operating systems)
- Free space: 30 GB (recommended HD with 7200 rpm)
- Graphic board: specific (e.g. NVIDIA GFORCE, ATI)
Note: a graphic board integrated in the motherboard could
compromise the performance of the application: not recommended
- Monitor Screen resolution 1024x768 colour 32-bit

12
2 Operator interface

Maestro interface is structured as follows:

There are six areas:

Menu
Trees
Parameters
Graphics
Current command
Status bar

Following chapters describe all commands included in the menus.

13
3 Project

Project refers an object that can contain the definition of one or more workpieces with 2D
geometries and associated machining.

The project contains all the information needed to define a machining process.
This process will be illustrated in the following chapters:

1) Project management

2) Workpiece

3) Worktables

4) 2D geometries

5) Machining operations

6) 3D machining

7) Macro and Subprograms

8) NC functions

9) Work phases

10)Workpiece setup in machine

11)Blocking system

12)Workpieces to be machined contemporaneously

13)Projects optimisation

14)Mathematical functions

14
3.1 Project management

The "Project" file - with a .pgmx size- must contain at least one workpiece and it might
include - but not necessarily- also working processes.
It is a compressed file including:
tool.tlgx Data Base Tools
progetto.xml Instructions to set the geometry.
progetto.epl Clamp/suction pad definition

A project can be:

Created
Started
Ended
Saved

By using these icons in the Menu area:

15
3.1.1 Project default

You may change project defaults by clicking on the icon "Options" in the folder "Tools".

3.1.1.1 Default: "Project name”

If you wish to modify the default name of a new project:

Click on the icon "Options"
Fill the field "Project name" .

3.1.1.2 Default “Project folder”

If you wish to change the name of the folder where projects are started/saved:
Click on the icon "Options"
Fill the field "Project folder".

16
3.1.1.3 Save the configuration parameters

As well as the default settings described above, there are many other configurations
possible in the “Options” session, described below.
If a new Maestro Release is installed all the configuration parameters set will be
overwritten.
This is why we recommend saving all the configurations set with the “Backup” key in the
“Tools” folder.

After having selected the command, the following menu will be displayed, to select which
parameters to save.

Press “Cancel” to end the operation.

Press “Save” to save a .settingsx file with all the configuration information.

17
3.1.1.4 Restore the configuration parameters

To restore the previously saved configuration parameters use the “Restore” command in
the “Tools” folder.

After having selected the command, the following menu will be displayed, to select the
type of restore desired.

Press “Cancel” to end the operation.

Press “Open” to display the following confirmation window.

Press “Cancel” to end the operation.

Press “OK” to select the previously saved .settingsx file and then restore the parameters
that will take place after closing Maestro.

18
3.1.2 New project setting

If you wish to set up a new project,.click on the icon "Create project"

The name of such new project will be definedas described in paragraph

3.1.1.1 Default “Project name”

Since a project must include at least one workpiece, whenever you create a new Project,
you activate the option
“Create Workpiece”.

If a project was already been started, following option would automatically start.
“Closing project”

3.1.3 Open an existing project

If you wish to open an existing project, click on the icon "Open".
The resulting window shows you the list where you may select a pgmx file.
The default folder will be defined as described in paragraph
3.1.1.2. Default ”Project folder”
Please select a pgmx file and click on "Open".
Or click twice on the pgmx file.

For a project that has already been started, following option would be automatically
performed:
“Closing project”

19
3.1.4 Import Pgm/Xxl
This function is used to convert a .pgm or .xxl file into a project.

To import a .pgm or .xxl file click on the “Import Pgm/Xxl” icon in the
“Import” menu.
You will be asked to close any open project as the Import Pgm/Xxl
function is equivalent to opening an existing project.

A window will be displayed from which you can select a file with
extension .pgm or .xxl.
The default folder will be the one defined, as described in section
13.1.2 Post-Processor Options which describes the “Output folder”
Then select an .xxl file and then press “Open”.

Any unrecognised instructions will be displayed in a “XXL errors found” screen with the line
number of their location in the input life.

If there are no errors the “Parameters found” screen is displayed with a list of the known
parameters in the file to import.
The following keys are found on the bottom:

To proceed click on “OK” and the input file will be imported as if it were an existing project.

To interrupt the import click on “Cancel”

20
For a list of the instructions click on “Help”.

21
3.1.5 Import 3D template
It is possible to import a 3D model using the IGES formats (* .igs, *. Iges) or the STEP (*
.stp, *. Step) formats using the "Import 3D model" command in the "Home-Import" menu.

After selecting the command, simply select the file to be imported.

If the model is imported when there is no part in the project, a new part will be created with
the minimum dimensions needed to contain the imported model.

3.1.6 Import from STL

You can also import a model from an STL file (* .stl) using the "Import from STL" command
in the "Home-Import" menu.

After selecting the command, simply select the file to be imported.

If the model is imported when there is no part in the project, a new part will be created with
the minimum dimensions needed to contain the imported model.

22
3.1.7 Import Image
You can import an image and turn it into three-dimensional geometry
using the "Import image as a surface" command in the "Home-Import" menu.

After selecting the command, you can select a file to be

imported with the following formats:

After selection, the following dialog box

will appear so you can manage the
following characteristics of the surface that
will be generated:
- Dimensions (X, Y)
- Maximum and minimum size of Z
- Distance of the surface from part edge

The generated surface will be lower for

darker pixels and higher for light pixels.
This rule can be reversed by checking the
"Invert grey scale" item

With the "Detail reduction" potentiometer,

you can soften the surface by blurring the
grey tone of the image.

23
3.1.8 End project

If you wish to end a project click on the icon "Close".

If your project is saved, following question will appear:

If your project has not yet been saved, following question will be displayed:

If you click on "Yes”, following option will be automatically performed in order to save your
project: "Automatic Saving"

24
3.1.9 Save Project

If you wish to save an open project, click on the icon "Save"

If the project was already named, no question would be asked.
If the project was already created, the option "Save with name" would be performed.

You can specify the project name in the box "File name".
then click on "Save".

25
3.1.10 Project Graphic display

The project is displayed in the mein are at the centre of the screen.
it is a three-dimensional representation.
The operator can choose what, where and how to see interesting project workpieces.

3.1.10.1 What you see of the project

In order to select the working processes to display among all those included in a sole
project, you can use the commands available:
- In the plane tree (see paragraph 3.3.5.4 )
- in the working process tree (see paragraph 3.5.19.3 )
- in the menu of the step tree:

Or use the "Display" "Options" menu "Opaque View" control."

The command "Dim" displays only the working processes of the active plane.
If one or more working processes of the active plane have been switched off with the tree
menu, these will no be displayed.

26
3.1.10.2 Where to see the project

If you wish to see the project, it is possible to set the point from which you display it.
The main references to this purposes are the "Standard faces".
Immediate commands are available to see the different faces.
In the menu "Home" sub-menu "Views"
Clicking on the commands with the Face names, you will only display the face related to
the seleced view.

In the same menu, you can also see three commands related to three isometric views.

After selecting one out of ten views, you can zoom, size, shift or rotate the project view by
using the menu "Surfing" to the right of the menu "Views".

27
3.1.10.2.1 Zoom

The main icon of the Zoom displays the whole screen.

The icon "Zoom" allows you to zoom through a rectangle. You can select it by clicking on
the left button of the mouse.

The icon "Zoom +" allows you to size the view whenever you click with the left button of
the mouse.
You can use this option also by rotating the mouse roller forward.

The icon "Zoom" allows you to size the view when you click with the left button of the
mouse.
You can select this option by rotating the roller backwards.

The icon "Dynamic Zoom" allows you to zoom by cliking with the left button of the mouse
on the area to be zoomed and then to move in order to zoom/size the view.
You can select this option by rotating the roller backwards and forwards.

The commands "Zoom +", "Zoom -" and "dynamic Zoom" can be disabled if you click on
the "Esc key".

3.1.10.2.2 Pan

Pan allows you to shift the view by keeping the left button of the mpuse pressed and then
to shift with the mouse.
You can disable the command with the button "Esc" or by modyfing the command.
The same function is always available if you press the central button of the mouse and
then you move with the mouse.

3.1.10.2.3 Orbit

This option allows you to rotate the view by keeping the left button pressed and then move
with the mouse.
You can disable the command with the button "Esc" or by modifying the command.
This option is also available if you press the button "Ctrl", the central button of the mouse
while moving the mouse.

28
3.1.10.3 How to see the project

All project elements can be displayed in different ways.

In order to choose the way to see such elements, the commands of this menu allow you to
produce the different representations that have been shown.

29
The command CAMCAM allows you to display the tool path and the side of correction.

Here you can see a workpiece with a profiling and two tenonings in Shading
representation (25%)

The same workpiece in CAM representation shows you:

- the basic geometries of the profile
- paths in tool centre
- the circle with the arrow that indicates the initial point of the working process and the
direction

The command "Redraw" upgrades the whole graphic area.

30
3.2 Workpiece

Workpieces must be defined as "Finalised workpiece" and optionally also as "Rough

workpiece ". You may insert more workpieces in one project.

3.2.1 Rough workpiece

Function implemented only in “Script” mode (see MSL manual)

3.2.2 Finalised workpiece

The finalised workpiece can have several geometric shapes:

3.2.2.1 Parallelepiped shaped workpiece

If you wish to set a parallelepiped shaped workpiece click on the menu "Create
workpiece".
Introduce the values in the menu on the right.

Name of the
workpiece

Dimensions

Position

You can change your field values after creating the workpiece.

31
3.2.2.2 Extruded workpiece

Workpiece name

Select Geometry

Import geometry from a workpiece

Import geometry from Dxf file

Extruded height

A closed geometry, that can be obtained in 3 ways, is required to make the extruded
workpiece:
1) Creating a new geometry
2) Importing geometry from another workpiece
3) Importing geometry from dxf

Click on "Select Geometry" then on an available closed geometry

Click on "Apply" to create the "Extruded Piece" contained by a parallelepiped representing

its clearance.
The various fields' values can also be changed after the piece is created.

32
3.2.2.2.1 New geometry creation for extruded

Use the "Draw" menu controls (see paragraph 3.4) to create a new closed geometry.

3.2.2.2.2 Geometry importing for extruded from another workpiece

Use the "Import geometry from a workpiece" control to have the closed geometry
belonging to a project piece. Select a project from those in the memory.
If the selected project only has one piece, its closed geometry will appear.
If the selected project has more than one piece, select the piece which geometry is to be
imported. The closed geometry of the selected piece will appear.

3.2.2.2.3 Geometry importing for extruded from dxf

Use the "Import geometry from Dxf file" control to have the closed geometry contained in a
Dxf file. From the memory select a Dxf file containing a closed geometry.

3.2.3 Change workpiece dimensions

If three-dimensional geometries have been imported or completed for an existing project,

the part dimensions can be automatically updated to contain the selected geometries.

The function is activated using the "Fit part to surfaces" command in the "Draw-Modify
Surfaces" menu

After selecting the surface (s), the X, Y, Z super-material to

be added is requested in terms of the margins of the
selected area (s).

33
3.2.4 Import the workpiece
You may also import a workpiece to another project.
To this purpose you can use the command "Import workpiece” of the menu "Home"
"Importa".

The resulting window shows you the list of projects where you can select the workpiece to
be imported.
After clicking on the icon "Open", the list of workpieces in the selected project will be
showed:

You can select one or more workpieces to import and click on the icon "Open".
In the tree of our project the selected workpieces will be added.

3.2.5 workpiece Removal

The workpiece can be removed from the working processes.
(see paragraph3.5.19 )

In order to remove a workpiece:

- select the workpiece to remove from the tree of the working processes.
- click on the command "Remove” in the tree commands or in the context menu of
the workpiece

the workpiece removal implies also that all related workings processes are removed as
well.

34
3.3 Working planes

The "working plane" is a plane with Cartesian axis where you can add shapes of plane
geometry like line, arc, circle and so on (see paragraph 3.4)

The work tops are created in four ways:

- automatically during the creation of a new workpiece (Standard Faces)
- by creating a plane in parallel with an existing plane (Parallel Plane)
- by setting the rotations around axis Z and around axis X (Inclined Plane)
- Cut with blade (Generated work top)

In case of Parallel and Inclined Planes you can also modify - after the creation - any value
in the window - the name of the plane as well.
With regard to all standard faces, all fields remain unvaried.

35
3.3.1 Standard Faces
A workpiece has six faces in which six working planes called "Standard Faces" have been
created when a new workpiece is created.

Names and positions of the "Standard Faces" are as follows:

Upper Face Lower Face

Left Face Right face

Front Face Back Face

36
3.3.2 Parallel Plane
A parallel plane is a new plane in parallel with an existing plane in the project.
There are two possibilities in order to create a parallel plane:
by using the tree of planes

By clicking - with the right button of the mouse - on the selected face, the resulting menu
allows you to create a "New parallel plane"

by using the menu “Draw” “Inclined Plane” “Parallel Plane”

In both cases a window will be displayed:

By setting following options "Distance from the plane” and "Apply" (apply), a new parallel
Plane will be created.

Note: with positive value it is created on the workpiece, with negative it is created inside
the workpiece.

37
3.3.3 Inclined Plane

An inclined plane is a general plane created by the user with origin and inclination.
Two possibilities apply for every plane:
by using the plane tree

By clicking - with the right button of the mouse - on "Workpiece", the heading "New plane”
will appear.

by using the menu "Draw" "Inclined Planes" "Generic"

38
In both cases a window will be displayed:

The definition of Inclined Plane starts with the threesome related to the workpiece placed
at the lower corner on the left.
By setting X values as origin, Y origin and Z origin, the origin of the new plane is
established.
By setting the rotating angles of Z-axis and X-axis, you also set the plane direction.
You must also take into account that both rotation angles are sequential, that is to say:
only after the rotation around the Z-axis, the rotation around the new X-axis position will
be performed.

3.3.4 Plane from surface area

It is possible to create a coplanar plane to a surface using the "From surface" command in
the "Draw-inclined planes" menu.

Once the command has been selected, you simply select a surface and a coplanar user
plane to the selected surface will be set up.
Obviously the surface must be exclusively flat.

39
3.3.5 Work plane tree

The work plane tree collects all planes set for a certain project.

Properties

Display

Switch off

Remove

This tree - a workpiece from displaying existing planes- allows you to:
- activate an existing plane
- display and change the properties of existing planes
- remove a plane
- create parallel planes (see paragraph 3.3.2)
- create an inclined plane (see paragraph 3.3.3)

Buttons with light bulbs (on or off) allow you to display or switch off the working processes
(see paragraph 3.5.19.3)

3.3.5.1 Work plane selection

The work plane selection will identify the active plane, that is to say, the plane where the
two-dimensional geometry will be drawn.
In order to reactivate an existing plane, click - with the left button of your mouse- on the
name of the plane in the tree.
If you wish to know the active plane, check the plane highlighted in light blue.

40
3.3.5.2 Properties and plane modification

In order to see or modify the properties of a plane you can activate a plane then click on
the button "Properties” or click with the right button on the name of that plane and on the
heading "Properties" of the plane menu.

On the right side of your screen the menu will show you all current properties of the plane.
If you wish to modify the plane, click on "Apply" in order to change its values.

3.3.5.3 Plane removal

If you wish to remove a plane click with the right button on the plane name, then click on
"Remove" of the plane menu.

You can delete only the Parallel Planes or Inclined Planes.

You are not allowed to delete the Standard Faces.

41
3.3.5.4 Displaying working processes on planes

You are free to decide to display -or not- the working processes on the plane tree.
To the left side of every work plane there is the icon which stands for the face type. To the
left of the icon there is the symbol which represents an "eye".
By clicking with the left button on the eye, you change its status from open to closed.
If the eye is open, it means that all plane working processes will be displayed.
If the eye is closed, it means that all working processes will not be displayed.

In this example, you see a project in which the “Upper Face”

is active but all working processes on the same "Upper
Face" have been switched off.

If you wish to switch all working processes off you can:

1) close all eyes to the left of the planes.
2) close the eye to the left of the workpiece
3) or click on the light bulb that is off.

If you wish to display all working processes you can:

1) open all eyes to the left of the planes
2) open the eye to the left of the workpiece
3) or click on the light bulb that is on.

The selection on the tree has an immediate impact on the graphic area.

42
3.4 Geometries

3.4.1 Enter new 2D geometries

The 2D geometry is used in order to set the profile of an extruded workpiece as well as to
set a profile (open or closed) of a working process
Before introducing any two-dimensional geometric element, you must set and activate a
working plane.

The icons about the commands to insert the basic geometries are diplayed in the menu
"Draw" "Geometries"

All commands to create 2D geometry can be interrupted if you select a new command or
click on "Esc key".

43
3.4.1.1 Type a new point

Every command aimed at introducing a new geometric shape has to identify one or more
points by the operator.
Firstly, it is important to explain the meaning of "type a new point".
"Type a new point" means that the operator creates a new point or sets an existing one
within the project.
The point can be created with Cartesian Coordinates (X, Y) or with Polar Coordinates
(Lenght, Angle).

If you wish to type a new point with Cartesian Coordinates (X; Y) you can:
- move the mouse (X and Y coordinates are upgraded).
- click with the left button of the mouse or press Enter key.

Or:
- type the value of the X coordinate
- move your mouse (Y coordinate is upgraded)
- press Enter key.

Or:
- type the value of the Y coordinate
- move the mouse (X coordinate is upgraded)
- press Enter key.

Or:
- type the value of the X coordinate
- type the value of the Y coordinate
- press Enter key.

In order to type a new point with Polar Coordinates (Length, Angle) you can:
- move the mouse (values corresponding to Length and Angle are upgraded)
- click with the left button of the mouse or press Enter key.

Or:
- type the Length value
- move the mouse (the Angle value is upgraded)
- press Enter key.

Or:
- type the Angle value
- move the mouse (the Length value is upgraded)
- press Enter key.

Or:
- type the Length value
- type the Angle value
- press Enter key.

44
3.4.1.2 Type an existing point by using the Osnap

In order to type a point, it is often desirable to use the points of the shapes that are already
on our plane.
To this purpose, the Osnap (Object Snap) in the following
menu are a useful support.

For an existing point:

- click on one command Osnap
- move the mouse (a red cross appears on the geometry)
- click with the left button of the mouse or press Enter key.

Final It is linked to the final point of any graphic shape.

In a polyline it is linked to the final point of every entity that is contained in its
structure.

Intersection It is linked to the intersection of two entities.

Middle It is linked to the middle point of any entity (also a circle)

Centre It is linked to the centre of arcs and circles.

Quadrant It is linked to the X and Y points of maximum and minimum in the circles.

Perpendicular It is linked to the point perpendicularly projected to a segment.

Tangent It is linked to the tangent point of an arc or a circle.

Parallel It is linked to the point projected on the parallel to a segment.

Point It is linked to an entity "Point”.

Horizontal It keeps the Y coordinate of the previous point.

Vertical It keeps the X coordinate of the previous point.

Near It is linked to the point nearer to the point of the mouse.

45
3.4.1.3 Point

It introduces a geometric element: "Point”

In order to introduce a point:

- click on the command "Point"
- type a point

In the graphic area the point is represented with this symbol:

Point properties

46
3.4.1.4 Line

It inserts a line

A line can be inserted in two ways:

1) Line for 2 points

2) Length and angle line

In order to introduce a line for 2 points:

- click on the command "Line”
- type the initial point of that line
- type the final point of that line

In order to introduce a Line with a certain length and a certain angle.

- clcik on the command "Line length and angle”
- type the initial point of that line
- type the final point of the line (with Polar Coordinates)

Line properties

47
3.4.1.5 Arc

It inserts an arc.

An arc can be inserted in 5 ways:

1) Arc for 3 points

2) Centre data arc and 2 Points

3) Arc given radius
4) Arc given centre
5) Continous tangent arc

In order to insert an Arc for 3 points:

- click on the command "Arc"
- type the initial point of the arc
- type the intermediate point of the arc
- type the final point of the arc

In order to insert an Arc whose centre radius initial and final angle are known:
- click on the command "Arc Centre and 2 Points"
- type the point of the arc centre
- insert the radius value and press Enter key
- insert the value of the initial angle and press Enter key
or move the mouse (the radius value is upgraded) click on the left button of the
mouse (also the initial angle is captured)
- Insert the angle value at the centre of the arc
or move the mouse (the angle value in the centre is upgraded) click on the left
button of the mouse

This command has two options at disposal:

- Sequence (Single/Multiple)
- Input (radius/Diameter)
that can be changed by the dynamic menu

The multiple sequence allows you to insert a further concentric arc to the previous one.

In order to insert an Arc whose final point and radius are known:
- click on the command "Arc given radius"
- type the initial point of the arc
- type the final point of the arc
- insert the radius value and press Enter key
or move the mouse (the value of the radius is upgraded) click on the left button of
the mouse

This command has two options at disposal:

- Direction (clockwise-anticlockwise)
- Arc length (Shorter/Longer)
that can be changed by the dynamic menu

48
In order to insert an Arc whose centre and final point are known:
- click on the command "Arco dato centro" (arc given centre)
- type the initial point of the arc
- type the point of the arc centre
- type the final point of the arc

This command has following option at disposal:

Direction (clockwise-anticlockwise)
that can be changed by the dynamic menu

In order to insert a tangent Arc in the previous element in a continuous manner:

- click on the command “Continuous tangent arc”
- select a geometric element
- type the final point of the arc
- click on the left button of the mouse

This command has three options:

- Type of feature (Arc/Line)
- Sequence (Single/Multiple)
- Tangency (Direct
Inverse
Shorter length
Longer length)

that can be changed from the dynamic menu

The multiple sequence allows you to make tangent elements with the previous one.

The direct tangency does not create a sharp edge

The inverse tangency creates a sharp edge
The length options create the workpiece of Shorter or Longer arc.

Arc properties

49
3.4.1.6 Circle

It introduces a circle:

A circle can be inserted in 3 ways:

1) Circle for 3 points

2) Circle given radius

3) Circle given diameter

In order to insert a Circle for 3 points:

- click on the command "Circle”
- type the initial point of the circle
- type the intermediate point of the circle
- type the final point of the circle

In order to insert a Circle whose centre and radius are known:

- click on the command "Circle given radius"
- type the point at the centre of the circle
- insert the radius value and press Enter key
or move the mouse (the value of the radius is upgraded) click on the left button of
the mouse

This command has two options at disposal:

- Sequence (Single/Multiple)
- Input (radius/Diameter)
that can be changed by the dynamic menu

The multiple sequence allos to insert a further concentric circle to the previous one.

In order to insert a Circle whose centre and diameter are known:

- click on the command "Circle given diameter"
- type the point at the centre of the circle
- insert the value of the diameter and press Enter key
or move the mouse (the value of the diameter is upgraded) click on the left button of
the mouse

This command has two options at disposal:

- Sequence (Single/Multiple)
- Input (radius/Diameter)
that can be changed by the dynamic menu

The multiple sequence allows to insert a further concentric circle to the previous one.
It is the same command used for the circle given radius, in which the default "Input" has
been turn into "Diameter"

50
Circle properties

51
3.4.1.7 Polyline

It introduces a polyline that is a continuous sequence of arcs and/or open or closed

segments.
It can be drawn using the commands for the input of lines and arcs.

In order to insert a polyline:

- click on the command "Polyline"
- follow the instructions related to the command set in the option "Mode”

This command has two options at disposal:

- Closed (option that can be ticked off)
- Mode (Line given 2 Points
Arc given 3 Points
Arc given radius
Arc given Centre
Continuous tangent arc
Continuous tangent line)

that can be changed from the dynamic menu

End: it is an option that allows you to make an open or closed polyline

Modus describes the command to use in order to describe the next geometric element.
The six commands in the menu modus have been described in the previous paragraph
about lines and arcs.

Polyline properties are made of several tables that stand for the properties of all elements
in the structure (Lines or Arcs).
You can surf the tables by clicking on the left/right arrows.
If the field "Length” appears, the element described is a Line.
If the field "Radius” appears, the element described is an Arc.

Polyline properties

52
3.4.1.8 Rectangle

It introduces a rectangle that is performed with a closed polyline made of 4 lines.

The rectangle can be inserted in two ways:

1) By inserting 2 vertex:
2) Typing the dimensions

In order to insert a rectangle given 2 vertex:

- click on the command "Rectangle 2 points”
- type the point of the first vertex
- type the point of the second vertex

In order to insert a rectangle by typing the dimensions

- click on the command "Rectangle dimensions”
- type the central point of the rectangle
- Insert the Width value and press Enter key
or move the mouse (the Width value is upgraded) click on the left button of the
mouse.
- Insert the length value and press Enter key
or move the mouse (the Length value is upgraded) click on the left button of the
mouse.
- Insert the Angle value and press Enter key
or move the mouse (the Angle value is upgraded) click on the left button of the
mouse

Rectangle properties

53
3.4.1.9 Buttonhole

It inserts a buttonhole performed with a closed polyline of 4 elements two lines and two
arcs.
Arcs have a diameter like their width and a breadth of 180°.

In order to insert a buttonhole:

- by clicking on "Buttonhole”
- type the central point of the buttonhole
- Please insert the Width value and press Enter key
or move the mouse (the Width value is upgraded) click the left button of the mouse.
- Please insert the length value and press Enter key
or move the mouse (the Length value is upgraded) click on the left button of the
mouse.
- Please insert the Angle value and press Enter key
or move the mouse (the Angle value is upgraded) click on the left button of the
mouse

Buttonhole line
properties

54
3.4.1.10 Loop line

It inserts an arc of circle or a tangent circle to 2 existing entity.

In order to insert a loop line:

- click on the command "Loop line"
- type the radius value
- move with the mouse (a loop line next to the cursor)
- click on the left button of the mouse

Or:
- click on the command "Loop line"
- type the radius value
- select the first geometry
- move with the mouse (a loop line next to the cursor)
- click on the left button of the mouse

Or:
- click on the command "Loop line"
- type the radius value
- click on the option "Quadrante" (quadrant)
- select the first geometry
- select the second geometry
- move with the mouse (a loop line next to the cursor)
- click on the left button of the mouse

This command has three options:

- Cut/Widen (both
First
Second
Nothing)
- Quadrant
- Type (Usual
Inverted
Circle)

Cut/Widen serves as option to widen or cut the selected elements

Quadrant serves to insert the loop line in the third mode (2 geometries and the quadrant)

Type establishes the type of desired loop line.

The properties of the loop line are the same of the Arc.

55
3.4.1.11 Smooth

It inserts a segment that smooths 2 existing entities.

The smooth can be set in 4 modes (see option "Type")

In order to insert a Smooth:

- click on the command "Smooth"
- type the values to set the smooth
- move with the mouse (a smooth will appear next to the cursor)
- click on the left button of the mouse

Or:
- click on the command "Smooth"
- type the values to set the smooth
- select the first geometry
- move with the mouse (a smooth will appear net to the cursor)
- click on the left button of the mouse

Or:
- click on the command "Smooth"
- type the values to set the smooth
- click on the option "Quadrante" (quadrant)
- select the first geometry
- select the second geometry
- move with the mouse (a smooth will appear net to the cursor)
- click on the left button of the mouse

This command has three options:

- Cut/Widen (both
First
Second
Nothing)
- Quadrant
- Type (1 Distance
2 Distances
Length/Angle
Length)

The Cut/Widen option serves as option to widen or cut the selected elements

The Quadrant option aims at introducing the smooth in the third mode (2 geometries and
the quadrant)

The Type option establishes how to insert the data about the loop line
The values inserted in 1 Distance or 2 Distances are measured along the selected
geometries.
The length represents the length of the new smooth segment inserted.

The smooth properties are the same of a Line.

56
3.4.1.12 Offset

It creates one or more geometries that have a steady value compared to an existing
selected geometry.

The new entities will look like the selected ones.

In case of a polyline, the new entities will always be considered as polylines but the
number of elements in their structure can be higher or lower than the elements of the
selected polyline.

In order to creare an Offset geometry:

- click on the command "Offset"
- select one or more geometric elements
- insert your offset value
- set the number of repetitions
- select the reference point to establish where to create the offset

This command has two options at disposal:

- Repetitions
- Preview

The option "Repetitions" allows you to create one or more offset geometries

The option Preview - if it is marked - allows you to see - in Preview- the geometries that
will be created by moving the mouse.

It is possible to set off the initial and final tracts of an open break, when they are inferior to
a certain length because of the offset.
To do this you put the flag on the parameter
"Enable elimination of the outer tracts of the open curve" visible in the path:
Tools-Options-Parameters-geometries.
By ticking the parameter, the second parameter will also appear:
"Minimum length below which to delete traits"

57
3.4.1.13 Text

It inserts a text made of many polylines (one or more for every character)

The text can be inserted in several fonts and heights.

In order to insert a text:

- click on the command "Text"

- select the reference plane
- selected the desired character
- select the desired style
- insert the text
- type the height
- type a precision
- select the desired alignment
- type the position in X and Y of the text
- Click on the button "Apply"

58
3.4.2 Inserting blocking profile

The blocking profile consists of a geometry that indicates the part of the piece to be
blocked by the clamps.

To insert a blocking profile, you must first create a geometry with the
instructions seen in the chapter "Errore. L'origine riferimento non è
stata trovata." and then use the "Blocking profile" command in the
"Operations" menu.
The following rules must be respected:
- the clamps are always to be positioned to the right of the geometry
created.
- create the blocking profile in the correct work phase.

If, for example, you have to work an element to be blocked with the clamps to be profiled
on both sides, you must make a project with two work phases (Setup and Swap), with the
blocking profile to be inserted in each phase.

After selecting the command, this dialogue window appears:

where you can select the geometry and set a minimum

clamping.
Minimum clamping means the minimum quantity of wood that can be clamped during the
clamping phases with the clamps.

In the "Minimum clamping" field, you can enter a negative value or the name of a
previously-set parameter.

If, in generating the geometry, considerable points of the workpiece were used, the profile
is completely parametric.

59
3.4.3 Enter new surfaces
Maestro provides functions to create new surfaces. To access the commands enter the
“Draw” area of the application menu and press “Surfaces”.

The methods available and their main features are described below.

60
3.4.3.1 Flat surface
To create a flat surface click on “Flat surface”.

Then proceed as follows:

- select a closed 2D curve;

61
3.4.3.2 Linear extrusion

To create an extrusion surface click on “Linear Extrusion”.

Then proceed as follows:

- select a geometry on a plane;

- enter the geometry extrusion length.

The geometry to select can be on any project plane, on the workpiece faces and created
by the user (e.g. tilting plane). The length must be entered after having selected the
geometry. The extrusion is performed along the axis z direction with the Cartesian
reference system local to the plane. The sign determines the extrusion direction along the
direction.

The created surface can be closed by two other

surfaces by checking the corresponding flags,
provided the section is closed

3.4.3.3 Revolution

To create an extrusion surface click on “Revolution”.

Then proceed as follows:

- select a geometry on a plane;

- select a revolution axis;
- enter a revolution angle.

The geometry selected can be on any project plane.

The revolution axis must be a linear geometry not at right angles to the plane on which the
revolution geometry is drawn.
The revolution angle value determines the rotation quantity around the axis, whilst the sign
determines the clockwise/counterclockwise direction, usually clockwise.

The created surface can be closed by two other

surfaces by checking the corresponding flag,
provided that:
- the section is closed
- the angle is less than 360 °

62
3.4.3.4 Mesh lined

To create a surface with mesh lined click on “Mesh lined”.

Then proceed as follows:

- select a first geometry on a plane;

- select a second geometry on a plane.

The geometries selected cannot be closed geometries.

The surface is created by connecting the points of the first geometry with the points of the
second, with lines. Usually the start point of the first geometry is connected to the start
point of the second, the same applies to the end points. As this approach can create
surfaces that collapse in the middle, if the directions of the curves used are in conflict, the
algorithm inverts the start point and end point of one of the two geometries.

3.4.3.5 Mesh corner

To create a surface with mesh corner click on “Mesh corner”.

Then proceed as follows:

- Select the first corner geometry;

- Select the second corner geometry;
- Select the third corner geometry;
- Select the fourth corner geometry.

The corner geometries must have matching points, so that the total contour, formed by the
four elements, is closed.

3.4.3.6 Section surface

To create a surface that joins multiple curves that will form the sections
of the super surface, click on "Surface from Sections".

The function has the following requests:

The selection of three curves is mandatory while the selection of additional curves is
optional.

63
3.4.3.7 Sweeping

This function helps create a set of surfaces that form a tube with a
constant section following a trajectory.
The input will consist of two curves.
The function has the following requests:

The extrusion curve must have no edges and it is advisable that the first section forms an
angle of 90 ° with respect to the plane in which the profile curve has been created.
Generation occurs by making the initial points of the two curves coincide.

It is possible to plug the tube by ticking the related items "Closing surface"

Esempio :

64
3.4.4 Insertion of solids
Solids are inserted using the "Draw - Solids" menu.

The solids created are a set of multiple surfaces.

The methods available and their main features are described below.

3.4.4.1 Parallelepiped

This function allows you to create a parallelepiped consisting of 6

surfaces.

The function has the following requests:

Example:

65
3.4.4.2 Sphere

This function allows you to create a sphere or a portion of a sphere made

up of one or more surfaces.

The function has the following requests:

Example:

3.4.4.3 Cylinder

This function enables users to create a cylinder or a cylinder portion formed

by one or more surfaces.

The function has the following requests:

Example:

66
3.4.4.4 Cone

This function enables you to create a cone or cone portion formed by one
or more surfaces.

The function has the following requests:

Example:

3.4.4.5 Pyramid

This feature means you can create a pyramid having a closed, unjoined
geometry as a base.It will be made up of one or more surfaces.
The vertex of the pyramid will be the projection in height at the centre of
gravity of the base

The function has the following requests:

Example:

67
3.4.5 Enter new 3D curves
Maestro provides functions to create 3D curves. To access the commands enter the
“Draw” area of the application menu and press “3D Curves”.

The methods available and their main features are described below.

3.4.5.1 3D arc

To create an arc in the space click on “3D arc”.

Then proceed as follows:

- Select the start point

- Select the intermediate point

- Select the end point

This will result in an arc that lies on the plane through the 3 points described.

Note that:
- The points can be entered by combining the mouse and keyboard.
- The arc generated is shown in red to distinguish it from an arc that has been
defined on a plane

68
3.4.5.2 3D composite line

To create a break in the space click on “3D composite line”.

Then proceed as follows:

- Select the start point

- Select a series of subsequent

points

To complete the composite line press “Esc”.

Note that the line is not part of the active plane.

3.4.5.3 Projection

To create a 3D curve by projecting a geometry on a surface, click on

"Projection".

Then proceed as follows:

- select the geometry to project;

- select the target surface.

69
3.4.5.4 Normal surface projection

To create a 3D curve by projecting a curve normally on a

surface, click on "Normal surface projection".

The function has the following requests:

The selected curve will normally be projected onto the surface by generating a 3D curve

3.4.5.5 Wrapping

To create a 3D curve by wrapping a geometry on a surface, click on

"Wrapping".

Then proceed as follows:

- select the wrapping geometry;

- select the target surface.

3.4.5.6 Extract surface edges

To get the 3D curves that make up the surface perimeter, click

on "Extract Surface Edges".

The function does the following:

After selecting the surface, the 3D curves that form the surface perimeter are generated.

70
3.4.6 2D geometry imported from DXF
It is possible to import 2D geometry from an existing DXF file.
To do this, there must be a project with at least one workpiece defined.

To import a DXF file use the “Import dxf” command in the

“Home” “Import” menu.

After selecting the command, the dialogue box appears which allows you to select a “.dxf”
file from the PC disk.
The “DXF program (*.dxf)” filter is already set in the “File type:” box.

71
Once you have selected the file, the
menu shown here appears:

In the menu you can see the name of

the dxf file which is being imported in
the “File Name” field.

You can select:

- the Layers present in the dxf file
- the face on which you want to import
the geometric entities present in the
selected Layers

Use the “Cancel” key to interrupt the

operation.

Use the “Apply” key to begin importing

the dxf file.

At the end of the import

operation this window appears:
(Do you want to see the import report?)

Select “No” to conclude the operation.

Select “Yes” and another window opens,
showing the dxf import operation report.

In the report, for each

layer you can see how
many and which entities
were imported and how
many and which entities
were not imported and the
reason why.

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The report file is also saved in the “Maestro/Report/DXF” folder in XML format.

The name with which it is saved has the prefix “DxfImpor” followed by the date and time.
Example: “DxfImport_20110920_085538.xml”.

The following Dxf versions are supported:

12, 13, 14, 2000, 2004, 2007, 2010, 2013

With the restriction that in Maestro only the 2D geometries will be imported.

The geometries that can be imported are:

-DxfLine
-DxfCircle
-DxfArc
-DxfPolyline2D
-DxfLwPolyline
-DxfPoint
-DxfText
-DxfEllipse
-Spline 2D

Note: The following geometries cannot be imported:

1) SPLINE3D
2) POLYLINE3D

In Autocad 2004 ellipses can be exported as polylines using the “PELLIPSE” variable. This
would allow it to be imported into the packet.

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3.4.6.1 2D geometries advanced import from DXF

In order to associate machining operations to the geometries the CAD designer must
structure the project and the drawing of the geometries in a certain way.
First of all the CAD designed must know the dimensions of the workpiece being produced
and know which machinings must be applied to the geometries to draw. This information is
needed to structure the project correctly.
The CAD project must be structured in layers, as follows:

1. Possess a layer dedicated to the definition of the piece;

2. Possess a layer to describe the surface, for each surface on which you wish to draw
the geometries.
3. Possess a layer to describe processing, for each processing of geometries on a
surface.

The following rules apply especially to create layers:

1. All layers that are to be interpreted and managed by "advanced import" must have
their names beginning with the key: XLY.
2. The XLY key is followed by a set of key values. If the values are alphanumeric, they
must start and end with the separator character $.
3. The keys allowed in the layer name are:
- P: work plane (E.g.: XLYP1 is the layer referred to the upper plane). The
values allowed are: 1, 2, 3, 4, 5, 6 for standard planes (1=upper plane, 2=r
plane, 3=l plane, 4= front plane , 5= rear plane, 6=lower plane), and values
from 7 upwards for the user planes.
- T: technology and processing (E.G.: XLYP1T$FORA1$ geometries on the
upper surface and technology application FORA1 to the geometries). The
value of these keys is alphanumeric and represents the name of the
technology (technology file name without an extension). The values must
correspond to the technologies that will be used in Maestro.
- H: piece height. Valid key only for the layer that defines the piece: it is only
allowed if the surface is P1 and there are no associated technologies (E.G.:
XLYP1H18). The value of this key cannot be alphanumeric.
- OX: coordinate X of the plane origin. Key valid only for user planes and not
for standard planes: all planes of greater index equal to 7 are allowed and no
technologies must be associated (E.g.: XLYP7OX100). The value of this key
cannot be alphanumerical.
- OY: coordinate Y of the plane origin. Key valid only for user planes and not
for standard planes: all planes of greater index equal to 7 are allowed and no
technologies must be associated (E.g.: XLYP7OY100). The value of this key
cannot be alphanumerical.
- OZ: coordinate Z of the plane origin. Key valid only for user planes and not
for standard planes: all planes of greater index equal to 7 are allowed and no
technologies must be associated (E.g.: XLYP7OZ100). The value of this key
cannot be alphanumerical.
- RX: rotation angle expressed in degrees, of the reference system integral to
the plane around its X axis. Key valid only for user planes and not for
standard planes: all planes of greater index equal to 7 are allowed and no

74
 technologies must be associated (E.g.: XLYP7RX45). The value of this key
cannot be alphanumerical.
- RZ: rotation angle expressed in degrees, of the plane reference system
around the Z axis of the absolute reference system. Key valid only for user
planes and not for standard planes: all planes of greater index equal to 7 are
allowed and no technologies must be associated (E.g.: XLYP7RZ45). The
value of this key cannot be alphanumerical.
4. The layer name must not contain spaces, unless within the separator characters.
5. The piece definition (dimensions DX, DY and DZ) is carried out by means of a layer
that contains a rectangle whose dimensions define DX and DY. The thickness of
the piece (DZ) is defined in the layer name by means of the H key followed by the
corresponding value. Only one layer must contain this information.
6. For correct positioning of the geometrical entity, you must have a reference for each
surface used. Therefore, each surface containing one or more entities must have a
layer name like
XLYP<layer name>
containing a rectangle having dimensions equivalent to those of the associated
surface. The entity contained on it will then be positioned in the DXF project in
relation to the said rectangle. If one or more layers refer to a surface, which has not
been supplied with a layer description, processing contained therein will be rejected
with an error message for the user. The layer associated with the upper surface
must always exist since it is conventionally committed to describe the dimensions of
the piece, therefore, it is the only layer that contains the "H" key. The geometry
contained in this layer will describe the upper surface of the piece and, if necessary,
the lower surface (should this not be described).
7. The definition of the layer for a user plane follows different rules to the standard
planes. The layer is defined by drawing the rectangle that describes the plane in
any position of the DXF project. The geometries inside the rectangle must be drawn
with local reference at the rectangle origin, that is in relation to the origin of the
plane being created.
8. The sequence used to define the technological layers (ES XLYP1T$FORA1$)
defines the sequence with which the machining operations must be created inside
the project. For example, in order to create 3 layers, one routing, one trimming and
one drilling, to obtain the following type of machining:
1- Trimming
2- Drilling
3- Routing
the layers must be defined in the following order
XLYP1T$Contornatura$
XLYP1T$Foratura$
XLYP1T$Fresatura$

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VALID EXAMPLES:

XLYP1H18
XLYP3
XLYP1T$FORA1$
XLYP3T$FRESA LAMA$
XLYP2T$FORA LAT5$

NON-VALID EXAMPLES

P1H18 (initial XLY key missing)

XLYP1H18T$FORA1$ (H specified in combination with a technology)
XLYP1 T$FORA1$ (presence of a space besides the separators $)
XLYP1TFORA1 (no separators $ with alphanumeric type values FORA1)

Moreover, geometries must be made by keeping the characteristics of processing and the
tool path in mind:

- If processing envisages the use of a tool compensation, for example the use of left
correction, this restricts the CAD designer in drawing the geometries. For example,
making closed geometries in a clockwise and anticlockwise direction; the first case
of processing will be carried out externally from the geometry profile whilst the
second will be inside it. Similarly, the designer will have to keep the direction in
mind also for open geometries since processing an AB segment will be different
from that of a segment covering the opposite direction (segment BA).

3.4.6.1.1 Import 2D geometries from DXF for machining

By way of an example, here is a project to make a plank of wood composed of three

pieces. For each piece, it is necessary to define a .dxf file, which describes the associated
geometries for each individual piece and its relative processing. Below is a representation
of the plank and parts it is composed of.

In the example, we assume that the geometries refer to the upper surface of all pieces
taken into consideration and that each side of the geometry needs to be processed with a
different technology than the others. In detail, for each piece, assuming we have to firstly
execute contouring of all the geometries and then execute the required processing for
each of their sides. The upper side of the geometry requires milling processing by means
of a tool having a convex shape whilst the lower one requires a concave shape.

76
Instead, processing associated with the sides of the geometries enable the finish of the
side, if this corresponds to an external side of the plank, or shaping it as a junction to the
adjacent piece if this is the side of the junction.

For contouring operations, TECH0.tchx technology is assumed to be available, while

milling with a convex tool is for TECH2.tchx technology and a concave tool is for
TECH3.tchx technology. To make a junction, TECH1.tchx and TECH5.techx technologies
are assumed to be available, which correspond to milling the left and right side of the
junction. The finish is instead obtained by means of TECH4.tchx technology. For all
technologies taken into consideration, it is assumed that tool correction is on the left.

To import a DXF, you must use an "Importa dxf" control from the menu
"Home" "Importa".

After having selected the control, a dialogue window will appear that enables you to select
a ".dxf" file from the PC's disc.

Below are the layers created for each piece with the relative geometries and associated
processing.

77
PIECE A:

Layer Technology Operation

XLYP1H30 - Piece definition and upper
surface

Layer Technology Operation

XLYP1T$TECH0$ TECH0.tchx Contouring

Layer Technology Operation

XLYP1T$TECH1$ TECH1.tchx Left Junction

Layer Technology Operation

XLYP1T$TECH2$ TECH2.tchx Convex milling tool

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 Layer Technology Operation
XLYP1T$TECH3$ TECH3.tchx Concave milling tool

Layer Technology Operation

XLYP1T$TECH4$ TECH4.tchx Finish

PIECE B:

Layer Technology Operation

XLYP1H30 - Piece definition and upper
surface

Layer Technology Operation

XLYP1T$TECH0$ TECH0.tchx Contouring

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 Layer Technology Operation
XLYP1T$TECH5$ TECH5.tchx Right Junction

Layer Technology Operation

XLYP1T$TECH1$ TECH1.tchx Left Junction

Layer Technology Operation

XLYP1T$TECH2$ TECH2.tchx Convex milling tool

Layer Technology Operation

XLYP1T$TECH3$ TECH3.tchx Concave milling tool

80
PIECE C:

Layer Technology Operation

XLYP1H30 - Piece definition and upper
surface

Layer Technology Operation

XLYP1T$TECH0$ TECH0.tchx Contouring

Layer Technology Operation

XLYP1T$TECH5$ TECH5.tchx Right Junction

Layer Technology Operation

XLYP1T$TECH2$ TECH2.tchx Convex milling tool

81
 Layer Technology Operation
XLYP1T$TECH3$ TECH3.tchx Concave milling tool

Layer Technology Operation

XLYP1T$TECH4$ TECH4.tchx Finish

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3.4.6.1.2 Import 2D geometries from DXF for edge banding

The edge banding process can be defined starting from a project structured with the
specifications defined at the beginning of the chapter, introducing layers that identify the
edge banding machining operations.
In particular a layer associated to an edge banding technology must be defined as
specified in item 1, with the same structure and syntax (e.g. XLYP1T$BORDATURA$).
The difference in this case is in the way the geometries to which the edge bandings are
associated and the machining operations defined in the technological process are defined.
As opposed to earlier where the entire technology is applied to each geometry, in this case
one or more machining operations specified in the technology can be applied to each
geometry section, with the start and end points being the ends of the geometry.
Independently of whether the geometry being machined is closed or open, to perform a
specific machining on a section, the total geometry must not be drawn as a single curve
(e.g. polyline) but as a set of more or less elementary curves (e.g. segments, arcs,
polylines) and a colour associated to each section with the RGB code. This code must be
the same colour code of the machining in the technology. In this way the system will create
a single geometry as a combination of all the defined geometries and apply the associated
machining operations to each section. The order in which the geometries are drawn is
used to define the machining sequence of the edge banding process.
The drawing of the geometries must be produced so that the direction is always clockwise.

Figure 1 shows a practical example.

Figure 1.

The final geometry must be a rectangle, to which the edge banding process is applied.

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The resulting sequence must be as follows:

1- Routing the whole rectangle

2- Edge banding upper side with edge B1
3- Upper side end trimming
4- Edge banding lower side with edge B1
5- Lower side end trimming
6- Edge banding right side with edge B1
7- Right side end trimming
8- Edge banding left side with edge B2
9- Left side end trimming
10- Trimming upper-right-lower side with trimmer RE1
11- Trimming right side with trimmer RE2
12- Scraping upper-right-lower side with scraper RA1
13- Scraping left side with scraper RA2
14- Shaving the 4 corners

To obtain the sequence the 4 lines are drawn to form a clockwise rectangle and a colour is
associated to each line, as shown in figure 1.

The application of the technology associated to the layer, follows two fundamental rules:
1- Technological process
2- Order of the geometries and colour associated to the geometry

This means that during the application phase, if present in the technology, the routing is
automatically applied to the whole geometry obtained by joining the 4 sections that must
have matching start and end points. The routing is applied with start in the middle of the
first side.

Immediately after the routing the edges present, that will be applied by following the order
with which the geometries have been drawn, are analysed.
With the reference to the example, the geometries that must be edge banded must be
drawn in the following order:
1- Red upper segment
2- Red lower segment
3- Red right segment
4- Yellow left segment

In this way, during the import phase, if in the technology a red edge banding and a yellow
edge banding are found, the 4 edge bandings will be applied by following the sequence
with which the geometries have been drawn and the single requested edge banding
technologies.
The upper side will be edge banded first with edge B1, the lower side second with edge
B1, the right side third with edge B1 and the left side fourth with edge B2.

Once the edge bandings have been inserted it checks if there is, for each section that has
a colour, an end trimming technology with the same colour.
If there is the end trimming associated to the colour will be applied to each edge banding
section.

84
The same applies for the trimming, for each geometry section with a colour it checks if
there is the relative trimming technology, but in the application phase the trimmings with
the same tool are joined together, if possible, in a single trimming operation.
In the example, as the upper-lower-right side are red, they are given the same trimming,
therefore a single trimming with trimmer RE1 is created.
The yellow left side is trimmed with trimmer RE2.

The same applies for the edge scraping and glue scraping operations.

The shavings are managed automatically, during the application the applicability of the
shaving for each edge banding is checked and where possible it is applied.

To obtain the rectangle edge banded with 2 edges, B1 on the upper-right-lower and B2 on
the left, we have had to create the rectangle with 4 section in the correct sequence and
associate to each section the edge banding colour present in the technology.

85
The example in figure 2 shows a case with sections not edge banded.

Figure 2.

In this case the upper section of the panel must not be edge banded. This is achieved by
drawing the section, but the transparent RGB is associated as the colour.
As opposed to the example of figure 1 this achieves:
1- Routing the whole rectangle
2- Edge banding right side with edge B1
3- Right side end trimming
4- Edge banding left side with edge B2
5- Left side end trimming
6- Edge banding lower side with edge B3
7- Lower side end trimming
8- Trimming right side with trimmer RE1
9- Trimming left side with trimmer RE2
10- Trimming lower side with trimmer RE3
11- Scraping right side with scraper RA1
12- Scraping left side with scraper RA2
13- Scraping lower side with scraper RA3
14- Shaving the 4 corners

Similarly to example 1 the first machining applied is the routing of the whole panel, starting
from the geometry start point.
Followed by the edge banding of the right with edge B1 (red), left with edge B2 (yellow),
and lower with edge B3 (blue).
Followed by the end trimming associated toe the single edge bandings.
Followed by the trimming of the right with trimmer RE1 (red), left with trimmer RE2
(yellow), and lower with trimmer RE3 (blue).
Followed by the scraping of the right with scraper RA1 (red), left with scraper RA2 (yellow),
and lower with scraper RA3 (blue).
The shavings are applied automatically.

86
3.4.7 Geometry selection

Once all geometric entities or working processes have been inserted, it is often necessary
to select them in order to carry out several operations

You can select a single entity by clicking with the left button of the mouse on the desired
entity.
The selection is clearly visible because it is red-coloured.

In order to select more than one entity you can press - like for the single selection - "Shift".

In order to make a quicker multiple selection, this is a suitable method:

- press the left button of the mouse
- move the mouse (a rectangle is drawn)
- release the left button of the mouse

At this point all entities included in the rectangle will be selected and red-coloured.

87
3.4.8 Contextual Menu of graphic area

After selecting one or more geometric entities or working processes, if you click with the
right button of the mouse, one of these two menus will appear with the commands related
to the selected geometric elements.

The first menu will appear if you select two or more elements.
The second one if you select one geometric element.
The third if you select only one working process.

It is possible to display "Properties" only for one entity.

If there is no geometric entity among the selected elements, the commands "invert”, "Join”
and "Explode” are inhibited.

In case of one working process, it is possible to display the "Properties" of the working
process or the "Properties" of the geometry concerning the working process.

88
3.4.9 Geometry removal

After selecting one or more geometric entities, you can delete:

- by clicking with the button "Canc"
- or clicking on the command "Remove" of the menu "Home" "Clipboard"
- or on the command "Remove" if the contextual Menu.

3.4.10 Geometry properties

Every geometric feature has several properties.

In order to display the properties of one element:
- Select the object (red-coloured)
- click on the command "Geometric properties of the contextual menu”
- The resulting table will show you the geometric data.

The tables displayed for every entity have been reported in the paragraphs related to the
geometry inserting commands.

By marking the field "absolute Coordinates”, the data will not refer to the faces on which
the geometry has been built but to the three-dimensional "Zero" of the Project.

By changing the values in the fields of properties it is possible to modify the geometry.

This function cannot currently be applied to the 3D surfaces and curves.

89
3.4.11 Change existing geometries
Icons related to commands to modify basic geometries are to be found in the menu "Draw"
"Modify".

All commands of geometry modification are interrupted by selecting a new command or

pressing the button "Esc".

The “Cut”, “Extend”, “Start point”, “Join, “Explode” commands cannot be applied to the 3D
surfaces and curves. To change surfaces, see the relevant paragraph.

3.4.11.1 Cut

It removes a workpiece of a geometric entity intersected by other entities.

If an entity is not intersected by any line, it will be completely deleted.

In order to remove a workpiece of geometric entity:

- Click on the command "Cut”
- move the mouse (the entity workpiece to delete is green-coloured, in bold)
- click on the left button of the mouse

3.4.11.2 Extend

It extends the geometry of a geometrical entity until it intersects with other entities.

To extend a geometrical entity:

- click on "Extend"
- select the entity to be extended
- select an entity that intersects the entity to be extended
(the entity to be extended becomes blue and thick representing the new shape it will
have, while moving the mouse on the many entities).

90
3.4.11.3 Invert

It inverts the initial point with the final one of any geometric entity.
The command is available in the menu "Draw” “Modify” as well as in the “Contextual
menu).

In order to invert the direction of one or more geometries:

- Select one or more geometric entities
- click on the command "Invert”
The inversion is evident when the symbol linked with the geometric initial point has
changed.

The “Invert” command, if applied to surfaces, inverts the normal of the surface.

3.4.11.4 Initial point

It changes the initial point of a closed geometry (circle or polyline).

In order to modify the initial point of a closed geometry:

- click on the command "Initial point”
- move the mouse
- click with the left button of the mouse (for a new initial point )

The representation of the initial point is performed with an arrow that detects the position
and the direction.

3.4.11.5 Join

It creates a polyline by combining geometric entity with coinciding vertex.

The command is available in the menu "Draw” “Modify” as well as in the "Contextual
menu”.

In order to combine one or more geometries with coinciding vertex:

- Select one or more geometric entities
- click on the command "Join"

One or more polylines can be combined only with the entities that have coinciding vertex.
In case of more entities with coinciding vertex, the entities inserted in the polyline will
follow the selection order.

The direction of the new polylines is casual

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3.4.11.6 Explode

A polyline explodes in all basic geometric elements in its structure.

The command is available in the menu "Draw” “Modify” as well as in the "Contextual
menu”.

In order to explode one or more polylines:

- select one or more polylines
- click on the command "Explode”

The direction of the single entities will be the one inside the polyline.

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3.4.11.7 Change surfaces

To change a surface click on “Change surfaces”.

There are two commands to change the surfaces:

- Extend surface;
- Intersection between surfaces.

3.4.11.7.1 Extend surfaces

To extend the surface proceed as follows:

- select the surface to extend;

- enter the extension length values.

The surface extension occurs in tangency and it generates a new surface that replaces the
original one.

3.4.11.7.2 Intersection between surfaces

The surfaces intersection procedure is performed as follows:

- select the first surface;

- select the second surface.

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3.4.11.7.3 Cut surface

The surface cutting procedure requires:

- selecting the surface to be cut;

- selecting one or more curves.

The permitted curves must be:

- Closed (if inside the surface)
- Open but with the initial and final points on the edge of the surface

The result will be to divide the original surface into two or more surfaces.

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3.4.12 Move and/or copy the existing geometries

The icons on the commands to move, rotate, mirror or copy the existing geometries are to
be found in the menu "Draw” “Modify”

All commands of geometry modification are interrupted by selecting a new command or

pressing the button "Esc".

Further recurring commands are to be found in the menu "Home" "Clipboard".

The “Mirror” and “Oppose” commands are not valid for 3D surfaces and curve geometries.

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3.4.12.1 Move

Move one or more entities from one point to another one.

The command is available in the menu "Draw” “Modify” as well as in the "Contextual
menu”.

In order to move one or more entities:

- select one or more entities
- click on the command "Move”
- type the reference point
- type the final point

Or:
- click on the command "Move”
- select one or more entities
- type the reference point
- type the final point

This command has three options:

- Create a copy
- Sequence (Single/Multiple)
- Coordinates (Relative/Absolute)

The option "Create a copy” allows you to make a copy out of the source text.

The option Multiple Sequence allows you to keep on moving the element by typing further
final points.

The option "Absolute Coordinates" allows you to stop the select geometries at a certain
level starting from a zero level of the work plane.

96
3.4.12.2 Rotate

Rotate one or more entities.

The command is available in the menu "Draw"”Modify” as well as in the "Contextual
menu”.

In order to rotate one or more entities:

- select one or more entities
- click on the command "Rotate”

Or:
- click on the command "Rotate”
- select one or more entities

If you rotate two-dimensional elements:

- type the reference point
- set an angle (typing the point or inserting the value)

If you rotate three-dimensional elements i :

- Select an axis or a vector or define a vector by entering two points
- set an angle (typing the point or inserting the value)

This command has two options at disposal:

- Single Sequence
- Multiple Sequence)

The Multiple Sequence option allows you to continue rotating the selected items by making
a copy each time you set a new angle.

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3.4.12.3 Mirror

It mirrors one or more entities compared to the axis of the centre line in the work face.
The command is available in the menu "Draw" "Modify" as well as in the "Contextual
menu”.

This command works only in case of standard faces.

In order to mirror one or more entities:

- select one or more entities
- click on the command "Mirror”
- select the mirror mode in the menu
- click on the button "Apply"

This commands has five options:

- Mirror in X
- Mirror in Y
- Mirror in X/Y
- Keep in the source form
- Invert the working process

The option "Mirror in X” mirrors the geometry compared to the Y-axis of the centre line in
the active face.

The option "Mirror in Y” mirrors the geometry compared to the X-axis in the middle of the
active face.

The option "Mirror X/Y" mirrors the geometry compared to the X and Y axis in the middle
of the active face (this mode is like a rotation of 180°)

The option "keep the source geometry" allows you to make a copy out of the source
geometry.

The option "Invert working process” allows you to invert the direction of the working
process if the command "Mirror” is used to mirror a working process.

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3.4.12.4 Oppose

It copies one or more entities on the standard face opposite to the active one.
The command is available in the menu "Draw" "Modify" as well as in the "Contextual
menu”.

This command works only in case of standard faces.

In order to copy one or more entities on the opposite standard face:

- select one or more entities
- click on the command "Oppose”
- click on the button "Apply"

This command has two options at disposal:

- Keep in the source form
- Invert the working process

The option "keep the source geometry" allows you to make a copy out of the source
geometry).

The option "Invert the working process” allows you to invert the working direction if the
command "Oppose" is used for a working process.

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3.4.12.5 Cut

It cuts one or more geometric elements or working processes in order to put them in the
buffer for the option "paste”.
The command is available in the menu "Home" "Clipboard" as well as the "Contextual
menu”
and works only for elements of the active face.

In order to cut one or more entities from the active face.

- select one or more entities
- click on the command "Cut” or press "Ctrl-x"
- type one reference point.

As a result of the geometry of the selected working process it will disappear from the
display.

3.4.12.6 Copy

It copies one or more geometric elements or working processes in order to put them in the
buffer of the option "Paste)
The command is available in the menu "Home" "Clipboard" as well as the "Contextual
menu"
and works only for the elements of the active face.

In order to copy one or more entities from the active face:

- select one or more entities
- click on the command "Copy” or press "Ctrl-c".
- type one reference point.

You do not notice any effect but the previously selected geometry will be available to be
copied through the option "Paste”

3.4.12.7 Paste

It pastes one or more geometric elements or working processes that have previously been
selected from the option "Cut” or "Copy”
The command is available in the menu "Home" "Clipboard" as well as the "Contextual
menu”

In order to paste one or more entities on the active face:

- click on the command "Paste” or press "Ctrl-v"
- type one reference point.

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3.5 Working processes

The commands in order to insert the working processes are to be found in the menu
"Operations”

Every working process must be carried out combining a tool with a 2D geometry.
As a result, it is necessary to activate a Tool- Data-Base (see paragraph 10.8)

In order to set any working process, it is useful to keep this structure in mind:
1) Set the position in which you carry out the working process (Pos)
2) Set the Geometric Shape of the working process (Geo)
3) Set the Work mode (Mode)
4) Set the technology adopted (tool, speed and so on).

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3.5.1 Boring

In order to bore, you can:

- click on the command "Boring”
- select one or more 2D elements

Or:
- select one or more 2D elements
- click on the command "Boring”

The selection of 2D elements can be single or multiple as

the option for boring will make bores connecting them with
the points or the circles.

3.5.1.1 Bore position

If, among the selected elements, there are points and/or

circles, the bore position is automatically set.

If no point or circle has been selected, you can set the

position of a new point in this way:
- select the reference face
- select the reference edge on the face
- fill the field X Coordinate in
- fill the field Y Coordinate in

The reference edge on the face allows programming the hole

with X and Y coordinates that are related to the user-selected
reference point. In the case of PowerFlex machines, if you
want to draw holes with coordinates relative to the
mechanical zero of the machine, for the upper face holes you
must select the left upper edge.

102
It is possible to set a set of matrix bores by using the sub-menu "Repetitions”

to this purpose, the nearby menu fields must be filled in.

Rotat. 1 represents the angle to set the lines
Rotat. 2 stands for the angle to set the columns compared to
the lines

By clicking on the button "Preview", you obtain a

representative table that displays the bore position as
described above.

3.5.1.2 Bore structure

In order to set the bore structure, Diameter, Depth and bore Type must be set in the menu.

In field "Depth" you will insert the value corresponding to the

thickness of the workpiece in case the option "Passer-by” is
selected.

If the "boring" operation has been performed by selecting a

circle rather than a point, the field "Bore diameter” will be filled
with the value of the circle diameter.
In this case, if you wish to change the diameter, you can
unmark the heading "Keep circle diameter” and set a new
diameter.

The field "Extra depth is filled with the extent through which the bore must go beyond the
thickness of such workpiece (this heading will appear only if the option "Passer-by" has
been selected")

The type of bore must be specified when it is not linked to a drilling tool and in this case, in
order to choose the tool, you need this information.

The hole types are as follows:

- Hole with flat bottom
- Hole with tapered bottom
- Counterbored hole in top part and with tapered bottom

Select the types from the "Type of hole" field

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3.5.1.3 Boring mode

In order to set how to structure the bore, you use the sub-menu "Strategy”

The bore can be performed in a single or a multiple rub.

The following can be set with multi-pass:
- the "Number of passes" required to make the hole.

- The "Pass depth" visible when selecting "Enable

pass depth" field.

3.5.1.4 Boring technology

In this step, you set all technical aspects related to tools, spindles and machines at
disposal.

See the following chapters:

3.5.13 Technological data (shared by the machining operations)

3.5.15 Advanced data (common to machining)
3.5.16 Machine data (shared by the machining operations)

3.5.1.5 Drilling deduced from the surface

If a cylindrical surface is selected which refers to a hole, all the geometric parameters of
the dialog boxes will be automatically filled.
In the case of multiple selection of coaxial surfaces of suitable shape and position, the
system can recognize flared or counterbored holes.
The user can still modify the precompiled fields.

If a through hole is recognized, if possible a lance point will be used and a depth
determined to guarantee the through hole.

The condition in which the hole is made is that the hole axis is orthogonal to one of the six
planes of the part or to a previously created user plane.

104
3.5.2 Inclined drilling

To insert one or more holes we can:

- click on the "Drilling" command
- select one or more 2D elements

Or:
- select one or more 2D elements
- click on the "Drilling" command

The 2D elements selected can be single or multiple because the

"Inclined drilling" function will produce holes by associating them
only with the points or circles.

3.5.2.1 Position of the inclined hole

If the selected elements have points and / or circles, the position

of the holes is determined automatically.

If no point or circle has been selected, the position of a new point

can be defined by entering the coordinates X, Y, Z

3.5.2.2 Shape of the inclined hole

To define the shape of the hole, the Diameter, Depth, Angles A and B Type of hole must
be set in the menu.

If drilling was done by selecting a circle instead of a point, the "Hole diameter" field will
represent the value of the circle diameter.

The Type of hole must be specified when no tool is associated with the drilling, and in this
case, this information is needed to make the automatic tool selection.
The types of hole are the following:
- Hole with flat bottom
- Hole with conical bottom
- Flared hole in the upper part and with a conical bottom
- Counterbored hole (Blitz)

The types can be selected from the "Hole type" field

The angles A and B are used to determine hole inclination.

105
3.5.2.3 Inclined drilling mode

The same applies to drilling

3.5.2.4 Inclined drilling technology

The same applies to drilling

3.5.2.5 Drilling deduced from the surface

If a cylindrical surface is selected which refers to a hole, all the geometric parameters of
the dialog boxes will be automatically filled.
In the case of multiple selection of coaxial surfaces of suitable shape and position, the
system can recognize flared or counterbored holes.
The user can still modify the precompiled fields.

3.5.3 Automatic drilling deduced from the surfaces

This function recognizes all the inclined holes and holes present in the selected surfaces.

To use this function, use the "Automatic

hole recognition" command in the
"Operations-3D Machining" menu

The operating mode is similar to that

described in drilling and inclined drilling with
the following additional functions:

"Create User Plan for 3D Drilling" Creates a plane for each recognized inclined hole.

"Fast surface analysis" will only recognize cylindrical holes and involves a low processing
time.By removing the check to this parameter, also countersunk and counterbored holes
will be recognized at the cost of longer processing time.

Once the surfaces to be analysed have been selected, the maximum diameter below
which the surfaces are recognized as holes must be set.

The generated holes will start from the work plane closer to the hole geometry.
It is advisable to check the correct assignment of the tools which will perform inclined
drilling.

If more than one hole has been generated on the same user plane, it is advisable to check
that they can be implemented by switching to the safety level from the user's plane,
otherwise the programming must be corrected.

106
3.5.4 Milling

In order to insert one or more milling operations you can:

- click on the command "Milling”
- select one or more 2D elements

Or:
- select one or more 2D elements
- click on the command "Milling”

The selection of 2D elements can be single or multiple

because the function "Milling" will perform milling operations
connecting them with lines, polylines, arcs and circles.

3.5.4.1 Miling position

If there is any line and/or polyline and/or arc and/or circle

among the selected elements, the milling position is
automatically set.

The real position of every milling is affected by the used tool

correction and the super-material.

In the following tables it is possible to understand how the different combination of options
work.

The light blue line stands for the "2D geometry" and the red line represents the tool path in
the tool centre.

By marking "Correction C.N.”, it implies that the coordinates of the 2Dgeometry are passed
and the effective path (red line) will be calculated by the CN.

If you mark "Cad correction”, the coordinates of the red line are directly transferred to the
CN and this latest will not make any correction.

107
Behaviours with left, central and right corrections without any correction in length and
without any super-material.

Behaviours with left, central and right corrections in length and without any super-material.

108
Behaviours with left, central and right correction without any correction in length and with
super-material.

Behaviours with left, central and right corrections in length and with super-material.

109
3.5.4.2 Milling form

In order to set he milling form you have to set Length and Depth in the menu.

The field Width is automatically filled when a tool is

connected with the milling.

In field "Depth" you will insert the value corresponding to the

thickness of the workpiece in case the option "Passer-by is
selected.

The field "Extra depth" sets the extent of the milling to cross
the workpiece. (This heading will appear only the option
"Passer-by" has been selected)

The field "Indivisible processing" (currently used only for Cyflex machines) ensures that
such machining is not performed in one or more stages for those automatically generated
when using Cyflex
If an error is generated during the optimisation phase, the operator must replace the
machining operation with the selection with two or more machining operations that
produce the same operation.

110
3.5.4.3 Milling modes

In order to set how to perform the milling, you use the sub-menus "Strategy" and
"Approach/Removal".

The milling can be performed only in one or more rubs.

In case of "multi-rub", you must choose between One- way

or two- ways strategy.

In the "one-way strategy", you have to establish if the rise

between two rubs must occur:
- at a safety level on the workpiece
- or in the workpiece

Use the "Tools" "Options" "Parameters" "Machining" menus

to modify these two parameters.

For the one-way strategy as well as for the two ways

strategy, the heading "Enable multi-rub” must be marked
and the values "Rub depth” and depth "Last rub.”

Another modification to the milling mode can be set by the menu "Advanced data" through
the parameter "Invert".(See 3.5.15 Advanced data (common to machining)

By marking this parameter, the working process can be performed starting from the final
point of the selected 2D geometry.(See 3.5.14 Approach/Retraction (shared by the
machining operations))

3.5.4.4 Milling technology

See the following chapters:

3.5.13 Technological data (shared by the machining operations)

3.5.15 Advanced data (common to machining)
3.5.16 Machine data (shared by the machining operations)

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3.5.5 Slanted routing

To enter one or more tilting routing proceed as follows:

- click on “Tilting routing”
- select one or more 2D elements

Or:
- select one or more 2D elements
- click on “Slanted routing”

The 2D elements selection can be single or multiple.

3.5.5.1 Tilting routing position

The position of the tilting routing is determined automatically by the geometry selected.
The tool correction is available only if the tool is perpendicular to the right or left and the
Angle A is equal to 0.
To use the tool correction see chapter 3.5.4.1 Routing position.

3.5.5.2 Tilting routing shape

To define the tilting routing shape set the parameters in the menu:

The “Width” is set automatically based on the diameter of the tool

selected (cannot be edited).

The “Depth” is the position Z in relation to the plane selected.

The “Angle A” indicates the tool rotation in relation to axis X

The “Angle B” indicates the tool rotation in relation to axis Z.

The “Tools position” can be set in the 5 modes visible in the menu.
Bear in mind that the positions are considered before the setting of
the “Angle A” parameter.

By selecting “Parallel axis X” the tool axis will be parallel to axis X,

angle B will rotate the tool in the X-Z plane.
After having selected this mode, setting Angle A the tool axis will
no longer be parallel to axis x.
During the whole tilting routing in this mode the tool will always
maintain the same setup.

Selecting “Perpendicular to the right” the tool will enter from the

112
right in relation to the first geometrical entity of the trajectory.
The setup will be maintained for the whole machining operation.
Selecting “Perpendicular to the left” the tool will enter from the left in relation to the first
geometrical entity of the trajectory.
The setup will be maintained for the whole machining operation.

Selecting “Parallel start point” the tool will position itself with an inclination of Angle B set in
the plane of the first geometrical entity of the trajectory.
The setup will be maintained for the whole machining operation.

Selecting “Parallel trajectory” the tool will position itself with an inclination of Angle B set in
the plane of the first geometrical entity of the trajectory.
The setup will be recalculated in the same for each subsequent geometrical entity of the
whole machining operation.

3.5.5.3 Tilting routing mode

To define how the tilting routing is performed use the “Approach/Retraction” submenu.

See the use of the parameters of the “Approach/Retraction” menu in paragraph 3.5.14
Approach/Retraction (shared by the machining operations)
The arc approach and retraction are disabled.

3.5.5.4 Tilting routing technology

See the following chapters:

3.5.13 Technological data (shared by the machining operations)

3.5.15 Advanced data (common to machining)
3.5.16 Machine data (shared by the machining operations)

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3.5.6 Chamfering

To enter one or more chamfering proceed as follows:

- click on “Chamfering”
- select one or more 2D elements

Or:
- select one or more 2D elements
- click on “Chamfering”

The 2D elements selection can be single or multiple.

3.5.6.1 Chamfering position

The position of the chamfering is determined automatically by

the geometry selected.

3.5.6.2 Slotting shape

To define the slotting shape set:

The position of the tool in relation to the geometry (see “Tool position” icons).

The chamfer width quota measured on the plane selected.

The chamfer height (quota measured at right angles to the plane selected).

The chamfer angle is determined automatically after setting the width and height.

The “Extra depth” field is used to move the tool beyond the height set.

114
3.5.6.3 Chamfering mode

To define how the chamfering is performed use the “Approach/Retraction” submenu.

See the use of the parameters of the “Approach/Retraction” menu in paragraph 3.5.14
Approach/Retraction (shared by the machining operations)

3.5.6.4 Chamfering technology

See the following chapters:

3.5.13 Technological data (shared by the machining operations)

3.5.15 Advanced data (common to machining)
3.5.16 Machine data (shared by the machining operations)

115
3.5.7 3D routing
To enter a 3D routing click on “3D routing” in the “Routing” menu.

The geometry cannot be selected, but entered by points.

The tool inclination can be associated to each programmed point.

3.5.7.1 3D routing position

The 3D routing position is determined by all the points entered during the machining
definition.
The tool correction is not available.

3.5.7.2 3D routing shape

The 3D routing shape can be a segment or a broken line of

various segments.
To define the 3D routing shape set the coordinates of the
various points of the broken line.

The “Angle Q” indicates the tool rotation in relation to axis Z.

The “Angle R” indicates the tool rotation in relation to axis X

The tool will maintain the same setup for the whole machining
of the defined section.

To enter other sections use the “Enter point” key.

To see the points entered use the right and left arrows to
navigate in the broken line.

To delete a point use "Z".

3.5.7.3 3D routing mode

The “Approach/Retraction” mode cannot be used.

3.5.7.4 3D routing technology

See the following chapters:

3.5.13 Technological data (shared by the machining operations)

3.5.15 Advanced data (common to machining)
3.5.16 Machine data (shared by the machining operations)

116
3.5.8 Channel

The channel is a milling process with one limit and some added-values compared to the
general milling process.

The limit is due to the fact that the channel can be applied only for a line.
The added-values will be showed in the menu explanation.

In order to insert one or more channels, we can:

- Click on the command "Channel”
- select one or more 2D elements

Or:
- select one or more 2D elements
- Click on the command "Channel”
The selection of 2D elements can be single or multiple because the function "Channel" will
perform milling cutters associated with the lines.

3.5.8.1 Channel position

if there is any line among the selected elements, the channel

position is automatically set.

If no line has been selected, the position of a new line can be

set in this way:
- select the reference face
- fill the X field initial point
- fill the Y field initial point
- fill the X field final point
- fill the Y field final point

The real position of every milling is affected by the used tool

correction and the super-material.

In the tables in paragraph 3.5.4.1(milling position) it is

possible to understand how the different combinations of
options work.

117
We can also change the channel position by using the
parameter "Enable edge” in the sub-menu "Advanced data".
By using this function, the selected segment will be stretched
until it crosses the panel edges.

You can also have a channel extension if you activate the

paramters "Extra initial distance” and "Extra final distance”.

3.5.8.2 Channel structure

In order to set the channel structure, Length and Depth

must be set in the menu.

The field Width is automatically filled when a tool is

connected with the channel.

In field "Depth" you will insert the value corresponding to

the thickness of the workpiece in case the option "Passer-
by” is selected.

It si possible to set a "Final Depth (associated with the final

point of the geometry) different from the one associated
with the final point).
Enter the channel's inclination value, varying from 0° to
180° (not included) in the "Angle °" field. (90° =
perpendicular channel to face)

3.5.8.3 Channel execution mode

The channel execution mode looks like the milling mode

(see paragraph 3.5.4.3).

3.5.8.4 Channel technology

See the following chapters:

3.5.13 Technological data (shared by the machining operations)

3.5.15 Advanced data (common to machining)
3.5.16 Machine data (shared by the machining operations)

3.5.8.5 Channel deduced from surface

If a flat surface is selected, all the geometric parameters of the dialog boxes will be
automatically filled.
The user can modify the precompiled fields and must insert the blade to be used.

118
3.5.9 Blade cut

In order to insert one or more blade cuts you can:

- click on the command "Blade cut”
- select one or more 2D elements

Or:
- select one or more 2D elements
- click on the command "Blade cut”

The selection of 2D elements can be single or multiple because the option "Blade cut" will
performs cuts associated with the lines.

119
3.5.9.1 Cut position

Blade cuts can be performed only on lines on the upper

face.
If there are lines among the selected elements, the cuts
position is automatically set.

If no line has been selected, the position for a new line can
be set in this way:
- Fill the X field initial point
- Fill the Y field initial point
- Fill the X field final point
- Fill the Y field final point
- fill the Inclination field

The real position of every cut is affected by the used tool

correction and by the super-material.

In the tables in paragraph 3.5.4.1(milling position) it is

possible to understand how the different combinations of
options work.

We can modify the cut position using the sub-menu

"Advanced data”

The parameter "Enable edge” extends the selected segment

until the cross of the panel edges.
You can extend it using the parameters "Extra initial dist." and
"Extra final dist."

By using the parameter "Lower reference” the selected

geometry will lie on the lower face.

This working process generates also a work plane on one of

the two surfaces caused by the cut.
The surface will be created on the new external face of the
workpiece, so you must specify the material placement after
the cut using the parameters "To the right of the geometry" "To
the left of the geometry".

120
3.5.9.2 Cut structure

In order to set the structure of the blade cut, Length and

Extra Depth must be set in the menu.

The field Width is automatically filled when the blade is

associated with the cut.

The Depth (whose field is not present) will correspond to the

thickness of the workpiece.

The field "Extra depth” indicates the extent of the cut

overcoming the thickness of the workpiece.

3.5.9.3 Cut mode

Use the following as cutting mode:

- The "invert" function
- The "Cutting" Strategy

See "Advanced Data" menu in paragraph 3.5.4.3 (Milling mode) for use of "Invert"
parameter

The "Cutting" strategy foresees incision for equal length to

the selected geometry, without cutting the workpiece at
"Incision depth", increased by the "Outlet distance".
The blade descends at programmed depth at end of first
incision, simultaneously moving outside the cut equally to
"Side movement" height. The cut will be completed by
returning to initial point.

Note: Side movement accepts values from -0.5 to +0.5m included.

3.5.9.4 Cut technology

See the following chapters:

3.5.13 Technological data (shared by the machining operations)

3.5.15 Advanced data (common to machining)
3.5.16 Machine data (shared by the machining operations)

3.5.9.5 Cut deduced from the surface

If a flat surface is selected, all the geometric parameters of the dialog boxes will be
automatically filled.
The user can modify the precompiled fields and must insert the blade to be used.

121
3.5.10 Contouring

The contouring is a milling that can apply the external contour of the workpiece or the
geometries.

In order to perform the contouring to the external

workpiece:
- click on the command "Contouring"

The resulting menu will show you the parameter of the

selected "workpiece".
By inserting the workpiece contouring, a closed polyline will
be created on the upper face, that overlaps with the
external profile of the workpiece.

In order to insert one or more geometric contouring, you

can:
- click on the command "Contouring"
- click on the parameter "Geometry"
- select one or more 2D elements

Or:
- select one or more 2D elements
- click on the command "Contouring"

The selection of 2D elements can be single or multiple

because the contouring will perform millings associated
only with closed polylines or with circles.

3.5.10.1 Contouring position

The contouring position is automatically set by the selected geometry.

If the contouring is set to the geometry, then it is possible to choose the "Eternal" "Internal"
"Side" from the menu where you can set it.

122
3.5.10.2 Contouring structure

In order to set the contouring structure, you must set Length and Depth in the menu.

The field Length is automatically filled when you associate a

tool to the contouring.

In field "Depth" you will insert the value corresponding to the

thickness of the workpiece in case the option "Passer-by” is
selected.

The field "Extra depth" sets the contouring extent to go

beyond the workpiece (This heading will appear only if the
option "Passer-by" has been selected)

The contouring leaves extra material for subsequent

machining thanks to the "Excess-material" field.

3.5.10.3 Contouring modes

See the use of the parameter “Invert” of the menu Advanced data in the paragraph 3.5.15
Advanced data (common to machining)
See the use of menu parameters "Approach/Removal” in paragraph 3.5.14
Approach/Retraction (shared by the machining operations)

3.5.10.4 Contouring technology

See the following chapters:

3.5.13 Technological data (shared by the machining operations)

3.5.15 Advanced data (common to machining)
3.5.16 Machine data (shared by the machining operations)

123
3.5.11 Emptying

In order to insert one or more empty workpieces you can:

- click on the command "Emptying"
- select one or more 2D elements

Or:
- select one or more 2D elements
- click on the command "Emptying"

The selection of 2D elements can be single or multiple since

the option "Emptying" will carry out working processes
associated with closed polylines or with circles.

For "gripper" machines (CyflexS and CyflexHP), embroidery work is carried out within the
same stapling phase and is not automatically broken.
So if an emptying that is X in size X above the stroke X of the CyflexS clamp or the pitch
between CyflexHP clamps is programmed, Master does not optimize the program by
communicating this error:

In this case it is up to the operator to break the pockets in multiple overlapping pockets
and reduced X size

3.5.11.1 Emptying position

The emptying position is automatically set by the selected geometry.

124
3.5.11.2 Emptying structure

In order to set the emptying structure, you have to set Length Cut and Depth in the menu.

The field Length cut is automatically filled when you

associate a tool with the emptying.

In field "Depth" you will insert the value corresponding to the

thickness of the workpiece in case the option "Passer-by” is
selected.

The field "Extra depth" indicates the extent of the emptiness

on the workpiece ( This heading will appear only if the option
"Passer-by" has been selected).

3.5.11.3 Emptying mode

In order to set how to perform the milling, you use the sub-menus "Strategy" and
"Approach/Removal.

The strategy "Parallel to the contour" aims at making a set

of polylines to a certain offset from the selected polyline.
The space among polylines is calculated according to the
tool-diameter and the parameter Overload. (%).

For a multi-rub management, see paragraph 3.5.4.3 (milling

modes)

See the use of menu parameters "Approach/Removal” in paragraph 3.5.14

Approach/Retraction (shared by the machining operations)

3.5.11.4 Emptying technology

See the following chapters:

3.5.13 Technological data (shared by the machining operations)

3.5.15 Advanced data (common to machining)
3.5.16 Machine data (shared by the machining operations)

125
3.5.12 Work on the lower face
You must have a Weldon head to perform work on the lower part of the workpiece.
The head should be configured correctly following the instructions in the chapter
10.9.1.7.1.

Using the Weldon head requires you to program the machining exclusively on the lower
face of the workpiece.

When working with the Weldon head, an "Angle" field will

appear, indicating the orientation (around the Z axis) that will
have to be headed during machining.

This angle will be calculated beforehand by Master who will

achieve the approach to machining from the side closer to the
machining itself.

126
3.5.13 Technological data (shared by the machining
operations)
This chapter describes those parameters common to most machinings in order to group
the description.

The "Technological Data" session is used to:

Select the head for the machining.

Selecting "Automatic" the system will determine which head to use
for the machining.

Select the tool for the machining.

Set the feed speed during the machining.

Set the number of spindle RPMs.

For PowerFlex machines in the "Technological Data" section you can:

Select the head for the machining. Selecting "Automatic" the system
will determine which head to use for the machining.

Select the Head Group you want to use to do the work. Selecting
"Automatic" the system will determine which head to use for the
machining. To select a heads group, you must select the machine
with which to perform the machining.

Select the head for the machining. Selecting "Automatic" the system
will determine which head to use for the machining. To select a
head, select the group of heads with which to work.

Select the Spindle with which to do the work. To select a spindle,

select a head and activate the "Spindle Selection"

Set the feed speed during the machining. Please note that the
actual speed used in the machine may differ from the one shown
here, depending on the machining couplings operated by the
optimizer by the technology profiles associated with the machine.

Set the number of spindle RPMs.

127
3.5.14 Approach/Retraction (shared by the machining
operations)
In the menu "Approach/Removal" you set the in-and-out mode from the milling path.

For the entry as well as for the exit, you can choose the line or
arc geometry.
The length of these paths is set by "Radius multipl." that, in
case of a milling cutter of 10 radius and a multiplier of 1.2, a
length line of 12 will be added to our path or a radius ray of 12
with a width of 90° and tangent to the initial/final point or the 2D
geometry.

These additional properties can be performed by the machine:

- in case of security level (on level)
- while the point of approach in reached (in fall)
- while the point of removal is reached (in rise)

The surmount is the workpiece worked along the first object of

the polyline.
if this value is higher than the length of the first polyline
element, the working process would end in the last workpiece
of the element.

128
3.5.15 Advanced data (common to machinings)
This chapter describes those parameters common to most machinings in order to group
the description.

The "Advanced Data" menu is used to:

Invert the machining, starting from the final point of the
geometry selected.

Enter a condition that determines whether the machining must

or must not be executed.

Set the start point automatically at:

- In the middle of the first section
- In the middle of the longest section

Enter a comment.

Enter a "Safety quota" for the tool before executing the

machining.

Set the execution priority.

This parameter allows you to group project machining while maintaining the technological
sequence during optimization.
Optimization is done in these cases:
1. When you plan to machine 2 or more workpieces on the surfaces
2. When processing a workpiece on Cyflex machines

When machining multiple workpieces on the surface, the Master Trainer Optimizer may
change the technology sequence.
To maintain the desired technological sequence, you must define the operational priority
for all the jobs which need to remain related by inserting positive and increasing values.
If a Priority value is lower than or equal to the previous one, the batch will be interrupted.

When working on the Cyflex machine, machining associated with increasing Priority values
will be performed at the same stage.
Such method is due to accuracy problems with Cyflex machines when the piece is moved
from one stage to the other.
Machinings consisting of more tool paths: for example, a counterboard hole made with two
different tools might be imprecise if machining consists of two stages.

"Execution priority" mode requires the insertion of a growing value in all machinings that
need to be performed in the same stage.

When the value is equal to zero or to another value that is lower than the last one entered,
the series of machinings to be performed in the same stage is interrupted.

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Example of pgmx
- Hole Execution priority = 1
- Hole Execution priority = 2
- Hole Execution priority = 5
- Hole Execution priority = 3
- Hole Execution priority = 4
- Hole Execution priority = 6

When this program is optimised, holes 1,2,5 shall be executed in the same stage, and
holes 3,4,6 shall be executed in the same stage too although this is different from the first
one.
You want to prevent hole 1 from being in a different stage compared to holes 2 and 5.

For PowerFlex machines in the "Advanced Data" menu, you can:

Set the Processing Priority of the Processing with reference to the following rules:
- Priority 0: Workmanship is not priority over other workmanship, its execution can
take place before, after, or at the same time as other workings, regardless of the
priority value of the latter.
- Priorities 1 to N: Work must be done after all jobs have a priority value other than
zero and lower than the one set for machining, but before all those with a value
other than zero and higher than working priority value. If two jobs have the same
priority value, this does not imply their execution at the same time, but only the use
of the same sorting rule for both.

Set the "reference point" of the machining. This parameter

allows you to specify the reference point that will be
considered for machining machining machining offset after
panel measurement. For each machining you can specify the
reference point by choosing between the four edges of the workpiece or the center point of
the workpiece.
If the user does not specify any reference, during the optimization phase the machining will
be assigned the default reference for the work face. Below is the table of default
references, used for PowerFlex machines with upper left stop of the workpiece:

Work face Default reference

Upper Upper left
Left Lower left
Right Lower right
Front Lower left
Rear Lower right
Lower Lower left

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3.5.16 Machine data (shared by the machining operations)

This chapter describes all the "Machine functions" that can be found in most machining
operations to group the description.
The machine functions available depend on the machine configuration, therefore instead
of describing them together they will be described individually.
This session will probably have a certain amount of dynamism, as it manages devices in
the machine that in the future may be removed or new ones may be added.

The machine functions currently available are:

1) Jerk
2) Jerk3D
3) Main hood
4) Additional hood
5) Rotating axes brakes
6) 5-axes head unrolling
7) Electronic feeler
8) NC speed adjustment
9) Tool blower
10)Mechanical hold-down

3.5.16.1 Jerk

This parameter affects the machine behaviour during the bi-

dimensional machining operations.
The "Adjustment" parameter is set with a value that is significant
from -2 to +5.
With the -2 value the machine will be slow but the machined pieces
will have a good finish.
With the 5 value the machine will be fast but the machined pieces
will not have a good finish.

Selecting the "Spline interpolation" parameter the finish will improve when the machining
has been described with some "Splines" as the edge will be rounded.

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3.5.16.2 Jerk3D

This parameter affects the machine behaviour during the three-

dimensional machining operations.
One of the items from the drop down menu at the side can be
selected.
Selecting "Roughing" the finish will be less accurate
Selecting one of the 3 Finishes the finish will improve.
Generally, as various factors can affect the finish, it is advisable to
perform tests in the machine until the desired finish is achieved.

3.5.16.3 Main hood

This parameter is used to position the main hood of the machining

unit in 5 positions that can be selected from the drop down menu at
the side.

Selecting the "Automatic" option the hood will position itself so that it
skims the surface of the piece.
It will position itself at a value which is the tool length minus the
useful length.

3.5.16.4 Additional hood

This parameter is used to position the additional hood of the

machining unit in 5 or 8 positions that can be selected from the drop
down menu at the side.
The number of positions displayed depends on the machine
configuration.

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3.5.16.5 Rotating axes brakes

The braking of the rotating axes is used in order to improve the

finish of the machined piece.
Braking the rotating axes reduces the vibrations due to the fact that
the motor maintains the rotating axis constantly in position.
The axes that can be braked can be selected from the drop down
menu and depend on the machine configuration.

3.5.16.6 5-axes head unrolling

This function is used when wanting to continue

machining rotating always clockwise or counterclockwise
with the machining unit.
The machine, in order to execute the machining
requested once it reaches the axis limit switch, must
reposition the axis on the opposite limit switch.
to do this:
- the tool must be removed from the piece
- the head rises in Z
- the axis goes to the opposite limit switch (in jargon it
"unrolls")
- the head drops back down in Z
- the tool must return to the machining.

The mode in which the tool will restart the machining can be selected in the drop down
menu.
For entries in "Tangency" there will be an arc entry whose radius will be equal to the tool
radius multiplied by the value set in the "Multiplier" field.

3.5.16.7 Electronic feeler

The electronic feeler is a device that changes the tool Z position

based on the irregularities of the panel being machined.
The management is performed with the following parameters:
- Offset is the distance between tool and feeler
- Compression refers to the compression of the feeler springs
- Gain is a factor that combined with the feed speed delays the Z
movements of the tool in relation to when the feeler has found a
change in the Z position of the piece.
The compression and gain values can be set after carrying a few tests on the pieces being
machined.

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3.5.16.8 NC speed adjustment

The NC speed adjustment, also referred to as "Adaptive cut" allows the NC to change the
feed speed when an excessive cutting stress is detected.
This method could result in non-homogeneous finishes on the piece.
To enable this function click the "Select" field.

3.5.16.9 Tool blower

The following types of blowing options can be enabled:

- Air (air is blown on the tool)
- Air and oil (air and oil are blown on the tool)
- Head (a pneumatic option is enabled on the head)
- Air tank (air is blown on the tool from the lubricant/coolant)
- Air and oil tank (air and oil are blown on the tool from the
lubricant/coolant)

3.5.16.10 Mechanical hold-down

The mechanical hold-down presses the panel on the machine table to guarantee a precise
machining operation.
To enable this function click the "Select" field.

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3.5.17 Edge banding process
Edge banding a panel is a process that includes the following operations:
- Edge banding
- End trimming
- Trimming
- Edge scraping
- Glue scraping
- Shaving

The edge banding process consists of applying the edge to a panel, whilst the end
trimming, trimming, scraping (edge/glue) and shaving operations all complete the process,
but are only found with the edge banding process.

3.5.17.1 Edge banding

The edge banding operation applies an edge to the panel contour.

The edge banding process is created by selecting the Edge banding button in the
"Operations" menu.

Clicking on the button opens the Edge banding window:

Press the Select Geometry button in the window to select a

geometry on which to apply the machining. Please note that
the geometries must lie on the upper plane of the panel and
the edge banding cannot be applied to a point.

Pressing the select geometry button also activates the

“Select Machining Start Point and End Point” command,
which is used to select the start and end point of the edge
banding. You can also specify the routing parameters that
can be applied before the edge banding automatically.

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3.5.17.1.1 Technological Data

The edge banding technological data define the following:

- the type of edge banding; whether the edge is loaded
automatically or manually
- the type of edge to apply; when an edge is selected,
its machining parameters and the feed speed in
particular, will be displayed automatically.

136
Enabling the routing in automatic with the relative router
parameters, two types of machining operations will be
generated: one routing and one edge banding, totally
separate so that they can easily be changed in the future.

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Selecting an edge banding operation in the machining tree creates the panel displaying
the machining data.

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3.5.17.1.2 Approach/Retraction Data

The approach data are:

• Speed from magazine to first approach point

• Speed along approach section
• Speed in last approach section, when the head enters
with an arc on the trajectory.
Downstroke point:

• Coordinate polars of down point: distance and angle.

• Edge banding head inclination in the down section

Approach point:

• Coordinate polars of entry point: distance and angle.

• Edge banding head inclination in the entry section

The retraction data are:

• Speed along retraction section

- Stop time: any stop time in the last retraction section.

Closuret point:

• Coordinate polars of exit point: distance and angle.

• Edge banding head inclination in the exit section

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3.5.17.1.3 Edge banding advanced data

This data is found in the technical specifications of the edge assigned to the edge banding.

Edge Dispensing
• Infeed edge: quantity of edge to insert in infeed to the
profile.
• Total Edge: extra quantity of edge to insert in relation to
the profile calculation
• Safety edge: quantity of edge dispensed to avoid
having the edge in tension during the unwinding
Closure data
• Cut correction: quantity of edge in excess in relation to
the trajectory being edge banded.
End trimmer
- if selected it enables the edge cut by the edge bander
end trimmer blade (always active for closed edge
banding)

Multi edge banding

- if selected it assigns the multi edge banding state to the
edge banding (with a previous edge banding operation)
Lamps
Flat that enables the edge heating lamps in the approach
section

3.5.17.1.4 Machine Data

Machine functions:
- Autostart: if enabled it can be Active or the Stand-by
function after machining.

Head rotation direction, which can be:

- Optimized
- Counterclockwise
- Clockwise

The selection must be made based on the type of machining

being carried out, the type of approach and the type of
geometry being edge banded.

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3.5.17.2 End trimming

The end trimming operation is linked to the edge banding

operation on open profiles. End trimming is not available on
other operations.

End trimming is a cut with a blade performed with a special

tool called end trimmer, which removes the excess edge from
the panel.

Selecting an end trimming operation in the machining tree

creates the panel displaying the machining data.

End trimming data

• X, Y coordinates of the end
trimming point
• Extra depth of the machining
• Angle: end trimmer blade
angle
Tool correction
• Machining allowance:
machining movement in
relation to the point given by
the end trimming
coordinates.
Strategy: this is the machining
mode
- Cut with Blade Centre
- Cut with Blade Periphery

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- Advanced Data

- Safety quota: machining safety quota.

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3.5.17.3 Trimming

The trimming, performed with the trimming tool, removes the excess edge from the profile.
The trimming operation is linked to the edge banding operation. Trimming is not available
on other operations.
Selecting a trimming operation in the machining tree creates the panel displaying the
machining data.

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3.5.17.4 Scraping

Scraping, performed with the scraping tool, scrapes the excess glue or edge from the
profile after the trimming operation.
The scraping operation is linked to the edge banding operation. Scraping is not available
on other operations.
Selecting a scraping operation in the machining tree creates the panel displaying the
machining data.

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3.5.17.5 Shaving

Shaving is linked to the edge banding operation and it removes any irregularities from an
edge at the external angles of an edge banded panel.
It is performed with a double diameter cutter and it is in short a routing operation and the
technological information of this machining operation are the same as those for general
routing.

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3.5.17.6 Edge Banding default settings

The default settings can be set for all the edge banding operations.
Go to: tools, options.

Select parameters, machining to display all the edge banding machining operations and
the properties for each operation that can be entered as default and that will be displayed
automatically during the edge banding machining.

3.5.17.6.1 Edge banding Default

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Edge banding approach

Edge banding retraction

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Edge banding advanced data

Edge banding automatic routing

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3.5.17.6.2 End trimming default

3.5.17.6.3 Trimming default

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3.5.17.6.4 Scraping default

3.5.17.6.5 Shaving default

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3.5.18 Attributes
Various attributes can be assigned to the
machining operation created.
The attributes are assigned in the menu of the
same name:

3.5.18.1 Depth

The depth is used to change the machining

depth along a section of machining.

Select the Depth icon and then select the

machining geometry for which the machining depth must be changed.
For composite lines it is important to select the exact geometry section where the depth
attribute must be entered.

Then select the point along the section

selected.
The positioning can be done by moving the
mouse or by entering the section percentage.

Then enter the depth value.

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A cone symbol, that represents a machining depth change,
will be displayed.
For composite lines the depth will remain constant with the
machining depth for all the geometry sections before the
section containing the attribute. Then the depth will change
until the point with the attribute and then it will remain constant
until the end of the composite line or until the next depth
attribute.

To change the depth attribute

parameters again simply select
the cone symbol and change the
Depth or Position values that will
be displayed in the window.

3.5.18.2 Speed

Select the Speed icon and then select the

machining geometry for which the machining
speed must be changed for just a section or
completely.

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Once selected a marker will be displayed highlighting the percentage of the section where
the speed will be changed.

After the section percentage has been entered, left click on the mouse to enter the new
speed.

153
Once completed, a triangle-shaped marker, proportional to the speed, will be displayed to
highlight the machining speed change.

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3.5.18.3 Microjoints

Cut pieces can be inserted between the different microjoints' contouring to keep the
contoured workpieces linked, avoiding movements.

Passing contouring is the necessary condition for inserting a microjoint.

The Microjoints button is in the Operations-

Attributes menu.

Click on it to display an initial phase for entering the microjoints dimensions:

Particularly length and thickness

Length = microjoint dimension (bridge)
Thickness = bridge height

155
Insert the initial point (use the snap function) once the dimensions are confirmed through
the send key.

156
Insert the final point at the end.
The figure shows an example of microjoints made in the medium point of rectangular
figures' longer side.
System intercepts all passing contouring machining upon final point confirmation, in this
case inserting 10x1 mm microjoints in all detected intersection points.

157
Yellow parallelepipeds graphically represent the microjoints.

The passing machining part shown in figure is interrupted by the 1 mm re-ascent for a 10
mm section, to then return to being passing.

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The microjoints' dimensions can be individually modified. The specific dimensions of the
selected microjoint appear on right by clicking on the microjoint.

The dimensions can be modified and confirmed with the Apply key.

N.B. Microjoints are not only restricted to nesting function but are also managed in the
individual program.

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3.5.18.4 Start work

This attribute is used to set the machining start

point.

Select the “Start work” icon and then select the

machining geometry for which the start point must
be changed.
For composite lines it is important to select the
exact geometry section where the new start point
must be entered.

Then select the point along the section selected.

The positioning can be done by moving the
mouse or by entering the section percentage.

The machining start will be moved to the

requested point.
For composite lines any geometry sections before
the section where the new machining start has
been entered, will be ignored.

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3.5.18.5 End work

This attribute is used to set the machining end

point.

Select the “End work” icon and then select the

machining geometry for which the end point must
be changed.
For composite lines it is important to select the
exact geometry section where the machining
must end.

Then select the point along the section

selected.
The positioning can be done by moving
the mouse or by entering the section
percentage.

The machining end will be moved to the requested

point.
For composite lines any geometry sections after
the section where the new machining end has
been entered, will be ignored.

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3.5.18.6 Edge banding attributes

Due to the special nature of the machining and the considerable number of attributes
necessary for the edge banding we have created a group of attributes used solely for edge
banding.

3.5.18.6.1 Head rotation

The edge banding head rotation is used to

tilt the edge banding head as necessary.

The operation is similar to the speed change in a specific point.

Select a machining operation where the rotation is to be applied and enter the percentage
where the change must take place.

162
Enter the rotation angle in relation to the vertical line.

163
An arrow will be displayed indicating the rotation change.

If selected the edge bander head will be displayed tilted by the angle entered previously.

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3.5.18.6.2 Rotation X

The “Rotation X” attribute is used to

change the tilting of the trimmer in a
specific point of the trimming operation.

Select the “Rotation X” icon and then select the geometry of

a trimming operation.

If the machining operation selected is not trimming, the following message will be
displayed:

Then select the point along the section selected.

The positioning can be done by moving the
mouse or by entering the section percentage.

Then enter the rotation angle of the trimmer,

bearing in mind that 0° refers to the trimmer at
right angles to the geometry and that the value
entered can be positive or negative.

165
An arrow symbol will be displayed tilted at
the angle set.
If the trimmer dxf has been entered in the
fixturing rows, the trimmer image will
appear on the profile.

To change the Rotation X

attribute parameters again
simply select the arrow symbol
and change the Angle or
Position values that will be
displayed in the window.

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3.5.18.6.3 Ruller stop

The edge banding head roller stop is used

to stop the roller as needed to help the
gluing of the edge to the panel in specific
conditions in terms of shape and type of
edge used.

The operation is similar to the speed change in a specific point.

Select a machining operation where the roller stop is to be applied and enter the
percentage where the change must take place.

Enter the time, expressed in seconds.

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A symbol will be displayed indicating the time change.

3.5.18.6.4 Edge rollers opening

3.5.18.6.5 Edge rollers closure

3.5.18.6.6 Lamp on

This attribute is used to switch on the edge

heating lamps at a specific point to heat the
edge and increase its flexibility so that it
follows the geometry better.

The operation is similar to the speed change in a specific point.

Select a machining operation where the lamp switch on is to be applied and enter the
percentage where the change must take place.

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Enter the lamps power percentage.

A symbol will be displayed indicating the lamp switch on change.

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3.5.18.6.7 Edge supply

This attribute is used to increase the

length of edge during the edge banding to
avoid unusual bends and improve the
application on the geometry being
followed.

The operation is similar to the speed change in a specific point.

Select a machining operation where the extra length is to be applied and enter the
percentage where the change must take place.

Enter the measurement in millimetres of extra edge to be available at the head side.

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A symbol will be displayed indicating the extra edge length change.

3.5.18.7 Delete attributes

To delete any type of attribute simply select the attribute to delete and right click on the
mouse.
The following menu will be displayed:

Only the attribute selected, or all the attributes of the same type on the same geometry,
can be deleted.

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3.5.19 Working process tree

The working process tree represents the workpiece and all working processes set in a
certain project.
Move on working process Display

Move down the working Switch off

process

Properties Remove

3.5.19.1 Object selection

You can perform the object selection on the tree by clicking with the left button of the
mouse on any displayed element.
It is possible to select the workpiece or a working workpiece and it is not possible to select
more than one object.
When an object is selected, the name is written in white on a blue background.
The selected object in the tree will be marked also in the graphic area.

3.5.19.2 Working process ordering

The working process tree shows us the working processes in our project as well as their
sequence. so you could benefit from ordering the working process sequence.

In order to move a working process in the tree:

- select the working process
- use the command "Move on the working process, arrow upwards”
- or "Arrow downwards”

This option is inhibited by the working process tree when the project has more than one
step (see paragraph 3.9.6 )

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3.5.19.3 Working process display

On the working process tree you can display or not the different working processes.
To the left of every working process name, you can see the icon that represents the type
of working process and to the left of the icon there is the symbol that stands for an eye.
By clicking with the left button on the eye, you change its status from open to closed.
The open eye means that the working process will be displayed.
The closed eye means that the working process will not be displayed.

In this example you can see a project where the Emptying

has been selected and the Milling and the Countouring have
been switched off.

If you wish to switch all working processes off you can:

1) close all eyes to the left of the working processes.
2) close the eye to the left of the workpiece
3) or click on the light bulb that is off.

If you wish to display all working processes you can:

1) open all eyes to the left of the working processes.
2) open the eye to the left of the workpiece
3) or click on the light bulb that is on.

The selection on the tree has an immediate impact on the graphic area.

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3.5.19.4 Contextual menu

After selecting any object of the tree, by clicking with the right button of the mouse, a
contextual menu will show us what kind of operations we can carry out with the selected
object:

Contextual Menu workpiece

Contextual Menu Working process

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3.5.20 Working process selection

The working process selection in the graphic area occurs in the same way as the
geometry selection (see paragraph 3.4.7)
you can also select a single working process from the working tree (see paragraph
3.5.19.1)

3.5.21 Contextual menu for working processes

The contextual menu for working processes is available:

- In the graphic area (see paragraph3.4.8 )
- and in the working process tree (see paragraph 3.5.19.4 )

3.5.22 Working process removal

After selecting one or more working process you can remove them:
- by clicking with the button "Canc"
- or clicking on the command "Remove" of the menu "Home" "Clipboard"
- or on the command "Remove" if the contextual Menu.

This menu will appear:

You can choose if you wish to:

- remove only the working process
- remove Geometry and Working process

3.5.23 Working process properties

If you wish to know an existing working process properties, the dialogue menu during the
working process inserting will be showed.

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3.5.24 Working process modification

After selecting one working process (on the screen or in the tree) it is possible to modify
the parameter values in the dialogue menu.

3.5.25 Move and/or copy existing working processes

The options used to move or modify working processes are:

- Move
- Rotate
- Mirror
- Oppose
- Cut
- Copy
- Paste

these same options are also used for the geometries (see paragraph 3.4.12)

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3.5.26 Machining technologies
The technologies differ from the machining in that they do not have an associated
geometry.
As the technological information is often much more than the geometrical information it is
useful to save them in order to apply them to other geometries.

3.5.26.1 Create Technology

To create a technology do a project with a single

machining and save it as technology.

You will be asked to save the technology file with

the .tchx extension.
To reuse these files they must be located in the
“Technologies” sub-folder of the Maestro
installation folder.

The screen below will appear, to enter the

technology name and the sub-unit name where it appears in the Maestro menu.

177
After having selected “Next”, the second screen where the bitmap can be entered, is
displayed.

If the technology being saved is an edge banding process, the machining can be grouped
with colours (as shown in the figure).

These groupings do not affect the interactive use, but they apply during the DXF import
phase.
The segments with the same colours in the technology will be associated to the relative
machinings. (see chapter Errore. L'origine riferimento non è stata trovata.)

The technology is saved by pressing “End”.

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3.5.26.2 Copy technology

As well as imply copying the machining, you can copy all the technological information of a
machining and apply them to new 2D geometries.
(Equivalent to copying the whole machining, except for the geometry).
To do this use the “Technology” command in the “Operations” “Technologies” menu.

The following menu is displayed after clicking on Technology:

The dropper shape cursor reminds you that you are selecting an existing technology.
To select a technology to copy on other 2D geometries, simply select an existing
machining in the project.

As soon as a machining is selected the cursor becomes a syringe.

And the “Select geometry” item appears in the menu.
The previously selected technology will be applied to all the geometries selected.

To apply the technology to just one part of the geometry selected, check the “Partial
machining” item in the menu.
In this case, after having selected the geometry the menu asks to “select start point” and
then “select end point”, the technology will be applied only to the part of the geometry from
the start point to the end point.

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3.5.26.3 Apply technology

A previously saved existing technology can be applied (see chapter 1.2.11.1 Create
Technology) to one or more geometries.

In fact all the technologies created will appear in the “Technologies” menu:

To apply a technology to one or more geometries select the desired technology from the
technologies menu.

The geometry selection menu is displayed and the cursor

changes to the syringe symbol.

Select a geometry to apply the previously selected geometry.

To apply the technology to just one part of the geometry selected, check the “Partial
machining” item in the menu.

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3.5.27 Display tool path

The tool path of any machining operation can be displayed with the "Display tool path"
command.

The command can be launched from the

context menu of the machining operation
selected.

or with the “Tool path” icon in the Machines

menu.

After having selected the command the following player is displayed:

End display
Potentiometer speed
Previous machining
Further processing
Start / Resume viewing

The “Previous machining” and “Next machining” buttons are not available when the
command is launched from the context menu of a single machining operation.

Click on “Start/Resume display" to display the tool path, scrolling the tool with the
geometry described in the .tlgx file.
The machining speed can be changed with the “Speed potentiometer”.

181
When the tool path is displayed the menu changes as follows:

Sospendi visualizzazione

“Interrupt display” suspends the display and the “Start/Resume display” button will be
available.

3.6 3D machining
This function is used to create 3D machining operations of surfaces and curve machining
on surfaces.

These operations are executed only if the surfaces are within the workpiece volume.

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3.6.1 Roughing
This command is used to rough a surface and it can be applied to one or more surfaces at
the same time with a single tool path to remove as much material as possible from the
unfinished workpiece.

to perform the surface roughing, proceed as follows:

- click on “Roughing”

The specifications of the 3D roughing will be displayed on

the right.
The roughing parameters have the same properties of any
other machining operation (tolerance, machining allowance
and extra depth).

The main properties are the machining strategies:

- terraces
- bidirectional
- unidirectional

The tool strategy defines the tool movements in relation to

the surface:
- 3-axes management with vertical tool
- 3-axes management with tilting tool

183
By combining the various strategies you can achieve roughing operations on different
surfaces:
- terraces roughing, 3-axes vertical tool

184
- terraces roughing, 3-axes tilting tool

185
- bidirectional, 3-axes vertical tool

186
- bidirectional, 3-axes tilting tool

187
- unidirectional, 3-axes vertical tool

188
- unidirectional, 3-axes tilting tool

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3.6.2 Finishing
The “Finishing” command is used to machine one or more surfaces.
It is located in the “Operations” “3D machining” menu.

After having selected the command the menu at the side will be
displayed.

The surface can be selected after having clicked on “Select

geometry”.
A tolerance and a machining allowance in relation to the surface
can be set.

There are 5 finishing strategies that will be illustrated with 6

examples.

The Superimposition represents the percentage with which the

tool passes again on the previous machining.

The pass direction indicates an angle in relation to the X axis

(0° along X – 90° along Y).

There are 4 tool strategies that will be illustrated with 4

examples.

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3.6.2.1 Finishing strategies

Six examples will be illustrated for the five finishing strategies available. The first two will
have the same strategy with two right angle pass directions.
All the examples use the “normal to surface” tool strategy and the tool strategies will be
described below.

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192
3.6.2.2 Tool strategies

193
3.6.3 Swarfing
Command used to create surface machining with tool side. It can be applied to two curves,
an upper one and a lower one, or directly to one or more surfaces.
N.B.
To perform the machining directly on the surface, firstly select the surface and then click
on “Swarfing”. Now the surface is recognised automatically and you can proceed with the
direct creation of the machining operation.

Once the “Swarfing” 3D machining is open the machining menu

will be displayed, to select the various options.

You will also be asked to select the upper curve and then the
lower curve to create the surface in which the machining must be
generated.

194
Also in this case by combining the various strategies you can achieve machining
operations with different results.

Tool strategy
Synchronise curves

Tools strategy
Minimum distance

195
Tool strategy
Perpendicular to the
lower curve

196
3.6.4 Routing on surface
The “Routing on surface” command is used to perform the machining of a 3D curve that
lies on a surface.
It is located in the “Operations” “3D machining” menu.

After having selected the command the menu at the side will be
displayed.

A precision tolerance can also be set.

A depth can be set; with “0” the tool will skim the surface.

The tool strategies are three of the five described for the
“Finishing”.

To proceed with the machining select a 3D curve and then select a surface.

The following commands will be displayed:

Example:

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3.6.5 3D pocketing
The "Emptying 3D" command allows you to create a pocket by selecting the surfaces that
delimit it.

It is located in the “Operations” “3D machining” menu.

To perform the processing, select the following surfaces:

The bottom surface is mandatory, the side ones are optional

because if you select only the bottom one would be
completely cleaned.
Any upper surface will only be used when the bottom surface
is not parallel to the upper level, in this case one of the
following can be specified
emptying strategies which are (from left to right):
- Offset from bottom of the pocketing
- Adaptive offset from the start to the bottom of the pocketing
- Offset from the start of the pocketing

The Offset from the bottom runs parallel passes to the bottom
of the pocket.

The Offset from the beginning of the pocketing executes

passes parallel to the upper surface.

The Adaptive Offset performs variable shape passes

between the bottom of the pocket and the upper surface.

The remaining parameters are analogous to those present in

roughing machining.

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3.6.6 Tool path wrap
The “Tool path wrap” command is used to apply a tool path of a drilling, routing or
pocketing on a surface.
The original tool path will be wrapped on a surface and the tool orientation will be
perpendicular to the surface.

It is located in the “Operations” “3D machining” menu.

To proceed with the machining select a machining tool path and then select a surface.

The following commands will be displayed:

The original machining will be transformed in a 3D routing with the same specifications.

Example of a pocketing transported to the surface:

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3.7 Macro and Subprograms

3.7.1 Creating machining-macros (.xsp)

The “.XSP” Macro are a sequence of instructions used to add geometries or machining
operations to a project.
The macros can be launched more than once in the same project and the names
associated to them will be transcribed in the workpiece machining tree, as if they were
elementary machining operations.
The Maestro installation package contains various “.XSP” macros that can be used as
outline to create new macros.

The macro creation procedure can be described in two phases:

1. Creation of the macro basic structure ( wizard);
2. Implementation of the functions in the macro.

3.7.1.1 Creazione della struttura base della macro ( wizard);

During the planning phase the user must decide which parameters to supply as input
variables for the macro. The workpiece dimension parameters are passed to the macro
with the wizard, clearly for the user and therefore do not have to be parameterized. The
remaining parameters must be entered manually by the user, with the wizard as described
in the subsequent procedures.

To start the macro creation wizard select Tools in the Maestro menu bar, and press Macro
Management and select Create macro.

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The wizard window is displayed on the screen, used by the user to access four different
areas: general parameters, image selection, parameters, units and languages.

3.7.1.1.1 General parameters

In this section, in the first field the user must associated an identification name to the
macro, whilst in the remaining fields a short function description, a category, unit and sub-
unit type identifier can be entered.

These last fields can be used to organize the macro properties hierarchically, in order to
retrieve them more easily when required, from the Maestro menu. In particular there are
two options for the category: “Operations” and “Macro”. The first category enters the
macros in the ”Operations” tab , whilst the second in the “Macro” tab, in the Maestro menu.
If there is no Macro tab, it is created the first time a macro of this category is created.
Based on the category chosen groupings and sub-groupings can be created with the
following fields

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For example the general parameters for the Slot macro are:

These parameters define the Slot macro as a “Standard” macro, of the “Operations”
category, “Macro” unit and “Joints” sub-unit.
The user can check that the macro is placed in Maestro, in the specified sub-unit.

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3.7.1.1.2 Image selection

This section is used to associate different types of images to the macro:

• 16x16 pixel image: visible in the Maestro menu on the left of the macro (used when
small bitmaps are required);
• 32x32 pixel image: visible in the Maestro menu on the left of the macro (used when
large bitmaps are required);
• 200x154 pixel image: visible with the macro parameters.

The following formats are supported: .bmp or . jpg or .png

In general it is good practice for the16x16 and 32x32 images to provide a general idea of
the macro function, whilst the 200x154 image must provide the detailed meaning of the
macro input parameters. See the example below:

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3.7.1.1.3 Parameters

This section is used by the user to describe the macro input parameters. Usually the input
parameters for a macro are divided in:

1. geometric parameters;
2. technological parameters (tool, strategy, etc…).

To add an input parameter, right click on the mouse and select Add in the menu.

The following fields can be defined for each parameter in the table:
• Name parameter identification name (name of the variable used for the macro input
parameter);
• Type of parameter: defines the type of parameter (selected from: machining head,
tool, user and worktable);
• Type of value: defines the type of value in the parameter (selected from: Boolean,
decimal, integer, string);
• Physical unit: defines the unit of measurement associated to the parameter value
(length, speed or dimensional size);
• Null value: specifies if a null value can be assigned to the parameter;
• Default value: used to set a default value for the parameter;
• Multiple values: defines a restricted group of elements and ties the parameter value
to this group (if activated the group elements must be defined in terms of
key/value);

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 • Visibility: allows the visibility of the parameter in the interactive use of the macro (in
the Maestro expander);
• Group: defines the group of the parameter;
• Image: used to associate a descriptive image to the parameter.

3.7.1.1.4 Groups
In this section the user can decide how to group together the parameters entered in the
previous section, so that they appear in the desired group in the macro configuration
menu.

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For example for the Slot macro, the pass feed parameter
(AvPas) is defined in the AvPasGroup group and
corresponds in the Maestro expander to the “Strategy”
category of the image on the right

3.7.1.1.5 Languages
In this section the user can translate the descriptive information of the macros in the
desired languages. In particular, in the Parameters tab, the user must associate to every
previously entered parameter, the name that will be associated to the parameter and that
will be displayed in the Maestro editor. Or he can also enter a brief description of the
parameter use. These operations must be repeated by the user for every language that
the macro will be available in.

206
Similarly in the Groups tab the group ID created can be translated and a brief description
in the relative language can be associated.
In the Messages tab various error message can be translated, according to the
key/message layout. To recall the desired message when there is the corresponding error
condition, use the Print scripting instruction. This function uses as input parameter the
key associated to the message, preceded by the special character @ (the @ character is
used to identify and interpret the string that follows as a message key).
In the Documentation tab, any documents in the relevant language can be associated to
be available in the macro.
The flag can be enabled to help in the compilation and to copy the instructions from
another language, in order not to have to start from zero for each new language
introduced.

Once the wizard procedure is finished (End key), the macro is created and saved in the
Macros folder of Maestro, that is usually found with this path C:\Program Files\Scm
Group\Maestro\Macros.

With the completion of this first phase the basic structure of the macro is created, but no
function has been implemented inside it The wizard has in fact created in the .xsp file of
the macro a source file with extension .cs, with the parameters and values supplied by the
user, but the user has not described the behaviour in the execution of the file.

At this point the user must define the macro behaviour with the MSL scripting language.
Maestro must be restarted to proceed with this second phase (implementation of a macro).
Now this file can be accessed and the desired specifications can be implemented and edit
the macro created as the described in the next section.

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3.7.1.1.6 Macro Management

To access the macro management function select Tools in the Maestro menu bar, and
press Macro Management and select Display macro.

A window is displayed containing all the macros of Maestro and the ones created by the
user. Move on the desired macro and right click on the mouse to access the menu.

The flag in the list, on the left of each macro, allows the macro to be viewed or blocked
from the Maestro interactive menu. This does not mean that the macro will be deleted, but
just that it will be visible from the menu. At any time the user can access the complete list
of all the macros and change the display status of the ones that he is interested in.

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Select Edit to change the .cs file of the macro.
As the ideal solution to editing the macro is using Visual Studio 2010 or a later version, we
recommend using this tool, where possible. If the user does not have this tool, a free
version called Express can be downloaded at the website:
www.microsoft.com/visualstudio/.
See the MSL manual for the structure and content of the .cs file.

Select Check: to check if the macro is correct. In this case the macro is checked for any
file and parameters creation errors. The result of the check will be displayed on the screen.

Select Properties: to open the wizard graphic interface again. At this point the basic
structure of the macro can be changed by adding parameters or changing existing
parameters.

Select Delete: to delete the macro. Note that deleting a macro also affects the programs
that use the macro deleted. As the macro no longer exists, these programs can no longer
be changed.
Select Edit: To open the source code (extension. Cs) associated with the selected macro.

3.7.1.2 Implementation of the functions in the macro.

See the MSL manual.

3.7.2 Create Subprograms (.xsp)

The subprograms are used to enter recurring 2D geometries or machining operations in

the project.

The subprogram is created as follows:

1) Create project

2) Define the parameters

3) Save the subprogram

3.7.2.1 Create project

The creation of a subprogram starts by defining any project.

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3.7.2.2 Define the parameters

If you insert a workpiece in the project, parameters dx1, dy1, dz1 will be available in the
workpiece dimensions.
By inserting a second workpiece in the project, also dx2, dy2, dz2 will be also included.

The list of parameters available in the project is to be found in the interface down on the
left.

By using the command "Create a new variable", it is possible to insert new parameters.

Create a new
variable

Variable
properties

Delete variable

By using the command "Variable Properties", the same window used for the creation will
appear:

By using the command "Delete variable", it will be possible to delete the variables created
by the user but not those which have been automatically created (dx1, dy1, dz1).

All parameters available in the project can be used in every field that accepts a number in
order to create 2D geometries as well as to set working processes.

In order to use a parameter, it is sufficient to write it in place of such number, or you can
also write the formula with more parameters and mathematic operators.

Parameters can also be exported with the sub-program as input data (see paragraph
3.7.2.3 "Saving the sub-program").

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3.7.2.3 Save the sub-program

After the project setting, you can save the 2D geometries and the working processes as
sub-program in order to reuse them for further projects.
Subprograms can be performed only for projects with one workpiece.

In order to save a sub-program, use the command

"Save as sub-program" in the menu "Home" "Save".

The resulting window will allow you to save the .xsp subprogram.
The default folder for saving programs is the Maestro set up sub-folder "Macros".
You can also save sub-programs in another folder but if you wish to use them, you must
save them also in the default folder.

After naming the sub-program and clicking on "Save", following window will be showed:

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Fields included in "Display properties" serve as indicators for the menu where the sub-
program will be saved.

If you click on "Next", on the resulting window - almost like the previous one- you will be
asked to list the names of the bitmap to link with the subprogram. (Optional)

If you click on "Next", the resulting window will allow you to establish those variables to be
exported.

If you click on "End", the saving process will end.

You can check the saving process :

- in the menu "Operations" (written in the field "Tab Name")
- since the sub-menu "Forme" has been created (written in the field "Group Name").
- and it contains the sub-program "esagono" (field " Macro Name”)

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3.7.2.4 Open an existing sub-program

If you wish to open an existing sub-program, click on the icon "Open".

The resulting window shows you the list where you may select a pgmx file.
Select "File type" "Sub-program (*xsp)".
Select the folder "Macros".
Select a xsp file and then click on "Open".
Or click twice on the xsp file.

For a project that has already been started, following option would be automatically
performed:
“Closing project”

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3.7.3 Use of .XSP macros and subprograms
The .XSP macros can be used when a project is already open in the Maestro editor, or
when creating a workpiece program with the MSL scripting language (see next chapter).

To use the Slot macro in a project, it is in:

Operations Macro Joints Slot

After having clicked on “Slot” the various parameters can be changed, and the macro
applied by clicking “Apply”

The effect of the macro can be seen in the machining tree and in the Maestro graphic
area.

In the tree the name of the macro (Slot) can be seen, and in the graphic area the geometry
and the machining described in the Slot.cs function.

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3.7.4 Imort Script (.xcs)
To use a workpiece program in .XCS format in the Maestro interactive environment, use
the “Import script” command in the submenu “Import” of the “Home” menu.

The following will be displayed where a .xcs. file to import can be selected.

After having confirmed the selection of the .xcs file with “Open” the script is interpreted and
the workpiece will appear and any machining described inside it.
Bear in mind that a script file (.xcs) can contain all the workpiece information and the
relative machining, including the names of the tools associated to the machining, but it
does not contain the “.tlgx” tools database file.

To achieve the desired workpiece correctly when the script was produced, before
executing the “Import script” command, the “.tlgx” file, containing all the tools used in the
script functions, must be prepared and rendered active.
To activate the .tlgx see the “Activating the tools database” chapter of the Maestro manual.

215
3.8 NC functions
Used to define and make the machine perform operations different from the machining
operations.
The following NC functions can be entered in a program:

1. Enter an ISO instruction: CreateIso

2. Machine parking: CreatePark
3. Null operation: CreateNullOperation
4. Workpiece probing: CreateWorkPieceProbing
5. Display an operator message CreateMessage
6. Table cleaning
7. DY check

The functions are in the Machines – NC functions menu.

The icons of the available CN functions are visualised according to the machine set-up,
therefore they are all visible at all times.

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3.8.1 Enter an ISO instruction

To enter an ISO instruction in the machining tree select the “ISO” command in the “NC
functions” menu.

The following dialogue window is displayed:

Maestro will not check the syntax of the instructions entered by

the user.
Any syntax error in the ISO instruction will be performed on the
Machine Panel.

The Flag on the Xiso option lets you report the Iso instruction
written.

If the Xiso flag is not selected in the post phase the “ISO” prefix is
added to the instruction.

Examples:

Machining Tree Dialogue window Post generated

;**********************************
.OP1 ;G0 X0 Y0
;**********************************
G0 X0 Y0

Machining Tree Dialogue window Post generated

;**********************************
.OP1 ;G0 X0 Y0
;**********************************
ISO "G0" X0 Y0

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3.8.2 Machine parking

The machine parking functions moves the upright in the parking zone to access the
workpieces positioned in the machine in the unload phase.

To enter a parking instruction in the machining tree select the “Parking” command in the
“NC functions” menu.

The parking is available in the following modes:

- No stop
- Stop with start wait
- Stop with release and start wait

The modes can be selected from the “Stop” drop down menu.

Example of parking with start wait

Machining Tree Dialogue window Post generated

;**********************************
. OP1 ;Parking
;**********************************
PARK S=1

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3.8.3 Null operation

The “Null operation” function does not perform machining operations on the workpiece but
it can be used to park the machine in a desired point and perform a tool change.

To enter a null operation instruction in the machining tree select the “Null operation”
command in the “NC functions” menu.

The following parameters can be entered in the dialogue menu:

X final (position X to position the machine)

Y final (position Y to position the machine)

Reference (Relative or Absolute)

Speed (movement speed)

Electrospindle (Off or On)

The “Tools information” and “Heads data” fields must be filled in

only if you want to change a tool.

219
3.8.4 Workpiece probing
The workpiece probing is an operation that is used for precise machining operations, even
on workpieces that are irregular or positioned incorrectly.

There are three workpiece probing modes:

1) Probing with side position correction
2) Probing with tool length correction
3) Probing with workpiece roto-translation

3.8.4.1 Probing with side position correction

The probing with face position correction is performed with a probing tool.
The effect generated after the probing is to redefine the position of the working face so that
all the machining operations on that face are precise.
The function is disabled each time the face is changed.

To enter a face position correction probing instruction in the machining tree select the
“Probing” command in the “NC functions” menu.

The following parameters can be entered in the dialogue menu:

References (field used to select the work face).

X (X probing position)

Y (Y probing position)

Head return (can be performed to three different positions):

- Parking quota
- Probing quota
- Skimming quota

The “Tools information” filed is used to select the probing tool.

The “Heads data” field is used to select the head used for the
probing.

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3.8.4.2 Probing with tool length correction

The probing with tool length correction is performed with a pneumatic probe fitted on the
spindle.
The effect generated after the probing is to redefine the tool length so that all the
machining operations performed with that tool on that face are precise.
On long workpieces, even when working on the same face with the same tool, it is
preferable to perform various probing operations in different positions in case the
workpiece is warped.

The function is disabled each time the tool or the face are changed.

To enter a tool length correction probing

instruction in the machining tree select the
“Special probing” command from the “Probing”
menu in the “NC functions” menu.

The following parameters can be entered in the dialogue menu:

References (field used to select the work face).

X (X probing position)

Y (Y probing position)

Speed (probing speed)

The “Tool information” field is used to select the tool whose length
will be corrected and that will be used for the subsequent
machining operations.

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3.8.4.3 Probing with workpiece roto-translation

The probing with workpiece roto-translation is performed with a probing tool.

The effect generated after the probing is to redefine the position and angular orientation of
the workpiece so that all the machining operations performed with that tool on that face are
precise.

The function remains active for the whole workpiece program.

To enter a probing with workpiece roto-translation

instruction in the machining tree select the
“Workpiece rotation translation probing” command
from the “Probing” menu in the “NC functions”
menu.

The following parameters can be entered in the dialogue menu:

First quota side X (first probing position X)

Second quota side X (second probing position X)

Side Y quota (third probing position Y)

Quota Z (position Z of all the probings)

The “Tools information” filed is used to select the probing tool.

The “Heads data” field is used to select the head used for the
probing.

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3.8.5 Display an operator message

The display an operator message function is similar to the parking functions and allows the
operator to view a message and restart the program without moving the machine.

To enter a message for the operator in the machining tree select the “Print message”
command in the “NC functions” menu.

The message can appear in the following ways:

- No stop
- Stop with start wait
- Stop with release and start wait

The modes can be selected from the “Stop” drop down menu.

The “Input enable” and “Input variable” variables are not

managed.

The “Operator message” field can be filled with the message that
will be displayed for the operator during the program execution.

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3.8.6 Table cleaning

The table cleaning NC function enables a cleaning cycle of the machine table with the
extraction hood.

To enter a message for the operator in the machining tree select the “Table cleaning”
command in the “NC functions” menu.

Hood enable: determines the extraction hood enable or

disable.
- Hood position:
o for the motor—driven hood the value indicates
a position in millimetres
o for the pneumatic hood the value indicates one
of the possible positions
- Cleaning speed: speed for the cleaning cycle: 25
metres per minute, default
- Cleaning start X quota: position along the X axis
where the cleaning cycle starts in relation to the
workpiece origin (optional parameter, necessary for
Ergon type machines)
- Cleaning end X quota: position along the X axis where the cleaning cycle ends in
relation to the workpiece origin (optional parameter, necessary for Ergon type
machines)

In the machining tree it will be displayed as follows:

Examples:

1) All the programmed parameters and the motor-driven hood

Dialogue window Post Generated

;**********************************************************
.OP1 ;Table cleaning
;**********************************************************
XHOODPLANE a=1 s=25.000 Q=100.000 l=50.000 L=600.000

224
 2) All the programmed parameters and pneumatic hood in position 1

Dialogue window Post Generated

;**********************************************************
.OP1 ;Table cleaning
;**********************************************************
XHOODPLANE a=0 s=25.000 Q=1.000 l=50.000 L=600.000

3) no programmed parameter

Dialogue window Post Generated

;**********************************************************
.OP1 ;Table cleaning
;**********************************************************
XHOODPLANE a=0 s=25.000

225
3.8.7 DY check

CN function "DY check" is meant for CYflex machines and allows measuring the piece in Y
right after the loading stage.
If the dimensions of the piece in Y are not consistent, the machine shall signal an error.

In order to set the DY check of a panel, select control

"DY check" from the "C.N. functions" menu.

CN function "DY check" only has the parameter "Distance"

that represents the distance from the right edge of the piece
whose dimension needs to be checked.

By clicking on the function "DY check" allows adding such

function to the machinings tree.
Its position is not relevant in that during the "Optimisation"
stage this will always comes first.

If you try to set another "DY check", the following message will appear:

226
3.8.7.1 Automatic DY control

In the Cyflex S, the Y dimension control of the panel is fundamental, because in these
types of machines there is the aligner. If a piece is inserted with a different DY from the
one specified in the program, there is a risk of collision between the machining operations
and the aligner.

Maestro has been fitted with an automatic Y dimension control of the panel, with a specific
parameter in the options:

This option is displayed only when Cyflex S is selected as the type of machine and is
disabled by default, to save the current behaviour.
When the function is activated, the possibility of specifying the distance from the right edge
of the panel is enabled. This distance is the one that will be used in all the NC functions to
control the dimension of the piece entered automatically.

During the optimisation of a program, check if the option is active: if it is, if the pgmx does
not already contain the piece dimension control NC function, it will be entered
automatically with the distance specified in the options. If the user has already entered his
personal control, it will be saved so as not to change the distance value already entered.

With other types of machines, such as the Cyflex HP, the option, even if enabled, has not
effect.

227
3.9 Working steps

A working step describes the positioning of one or more workpieces and which working
processes must be performed if they are in the positions described.

When you create a new project, the step "Setup" is automatically created.

3.9.1 Working step tree

The working step tree represents all working steps set for a certain project.
Switch off
Move on working process
Remove
Move down the working
process Add
workpiece
Properties name

Display

Through this tree it is possible to:

- Insert a working step
- Removete a wokring step
- See the step properties
- Add working processes
- Move the working processes from one step to another one.
- Display or switch off the working processes
- Add the workpiece name to the working process name.

228
3.9.2 Inserting a working step

In order to insert a new working step, you use the command "New step” in the contextual
menu of the step tree.

After selecting the command, the menu to the right will show you where you can insert the
name of the "Working step".

3.9.3 Removal of a working step

In order to remove a working step, you use the button with the red cross or the command
"Remove" in the contextual menu of the step tree.
The initial "Setup" cannot be removed.

Remove

229
3.9.4 Working step properties

In order to display a working step, you use the button "Properties" or the command
"Property" in the step contextual menu.

After selecting such command, the menu to the right will show you the name of the
"Working step" and the workpiece positioning in that step.

Properties

3.9.5 Modifying the workpiece position in one step

It is possible to modify the workpiece position in a certain

step by using the command "Properties" in the contextual
menu of the step tree.

By clicking on the arrows to the left of the workpiece name,

the menu will show the current position of the machine
workpiece.

You can change the workpiece position in the selected step

by modifying the values to the right of the parameters.

- X origin
- Y origin
- Z origin

By clicking on the button "Apply"

230
3.9.6 Moving working processes from one step to another
one

In order to move the working processes from one step to another one, you use the buttons
with the blue arrows on the tree.
Move up working process

Move down the working

process

In the image above, if you click on the button with the arrow downwards, the Contouring
will be shifted on the Milling but it will remain the same during the step "Setup".

By using the arrow downwards, the Countering will always occur before the boring, but will
shift from "Setup" to "Working step"

231
3.9.7 Add workpiece name to working process name

If you look at the step tree, we see what kind of working processes are performed in every
step but we do not know to which workpiece they belong.
In order to obtain this information, you use the button "Add workpiece name".

Project example with 2 workpieces and 2 steps:

Add
workpiece
name

As you see in the step tree, you cannot understand to which workpieces the working
processes belong. By using the command "Add workpiece name", the step tree will
appear in this way:

The working processes are not modified, but you see only a temporary representation that
can be restored by clicking on "Add workpiece name".

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3.9.8 Sub-programs Activation/Deactivation
Use the "Tools – Sub-programs management" control to activate or deactivate the
"Macros" folder Sub-programs.

The following window appears once the "Sub-programs management" control is clicked:

From where the available sub-programs can be activated or deactivated.

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3.10 Workpieces layout in machine
Arrange the workpieces in machine based on its work top, blocking devices and
workpieces to be machined.

"Setup" is a detached session from the project environment.

Use the following to access "Setup":

The "Setup" control in the "Machines"

menu.

Or the "Workpieces layout" in the context menu of

the phases' shaft.
The menu appears when right-clicking the mouse on
a phase name.

"Setup" shows the following menu:

Some controls will not be active due to different work top configuration or setup.
The various controls are described below following a work trail and not in order of position
on menu.

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3.10.1 Choice of work area, references and devices
The machine has a work top divided by areas having various references and different
blocking devices.
They are selected through "Machine parameters" control in the "Setup" menu.

The following menu appears after selection:

3.10.1.1 Work area selection

Use the right drop-down menu showing the available areas in a given machine
configuration to select the work area.

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3.10.1.2 References Selection

Use the "Mechanical options" sub-menu to select the workpieces' references:

3.10.1.3 Type of blocking selection

Use the "Blocking" sub-menu to select the type of blocking:

236
3.10.2 Adding pieces on the machine plane
It is possible to add a piece on the machine plane by selecting it from an existing
project.The starting project can also be empty.
The mode is as follows:
- Select a project using the "Browser" folder that allows you to search for it on your PC.

- Select one of the pieces in the project

- Set a distance to maintain with respect to existing pieces

Add the new piece using the mouse

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3.10.3 Workpieces positioning
Use the right-hand window to position the workpieces on the
machine's work top:

The workpieces' position can be modified by changing the

"source" values and clicking on "Apply".
(Also see paragraphs 3.9.5)

The pieces can also be positioned using the "Select piece" and "Move piece" commands

The "Select piece" command is necessary because the default of Arrange is to select
suckers or clamps.

Once the piece has been selected, to move the piece, use the "Move piece" command
available in the layout menu or in the context menu

In this case, the selected piece will move with the mouse respecting the set offset.

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3.10.4 Elimination of pieces from the machine plane

The pieces can be removed using the "Select piece" and "Delete" commands

- Select the "Select piece" command

- Select the piece (the piece will assume a green outline)
- Select the "Delete" command

The confirmation message will appear before being deleted:

You can also select the piece (turning it green) click the right mouse button (the context
menu appears) and select "Delete piece"

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3.11 Definition of the blocking system
There are two types of blocking systems on the work centres:

1. Clamps blocking

2. Suction cups blocking

3.11.1 Workpiece blocking with clamps

Workpiece blocking using clamps normally happens to block window or door elements.
Select the devices via "Pressure switches" or "Vacuum gauges + Pressure switches", as
described in chapter 3.10.1.3.

Note: If working with machines not having motorised work top it is not necessary to
position the clamps.

3.11.1.1 Type of clamp

The types of clamps currently available are:

1. Clamps with round plate

2. Clamps with rectangular plate
3. Clamps with reference stops
4. Horizontal clamps

The first three types of clamp block the workpiece along axis Z.
The horizontal clamps block the workpiece along axis Y.

A code is used to identify the various types of clamps.

The code consists of a maximum of 4 separate fields. The first two are the same for all
types of clamps.
The code of the first two fields is:
Hzzz-U
Where
- zzz is the clamp work height (50/110)
- U is the type of use (M/A)(Manual/Automatic)

The remaining optional fields of the clamp code will be described in the following chapters.

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3.11.1.1.1 Clamps with round plate

For these clamps the third code field describes the plate diameter.
The code for this type of clamp is:
Hzzz-U-ddd

Where ddd can currently have a value of 145 or 185.

Examples:
H50-M-145 Clamp height 50mm manual with 145mm diameter
H110-A-185 Clamp height 110mm automatic with 185mm diameter

3.11.1.1.2 Clamps with rectangular plate

For these clamps the third code field describes the plate rectangular
dimension.
The code for this type of clamp is:
Hzzz-U-bbbxyyy

Where bbb and yyy are the length and width of the clamp plate
rectangle.
Currently there is only 165X165

Examples:
H50-M-165x165 Clamp height 50mm manual with square plate 165x165mm
H110-A-165x165 Clamp height 110mm automatic with square plate 165x165mm

3.11.1.1.3 Clamps with reference stops

For these clamps the third code field describes the plate rectangular
dimension and the fourth field the reference stop thickness.
The code for this type of clamp is:
Hzzz-U-bbbxyyy-Scc

Where bbb and yyy are the length and width of the clamp plate
rectangle. Currently there is only 165x165.
cc is the thickness of the reference stop on which the workpiece rests (values currently
available: 10,20,25,30)

Examples:
H50-M-165x165-S10 Clamp height 50mm manual with square plate 165x165mm and
10mm stop.
H110-A-165x165-S30 Clamp height 110mm automatic with square plate 165x165mm
and 30mm stop.

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3.11.1.1.4 Horizontal clamps

This type of clamp blocks the workpieces horizontally along axis Y and
is only managed manually.
For these clamps the third code field describes the rectangular
dimension of the whole clamp.
The code for this type of clamp is:
Hzzz-U-bbbxyyy

Where bbb and yyy are the length and width of the whole clamp. Currently there is only
150x294.

There is no parameter indicating whether it is an horizontal clamp.

At the moment it can only be seen by the dimension of the rectangle 150x294.

Example:
H50-M-150x294 Clamp height 50mm manual with rectangular plate 150x294mm
H110-M-150x294 Clamp height 110mm manual with rectangular plate 150x294mm

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3.11.1.2 Type of clamp selection

Use the bottom-left list of available clamps to select the type

of clamp:

The top-left window shows the clamps' preview:

3.11.1.3 Clamps positioning on the bars

Select the clamp to be used and drag it onto the manual bar or onto the motorised bars'
plates.

Assemble the clamps on all plates in case of motorised bars. Do this using the context
control and right-click the mouse on the clamp to be used.

In certain cases there may be collisions during the assembly. This is because Maestro
considers the total space of the machine elements (plate plus camp) in the collision control
between mobile elements. To overcome this issue simply move the plates from each other
before applying the clamp.

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3.11.1.4 Saving plane layout

Once the plane has been set up with clamps or suction cups, it is possible to save the
plane layout so that it can be used on other occasions.

To save, the command

"Save plane arrangement" command is used

A .eplx file will be created in its Eplx folder

3.11.1.5 Reusing the plane layout

To re-use the previously saved plane configuration, set the name to:
Tools-Options-Preferences File of the default work plane positioning

After setting the field with the name of the eplx file, every time you enter the "Layout"
session, the previously saved setup will appear.

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3.11.1.6 Blocking states of clamps

Each clamp can have 3 blocking states:

1) Open
2) Closed
3) Closed on the piece

The clamps state can change in every phase to manage the machining process.

3.11.1.6.1 Blocking state change

To change the blocking state of a clamp:

- select a clamp
(it becomes light green)
(a window appears on
right)

- right-click the mouse (a context menu appears)

- select the wanted state entry by left-clicking the
mouse

- or click on right arrow of the state

- select the wanted state entry by left-clicking the
mouse
- click on "Apply"

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3.11.1.6.2 Blocking state display

The blocking state is displayed through the "Clamp Data" – "State"

menu, but this only shows the selected clamp's state.

Use the "Setup" menu's "Blocking states" control

to see the overall clamps states.

The clamps are displayed as follows:

- Open (green with symbol "-")

- Closed (yellow with symbol "X")

- Closed on workpiece (red with symbol "+")

Tick "Display the clamps' blocking states" in the "Options" menu's "Work top" "Parameters"
to ensure the blocking state is always active when accessing "Setup".

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3.11.1.7 Clamps positioning on workpiece

One or more workpieces having one or more work phases can be blocked on the
machine's work top.

Every phase must contain information on position and states of clamps for machining
workpieces with machines having motorised work top (not essential for machines with
manual work top).

The clamps can be positioned:

1) Fully manually
2) Manually using the blocking profile
3) Automatically using the blocking profile

Once the clamp has been fitted, it can be moved in three ways:
- Click on the clamp and drag it keeping the mouse button pressed;

- Enter the precise coordinates where the clamp must

be positioned in the screen on the right displayed after
clicking on the clamp (figure 8);

- Enter the size of the movement to perform and clicking

on the arrows on the right displayed after clicking on
the clamp (figure 9).

The clamp movement is restricted by an anti-collision control that does not allow
movements if it detects collision between the clamp and other machine elements on the
plane.

The following functions can be used by the operator during the positioning.

This ribbon button is used to block the movement of the bars

to guarantee the positioning of the supports in Y without worrying about the
movement in X.

This ribbon button is used to block the movement of the supports

to guarantee the positioning of the supports in X without worrying about the
movement in Y.

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When a bar has a clamp closed on the workpiece, the movement of the bar is not allowed.
Therefore the movement in X is inhibited when trying to move the bar and when moving a
different support from the one blocked.
If there is only one clamp closed on the workpiece along the bar, its movement also moves
the bar in X.

When a clamp is moved by dragging, its blocking state changes to closed. This function
has been implemented to comply with standard clamps.

3.11.1.7.1 Manual clamps positioning

This positioning only has the screen viewing aid.

Position by dragging one clamp in the wanted position at a time.
Then change clamp state in “Closed on workpiece” (see paragraph 3.11.1.6)
Ensure the workpiece does not touch the clamps' rod.

3.11.1.7.2 Manual clamps' positioning with blocking profile

The blocking profile is a polyline that can only currently be realised from "Script": writing an
external file to be imported in Maestro.
As well as polyline geometry, the blocking profile also has a dimensional feature indicating
minimum pincering.

Different blockings can be made using the "Pincering

rules" in the "Setup" menu, with a piece having a
blocking profile.
- Load distance
- Minimum pincering
- Maximum pincering
- Maximum pincering without recoveries

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1) The "Load distance" rule is normally used to position the clamps that must internally
block a door to be profiled.
The clamp's axis sticks to an axis that becomes blue when a clamp nears the
blocking profile using the "Load distance" rule.
This guarantees the clamp remains at a distance from the blocking profile.
The clamp's state is automatically taken to "Open" when left on the blue axis.
Use the "Tools" "Options" control to modify the parameter establishing the clamp's
distance from the blocking profile (Load Distance (DCA)). The following screen
appears:

The "Load distance (DCA)" parameter is found in the "Options" "Parameters" "Work
top" folder.

2) The "Minimum pincering" rule is normally used to position the clamps that must
block the workpiece, pincering minimum wood section.
The clamp's axis sticks to an axis that becomes red when a clamp nears the
blocking profile using the "Minimum pincering" rule.
This guarantees the clamp pincers the blocking profile for minimum established
height.
The clamp's state is automatically taken to "Closed on workpiece" when left on the
red axis.
The minimum pincering dimension is written as blocking profile feature.

3) The "Maximum pincering" rule is normally used to position the clamps that must
block the workpiece, pincering maximum wood section.
The clamp's axis sticks to an axis that becomes green when a clamp nears the
blocking profile using the "Minimum pincering" rule.
This guarantees the clamp pincers the blocking profile for maximum established
height.
The clamp's state is automatically taken to "Closed on workpiece" when left on the
green axis.
The maximum pincering dimension depends on type of clamp and "Rod-workpiece
distance" parameter found in the "Options" "Parameters" "Work top" folder.

4) The "Maximum pincering without recoveries" rule is normally used to position the
clamps that must block the workpiece, pincering maximum wood section,
guaranteeing exchange of clamps without recoveries to speed-up the cycle.
This rules only remains active for horizontal, without arcs, blocking profiles.
The clamp's axis sticks to an axis that becomes blue when a clamp nears the
blocking profile using the "Maximum pincering without recoveries" rule.

249
 This guarantees the clamp pincers the blocking profile for maximum established
height.
The clamp's state is automatically taken to "Closed on workpiece" when left on the
blue axis.
The pincering dimension depends on type of clamp, workpiece width, "Safety
distance in Y" parameter found in the Bars' "Property" window configuration and on
"Rod-workpiece distance" parameter found in "Options" "Parameters" "Work top"
folder.

Notes:
- The "Load distance" rule deactivates the others and vice-versa
- The maximum pincering rules exclude one another
- "Minimum pincering" rule can be activated together with a maximum pincering rule.
This enables clamp positioning in the area between the red and green axes or
between the red and blue axes.

3.11.1.7.3 Automatic clamps' positioning with blocking profile

Use the "Automatic setup" control in the "Setup" menu's "Work top
setup" sub-menu to automatically position the clamps on the
blocking profile.

The clamps are automatically positioned on the blocking profiles of

all workpieces in all phases without adding further information,
after clicking on the function control.

Note: This function saves time compared to manual positioning.

250
3.11.1.7.4 Positioning terminals outside the work area

When you have a machine that has reference stops inside the work area, you may need to
place the clamps outside the work area.

This feature is enabled by ticking the entry:

Allows the positioning of the supports outside the area
the item is located by selecting:
Tools-Options-Parameters-Work Plan-Automatic Positioning Terminals

Enabling functionality allows you to get this set up, allowing you to have more work space
available:

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3.11.1.7.5 Enables the positioning of the clamps on the piece edge

When working a particularly tedious material, it may damage the special high-pressure
part that is created when the automatic positioner of the terminals places them on the
edges of the workpiece.

the axes can be moved with the mobile control panel.

Enables the positioning of the clamps on the piece edge
the item is located by selecting:
Tools-Options-Parameters-Work Plan-Automatic Positioning Terminals

Example that could crash the edges (With the flag selected)

Example that does not damage the edges (Without the flag selected)

252
3.11.1.8 Initial setup creation

An "Initial phase" is required for loading the workpieces to complete the project.

Use the "Initial setup" control in the "Setup" menu's "Work top setup"
sub-menu to do this.

A new "Initial Setup" phase, indicated in the first project phase with
regard to clamps' positions (the clamps blocking the workpiece will
have the "Open" state), is created after having selected the control.

The initial setup phase must be manually completed if preparing initial setup for a closed
structure workpiece, requiring internal blocking (door profiling).
Use the "Load distance" rule to position the clamps inside the door for loading. (see
chapter 3.11.1.7.2 point 1)

Note: the "Initial Setup" phase can be eliminated like any other
phase.
To do this, you can also use the "Cancel initial set up" command
in the "Plan recovery" menu

3.11.1.9 Final setup creation

Unlike initial setup, this function is compulsory. It is used if clamps must be moved to
remove the workpiece (internally blocked door) at program end.

Use the "Final setup" control in the "Setup" menu's "Work top setup" sub-menu to create a
final setup phase.

A new "Final Setup" phase is created, identical to "Initial Setup", after having selected the
control.
The function will not be successful if an initial phase is not already present.

Note: the "Final Setup" phase can be eliminated like any other
phase.
To do this, you can also use the "Cancel final set up" command in
the "Plan recovery" menu

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3.11.1.10 Cycles generation for clamps exchange

Establish the clamps' sequence of movements to change from one project phase to
another, once the clamps have been positioned in the various blocking phases.

This is done automatically using the "Cycles generate" control in the "Setup" menu's "Work
top setup" sub-menu.

A cycles structure, a set of phases to manage the clamps' exchange, is created after
having selected the control.

The following is a structure example:

The cycles names are composed of initials identifying the

clamps, followed by a letter expressing a change.

Examples:
- B1M1O (O) Opening of clamp 1 (M1) of bar 1(B1)
- B1M1Y (Y) Long Y movement of clamp 1 (M1) of bar
1(B1)
- B1M1B (B) Blocking on workpiece of clamp 1 (M1)
of bar 1(B1)

3.11.1.11 Cycles elimination for clamps exchange

The already created cycles must be eliminated if modifying one or more positions of the
clamps in any phase.

Use the "Cycles cancel" control in the "Setup" menu's "Plan

recovery " sub-menu to eliminate all cycles.

This happens automatically if re-using the "Cycles generate"

control.

254
3.11.2 Workpiece blocking with suction devices

255
3.11.3 Easier Load

The "Easier Load" function can be used to machine workpieces in a different position to
that loaded.

3.11.3.1 Easier Load Insertion

Use the "Easier Load" control in the "Setup" menu's "Work top
setup" sub-menu to make loading easier.

The following screen appears after the control is selected:

The names of workpieces in the project appear on left.

Specify the "Load Y Delta" and the "Unload Y Delta" for each workpiece on right.
The "Load Y Delta" indicates the distance the workpiece must be placed at compared to
loading initial position.
The "Unload Y Delta" indicates the distance the workpiece must be re-positioned at
compared to positioned defined with initial "Load Y Delta".

Two new phases are created by clicking on "Apply": "Load phase" and "Unload phase".

256
 - "Load phase" is identical to old "Setup" phase (without machining).
- The new "Setup" phase is like the old "Setup" phase plus "Load Y Delta".
- The new "Swap" phase is like the old "Swap" phase plus "Load Y Delta".
- The "Unload phase" is identical to the new "Swap" phase less "Unload Y Delta"
(without machining).

Example:

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3.11.3.1.1 Preset of easier load

It may be necessary to use different easier load heights based on type of workpieces to be
machined.
A range of "Presets" can be created to memorise the load and unload heights of the
various workpieces to be machined.

3.11.3.1.2 Preset of easier load creation/change

Use the "Modify Presets" control in the "Easier load" screen to create or modify a new
"Easier load preset".

The following screen appears after command is given:

The following screen appears by clicking on "New":

For entering a new preset name.

"Preset" field shows existing presets: for selecting the name of a preset to be modified.

258
All screen fields can be modified with a visible preset.
Click on "Add" to also insert a new workpiece.

Click on "Save" to memorise the made modifications.

3.11.3.1.3 Preset of easier load use

Select preset name from "Preset" box to associate those memorised to current project.
Note: Visible presets are only those having the same number of workpieces of those of the
current project.

The "Preset name" field is filled with names of workpieces described in preset and the "Y
Delta" fields with relative values memorised in preset, once this is associated.

The workpieces' names are automatically associated if those memorised in preset and
those in the current project coincide. If not, use the arrows right of the workpiece names to
correctly associate them.

With "Apply", the "Easier load" function continues creating new phases as previously
described.

259
3.11.3.2 Easier load elimination

Restore original phases if wanting to perform easier load again at different heights to those
previously set. Eliminating the two "Load phase" and "Unload phase" added phases would
be insufficient.

This is done using the "Delete easier loading" function in the

"Setup" menu's "Plan recovery" sub-menu.

260
3.11.4 Work top automatic setup

This chapter describes many phases that can be automatically performed in sequence,
without operator interaction.

This is done by directly clicking on the "Setup" menu's "Work top setup" control.
Note the "Work top setup" icon is the same used as sub-menu for the previously seen
individual functions.

The following screen appears after "Work top setup" command is given:

The following functions are performed in sequence once all is ticked and "Apply" is clicked:

- Automatic setup (see chapter 3.11.1.7.3)

- Easier load (see chapter 3.11.3.1)
- Initial setup (see chapter 3.11.1.8)
- Final setup (see chapter 3.11.1.9)
- Cycles generate (see chapter 3.11.1.10)

The project is enriched by the creation of all individual functions' phases, except "Final
Setup" phase created only if required (for doors blocking).

261
3.11.5 Restoring the plan

This function is used when you want to eliminate all those phases or cycles that were
automatically created with the "Plan set-up" function.

By clicking on the "Plan recovery" command in the "Setup"

menu, all the operations visible in the drop-down menu will
be performed automatically:
- Delete cycles
- Cancel final set up
- Cancel initial set up
- Clear facilitated load

The order of the cancellation operations is the exact reverse of the order of creation.

3.12 Definition of workpieces machined

contemporaneously
In order to machine various workpieces define the following:

1. Number of workpieces to machine contemporaneously on the table

2. Whether to minimize the tool changes in the program

3.12.1 Number of workpieces machined contemporaneously

The number of workpieces to machine contemporaneously on the table depends on the
dimension of the workpieces and the dimension of the machine table.
To enter various workpieces on the machine table you must create a project with various
workpieces and display the position in machine with the “Arrange” function.

262
3.13 Project optimization

This option allows you to minimise the number of tool changes and the paths related to the
transfer from one working process to another one.
Starting from a saved project, a new project will be created, with a working processes
structure according to the modes indicated.
The project name will be "NameProjectOriginalOpt.pgmx".
After the process, the source project will be closed and the optimised project will be
opened.

In order to optimise a project, use commands "Guided optimization" or "Automatic

Optimization" in the menu "Machines" "Optimizator".

After applying the optimization modes described in following paragraphs, the file
"NameProjectOriginalOpt.pgmx". will be created.
If the optimised file was already been created, following message would appear:

By choosing "No", the optimization will end without saving any optimised file.
If you choose "Yes", following message will appear:

By choosing "Cancel", the optimization process will end.

By choosing "OK", the source project will be closed and the optimized project will open.

263
3.13.1 Standard projects optimisation
The mode for project optimisation can be:
Guided
Automatic

3.13.1.1 Guided Optimization

This mode allows you to restructure the working process ordering in every step before
optimizing the project.

By using "guided Optimization", following menu will open:

You can decide the optimization on one step or all steps by using the area "Working
steps".
This workpiece of the menu will appear only if working processes on almost two steps
exist.

In the area "Working processes", all working processes in the step or in the selected steps
will be displayed. You can change the working process ordering with the arrows.

In the area "Tools", all tools in the selected type of working process will be selected. It is
possible if you change the tool ordering with the arrows.

264
If you select the check "Sub-programs optimization", all working processes in the sub-
programs will be drawn, following the same structure of the previuos project. In order to
avoid losing the ordering operations, following message will appear:

If you select the check "Optimization tool path", apart from tool change minimization, also
the whole tool path is minimised among the different working processes.

After the selection, you can:

- Click on the command "Cancel" to avoid the optimization
- click on the command "Restore"
- Click on the command "Apply"

The command "restore" could restore the working tree as it was in the source project, so
following message would appear:

With the command "Apply", the optimization for the tool change would be carried out
without keeping the technological sequence on all working processes in the selected step.

265
3.13.1.2 Automatic optimization

By using the command "Automatic Optimization", following menu is open:

If you do not insert any check, the optimization for tool change is carried out on all project
working processes without changing the technological sequence.

Tools change and overall tool path among the various machining are minimised if
"Optimisation enable" is checked.

If you select the check "Optimization tool path", apart from tool change minimization, also
the whole tool path is minimised among the different working processes.

IIf you select "sub-program optimization", before starting the process, all working
processes in the sub-programs will be drawn. The working tree of the source project will
be modified.

After the selection, you can:

- Click on the command "Cancel" to avoid the optimization
- Click on the command "Apply"

266
3.13.2 Nesting projects optimisation
The mode for Nesting project optimisation can be:
Guided
Automatic

3.13.2.1 Nesting Guided Optimisation

Guided optimisation is divided in another two modes:

Basic Guided Optimisation

Advanced Guided Optimisation

267
3.13.2.1.1 Basic Guided Optimisation

Before optimising the project, this allows manually re-organising the machining order
within each phase.

The following menu opens using the "Basic Guided Optimisation" control:

268
Basic optimisation is by machining sequence and a tool order can be indicated for every
machining (the order can be manually modified for both Machining and Tools menus using
the "UP" and "DOWN").

Enable tool path optimisation to:

- access the Optimisation type drop-down menu for specifying the tool path to be
optimised according to Generic mode, X Long (optimises path according to
movement along axis X), Y Long (optimises path according to movement along axis
Y).
- Enable/disable the "Execute boring first" option.
- Enable/disable the First cut the small pieces option

The generic optimisation allows the inversion of

the machining tool path, by selecting the relative
parameter.

269
The optimisation along X allows the sheet to be
virtually cut in horizontal strips that will have a Y
dimension equal to the dimension of the sheet
divided by the number of "Lines" set.
The final result will be that the machinings after the
optimisation will follow the progress displayed.

The optimisation along Y allows the sheet to be

virtually cut in vertical strips that will have a Y
dimension equal to the dimension of the sheet
divided by the number of "Columns" set.
The final result will be that the machinings after the
optimisation will follow the progress displayed.

The guided optimisation window is closed using the "cancel" control

Initial condition, highlighting the following message, is restored using the "Restore" control

Optimisation for tool change is made with "Apply" control.

270
3.13.2.1.2 Advanced Guided Optimisation
Machining order is manually re-organised, creating groups containing different machining,
through this mode.

The following menu opens by selecting this optimisation mode:

The machining section changes compared to basic optimisation: a button is present for
groups' creation/removal.

A group is a set of machining (list on left) associated for managing its order priority
compared to overall machining.

271
The following menu opens by selecting the Add/Remove Groups button:

A group can be created containing machining in the list on right, using the arrow towards
right button from the machining list on left.
Enter the group's name in top-left box.

This group is added to the list (scrolled via the drop-down menu) using the Apply button.

272
Advanced optimisation of all groups, following priority given during forming of the individual
groups, is made by selecting "All".

All machining in Milling (with order established in the same group), then all incisions and
finally the Cuts are performed in this case (above figure).

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3.13.2.2 Nesting Automatic Optimisation

The following menu opens using the "Automatic Optimisation" control:

Tools change optimisation is performed on all project machining without altering the
technological sequence if no check is inserted.

Tools change and overall tool path among the various machining are minimised if
"Optimisation enable" is checked.

For a detailed description of the type of optmisation process see 3.13.2.1.1

After the wanted selection is made:

- click on the "Cancel" control to miss optimisation
- click on the "Apply" control to proceed with optimisation.

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3.13.2.3 Edge banding optimization

Once all the edge banding machinings have been created, they can be optimized by
accessing machines, optimizer and select Edge Banding Optimizer.
At this point a table will be displayed to select the various operations to optimize.

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3.13.2.3.1 Rotations optimization

Select this optimization option to optimize

the rotations of the edge banding head for
the collisions check and to optimize the
gluing between edge and panel.

3.13.2.3.2 Lamps optimization

Select this optimization option to optimize

the switch on of the lamps used to heat the
edge, especially for geometries that include
arcs.

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3.13.2.3.3 Stop roller optimization

Select this optimization option to optimize

the roller stop of the edge banding head,
especially for geometries that include arcs.

3.13.2.3.4 Edge banding parameters optimization

Select this optimization option to optimize

the edge dispensing parameters and the
infeed and outfeed wait times by using the
technology data of the edge used for the
edge banding.

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3.13.2.3.5 Autostart optimization

Select this optimization option to disable

Autostart machine instruction for the first
edge banding and enable it for the
subsequent edge banding operations.

3.13.2.3.6 Trimmer rotations optimization

Select this optimization option to optimize

the trimmer rotations to avoid collisions
with the edge, especially when the trimmer
changes direction.

N.B.:
The edge banding optimization will cancel all the attributes
entered previously during the creation phase, replacing them
with the optimized attributes.

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3.14 Automatic parts arrangement and optimization

This function enables users to automatically place several pieces on the plane and to
optimize the blocking and processing sequences

The premise is that a .eplx file has been previously saved defining how the plane is set up
(see chapter 3.11.1.5)

To activate the function, use the command

"Project-Pieces layout"

The following screen will appear:

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3.14.1 Add Project

With this command, you add a project to the list of projects to be optimized.
The project must have a single piece inside.

The "Add" command is used

A list of pieces to be placed on the plane will appear:

3.14.2 Pgmx editor

By selecting a pgmx from the list, it will become blue so you can:

- Remove the pgmx with the key

- Move it to the top of the list with the key

- Move it down in the list with the key

- Change the quantity in the "Repetitions" box

- Select one or two adjacent sides in the "Reference" field of the piece which must
obligatorily be into abutment.
The optimizer to decrease the generated pgmx could also rotate some pieces by 180 °.

- Select any mirroring in the "Mirroring" field

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3.14.3 Saving and opening .wpx files
Files with the .wpx extension contain a list of projects to be optimized and blocked on the
machine floor.

The wpx file is saved using the command

The save will create a file with the .wpx extension in the selected folder

To open an existing .wpx file, use the command

3.14.4 Optimisation criteria

The optimisation criteria determine from which part of the plane the pieces will start to be
positioned.
To this end, the "Departure areas" and "Starting area" drop-down menus are used.

The areas where you can position pieces

are those read from the configuration:

The front areas are those near the operator, while those to the rear are those away from
the operator.By clicking on ABCD, the following screen appears:

Where you can select or deselect the desired row of areas

The selection of the "Left half-plane" or "Right half-plane" will make the wizard choose the
"pendulum" mode to calculate the area of the optimised programs.
Selecting the "Whole Plane" will generate all programs in the AD area.

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3.14.5 Optimisation
Piece layout optimisation is done with the button

The processing result will consist of:

-A .mixx file containing the list of generated pgmx
- many pgmx files containing one or more pieces

3.14.5.1 Generated .mixx file

The generated .mixx file can be positioned and renamed using the field:

The .mixx file will contain a list of all the .pgmx files generated during processing

3.14.5.2 Generated .pgmx files

The generated .pgmx file can be placed in the desired folder using the field:

Each generated .pgmx file will respect the set criteria.

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3.15 Mathematical functions

Maestro features the following mathematical functions:

Abs(value) (Absolute value)

Acos(value) (Arcsine)
Asin(value) (Arcsine)
Atan(value) (Arctangent)
Tan(value) (Tangent in degrees)
Tanh(value) (Hyperbolic tangent in degrees)
Cos(value) (Cosine in degrees)
Cosh(value) (Hyperbolic cosine in degrees)
Sin(value) (Sine in degrees)
Sinh(value) (Hyperbolic sine in degrees)
Exp(value) (Exponential)
Ceiling(value) (Round up)
RU(value) (Round up)
Floor(value) (Round down)
RD(value) (Round down)
Log(value) (Natural logarithm)
Log(value, newBase) (Basic logarithm newBase)
Max(val1; val2) (Maximum)
Min(val1; val2) (Minimum)
Pow(x; y) (Raise x to the y power)
Round(value) (Rounding off)
Sqrt(value) (Square root)
- (Subtraction 600-400 = 200)
+ (Addition 600+400 == 1000)
/ (Division 400/200 = 200)
% (Remaining division (417% 100 = 17)
* (Multiplication 400*2 = 800)
() (Round brackets)
> (Greater dx1>200)
< (Lower dx1<200)
>= (Greater equal dx1>=200)
<= (Lower equal dx1<= 200)
<> (Different 200 != 300)
= (Equal 200 == 200)
^ (Power 2^2=2*2= 4, 2^3=2*2*2=8)
(Value1)AND(Value2) (Operator AND (dx1>600)AND(dy1>400)
(Value1)OR(Value2) (Operator OR (dx1>600)OR(dy1>400))
(Value1)XOR(Value2) (OR exclusive (dx1>600)XOR(dy1>400))
NOT(Value) (Negation NOT(dx1>1600))
IF(Condition;Value1; Value2) (Condition IF (Condition == true) (Value1)
else (Value2)

The functions listed can be used in the parameter or variable fields of the context menus.

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4 Project Management for Cyflex

Cyflex machines have a different table compared to classic routers provided with a
multifunctional table or a bars one; this is why the tools disposition on the machine needs
to be treated separately.

4.1 Loading panels on Cyflex.

The panels to be machined in Cyflex must be loaded manually, positioning them on the left
side of the machine and moving them against the reference stop on the right.

4.2 Unloading panels on Cyflex.

The panels are unloaded from the machine automatically, but the side and unloading
mode can be selected.
The selection is made on the "Machine parameters" - "Hold-down device"

The options in the drop down menu are:

- Unload to the right
- Unload to the left
- Unload to the right complete
- Unload to the left complete

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4.2.1 Unload to the right (V70)
The unload to the right differs whether you are using a Cyflex S or a Cyflex HP.

The unload to the right for the Cyflex S moves the centre of the clamps to the "Right
release quota", however the tail of the panel could remain the work zone when:
- the clamp reaches the positive limit switch
- the panel head reaches the "Maximum unload to the right quota"

work zone
load zone unload zone
Panel

Shaft 1

Clamp

Right release
quota

Maximum unload to the right quota

The "Right release quota" parameter for the Cyflex S can be changed in the session:
"Tools-Options-Parameters-Work table-Cyflex -Work table" selecting "CYFLEX S"

Whilst the "Maximum unload to the right quota" must be set in Xilog

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The right discharge for the Cyflex HP is carried out by bringing both clamps to their right
limit switch, opening the right clamp before moving. In this case, the "Right junction level"
is not considered: if the clamps have enough running to bring the panel beyond that
height, the movement is carried out without limitation. The only constraint is given by the
parameter "Maximum discharge level on the right", which represents the limit beyond
which the head of the panel cannot be carried.

work zone
load zone unload zone
Panel

Shaft 1

Clamp

Right release
quota

Maximum unload to the right quota

The "Right release quota" and "Maximum unload to the right quota" parameters for the
Cyflex HP are changed in the session:
"Tools-Options-Parameters-Work table-Cyflex -Work table" selecting "CYFLEX HP"

With this type of unloading, no ribbing is performed: the left clamp remains at the same
coordinate used to perform the last machining, resulting in different unloading positions
depending on the machining and optimization performed. To ensure that the panel is
moved to a fixed coordinate, you must use "Full right unloading".

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4.2.2 Unload to the right complete (V72)
For the Cyflex S, this unloading mode involves, like the V70, bringing the centre of the
clamps to the "Right junction level", with the only difference being that before unloading
the clamp will be repositioned to avoid the panel remaining in the machining area. In
practice, you will bring the centre of the clamp to the "Panel tail clamp position" level (this
level can only be modified by Xilog).

Panel

Clamp
Panel tail clamp
position

As for Cyflex HP, with this unloading mode, the tail of the workpiece is moved to the "Right
junction level", taking into account also the "Minimum portion of the part to be unloaded".
To ensure that the desired position can be reached, reinsets may be made before the
panel is unloaded. As in the V70 mode, even in this case, do not take the head of the
panel beyond the "Maximum right unloading level".

Panel

Clamp
Minimum portion of piece for
unloading

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4.2.3 Unloading to the left (V71)
The unload to the left has a slightly different mode whether you are using a Cyflex S or a
Cyflex HP.

The unload to the left for the Cyflex S is executed by trying to move the panel head to the
"Offset X stop", however the panel head could remain in the work zone as no re-clamping
is performed

work zone
load zone unload zone
Panel

Piece
alignme Shaft 1
nt stop
Clamp

Offset X
stop

The "Offset X stop" parameter is a configuration parameter, changed in Xilog.

Left side unloading for the Cyflex HP is carried by bringing both clamps to their left hand
limit switch, opening the left clamp before moving. In this case, the "Offset unloading stop"
is not considered: if the clamps have enough running to bring the panel beyond that
height, movement is carried out without limitation. The only constraint is given by the
parameter "Maximum left unloading level", which represents the limit beyond which the
head of the panel can not be carried.

work zone
load zone unload zone
Panel

Piece
alignme Shaft 1
nt stop
Clamp

Stop unload Offset X

offset stop

Maximum unload to the left quota

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The "Stop unload offset" and "Maximum unload to the left quota" parameters for the Cyflex
HP are changed in the session:
"Tools-Options-Parameters-Work table-Cyflex -Work table" selecting "CYFLEX HP"

With this type of unloading no ribbing is made: the right clamp remains at the same
coordinate used to perform the last machining, resulting in different unloading positions
depending on the machining and optimization performed. To ensure that the panel is
moved to a fixed coordinate, you must use "Full left unloading".

4.2.4 Unload to the left complete (V73)

This unloading mode is only available for Cyflex HP. With it the workpiece head is moved
to match the "Stop unloading offset", also taking into account the "Minimum portion of the
workpiece for unloading". To ensure that the desired position can be reached, reinsets
may be made before the panel is unloaded. As in the V70 mode, even in this case, do not
move the head of the panel beyond the "Maximum left unloading level".

Panel

Clamp
Minimum portion of piece for
unloading

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4.3 Optimisation for Cyflex programs
The operator does not have to launch the optimisation, because when the pgmx is called
from the machine panel, the optimisation process will be launched automatically.

Before the program is optimised proceed with the following:

- Cluster the machining operations
- Set the clamps-machining operations distances

4.3.1 Machining clustering

The machining process on Cyflex machines requires one or more clampings to machine a
piece completely.
For precision requirements it may be useful to cluster the same type of machining
operations and clearly the machining times will increase in relation to the greater number
of clampings.
The machining clustering is managed with the following dialogue window
"Tools-Options-Parameters-Work table-Cyflex-Machining-Machining clusters"

The mode requires you to move up or down the four types of machining operations:
- Horizontal boring
- Vertical boring
- Routing
- Cuts with blade
changing their order.
When a type of operation is the last in the cluster and you click on "Arrow down”, it will be
moved in the cluster below, that if it does not exit it would be created.
The maximum number of clusters that can be created are 4, but it is reduced to 3, when
selecting "Enable the management of all borings as horizontal boring".

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4.3.2 Clamps-machining distances setting
To set the distances between the clamps and machining use the session:
"Tools-Options-Parameters-Work table-Cyflex-Machining-Distance from machinings"

For each type of machining operation you can set a distance from the clamp:
- Unlimited
- Percentage
- Absolute

The setting can be made whether the piece is blocked with a one clamp or with two
clamps (only for Cyflex HP).

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4.3.3 Type of optimisation algorithm
The type of algorithm used to process the project can be selected in the menu:
"Tools-Options-Parameters-Work table-Cyflex-Optimiser"

The following "Clustering algorithm" can be selected:

- Automatic
- Clustering
- Linear
- Sequential

To display a report of the phases generated select the "Display optimisation statistics" at
the end of the optimisation.

4.3.4 Clamps options

With the session:
"Tools-Options-Parameters-Work table-Cyflex-Optimiser-Clamps"

to set the clamps intervention mode.

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In the "Clamp grip percentage on piece" field enter a high value (max 100%) to block a
piece very well or a lower value when the clamping is less significant.

The "Minimum piece dimensions" indicate the minimum piece that will be processed by the
optimiser.

The Flag on "Use only one clamp on long pieces" is used only on Cyflex HP adding also
the value in the "Maximum piece length" field.
The longer pieces will be blocked, if possible, with 2 clamps.

Selecting one or more types of machining operations means that during that type of
machining only clamp will be used.
This is to have less interruptions during the machining.

4.3.5 Pressers options

With the session:
"Tools-Options-Parameters-Work table-Cyflex-Optimiser-Pressers"

to set the pressers intervention mode.

"Minimum length" and "Minimum with" are the minimum piece dimensions, below which
the presser can move down also with one wheel.

"Minimum height" is the thickness below which the presser can move down in the lower
part of the panel.
This is to prevent collisions between the presser and the panel support rollers.

Selecting "Use pressers for horizontal boring", with the value in the "Maximum height for
pressers obligatory downstroke" field, forces the downstroke of the pressers for all
horizontal boring operations that are at a lower Y quota than the one specified.

Selecting "Clamp close to boring without pressers", with the value in the "Maximum clamp
distance" field, forces the presence of the clamp at a shorter or equal distance to the one
set when the pressers cannot operate.
This mode is used to achieve a greater machining precision.

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4.3.6 Probing
With the session:
"Tools-Options-Parameters-Work table-Cyflex-Optimiser-Probing"

to set the maximum difference for the panel to be optimised. Set the value in the "Probing
margin" field.

4.3.7 Panel anti-fall

The anti-fall is made by avoiding opening the clamp or clamps that block the panel at the
end of the discharge procedure. This behavior is conditioned by:
• using a Cyflex HP;
• to the left exhaust, complete and not.

The anti-fall feature can be enabled in the Maestro options or in the project's machine
parameters.

The section on the Cyflex HP Options page has added the visible section in the following
figure:

Through CheckBox, you can enable anti-fall functionality, which will become effective if at
least two of the following conditions are met:
• Panel length <Minimum piece length value
• Panel width <Minimum piece width value
• Panel height> Maximum workpiece height value

Values set in Options will be active for all projects that will be optimized by Maestro.

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When using a configuration for a Cyflex HP in machine parameters, the entry "Use panel
anti-fall functionality" appears in the figure below:

Through CheckBox, you can enable anti-fall functionality, which will only become effective
for the current project.
When activated by machine parameters, it has a higher priority and the anti-fall is applied
regardless of the value in the Options.

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4.3.8 Aligner
With the session:
"Tools-Options-Parameters-Work table-Cyflex-Optimiser-Aligner"

to set the aligner intervention mode. (Only for Cyflex S)

In the "Boring tolerance" field you can set the minimum material thickness, below which
the aligner will not operate.
This parameter is used to prevent that a through machining operation in the high part of
the panel can be damaged by the pressure of the aligner.

4.3.9 Processing with optimiser

This procedure provides the pgmx program with all the stages required by Cyflex to handle
and work the piece.

Optimisation can be started through the "Optimisation" control from the

"Machines" menu.

The result can be viewed in the "Arrange" section.

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4.4 Layout for Cyflex programs

The "Layout" for Cyflex is used to see the piece in all the phases from loading to
unloading.
The procedure can be executed to check the work phases that have been produced.

To access the Layout environment use the "Layout" command in the

"Machines" menu.

The "Layout" environment for a pgmx of a Cyflex machine appears as follows:

on the left there is the phases tree and in the centre of the screen there is the machine and
the piece moved by the clamps:

Move though the phases tree to see the piece moved by the clamps in the machine.

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5 Project Management for Uniflex

5.1 Create project

The Uniflex machine allows the machining of a single piece or two superimposed pieces
with the same dimensions in X and Y. In the latter case, it is required to construct a project
containing both pieces, suitably positioned on the plane.

To facilitate the implementation of the project, a tool was created using the
"Uniflex" command in the "Home-Project" command:
Three different types of projects will be possible:
Auto Double
Double
- Single

5.1.1 One piece mirror

In the paragraphs that will follow, when it comes to mirroring the workpiece, reference will
be made to the combined operation of mirror machining and rollover of the workpiece.
Both will be referenced to the Y coordinate: it is not permitted in the Uniflex to mirror or
reverse over the X, due to a loss of precision, since the reference is on the side supporting
the pliers.
The mirror operation, as shown in the following pictures, works by overturning the
workings leaving them on the same plane they belong to, except for those on the front and
rear faces, which are exchanged:

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This type of operation, if you want to do it manually, can
be done through the "Specchia - Y" command of the
workpiece context menu:

The tilting operation has no effect on the view of the

workpiece in the Maestro CAD environment, but only in the
Available. In practice, this is done by setting the roll over in
the positioning properties of the workpiece.

By using these commands and appropriately setting the positions of the pieces in Z, you
can manually construct, if you want to do so, the types of projects described below.

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 5.1.2 Creating the Double Dual Project

A Double Dual design contains two identical pieces, importing the same piece twice. The
panel in the top position is oriented as by the original program, and the bottom panel can
be mirrored. If it were, the machining of both pieces would be aligned, allowing them to be
executed at the same time by the upper and lower heads.

Entering the name of the project to be uploaded to its field will also automatically fill in the
name of the file to be created.
Mirroring is only allowed for the lower part and is selected by default because it represents
the most common operating mode.
Selecting "Create Project" will create the project with the pieces at the appropriate
locations, while selecting "Optimize" will be produced directly the optimized file, with the
work phases.

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